Pneumatic Vulcanizing Machine
Pneumatic Vulcanizing Machine
Pneumatic Vulcanizing Machine
1
CONTENTS
SYNOPSIS 8
1 Introduction 10
2 Literature Review 12
3 Description Of Equipments 16
3.1 Compressor 16
3.2 Pneumatic Control Component 17
3.3 Valves 18
3.4 Hoses 22
3.5 Pressure Gauge 23
3.6 Control Unit 23
3.7 Temperature Sensor 23
4 Design And Drawing 28
4.1 Calculation For Pneumatic Cylinder 28
4.2 Drawing For Three Axis Pneumatic Modern 30
Trailer
5 Working Principle 38
6 Merits & Demerits 40
7 Applications 42
8 List Of Materials 44
9 Cost Estimation 48
10 Conclusion 50
BIBLIOGRAPHY 52
PHOTOGRAPHY 53
2
LIST OF FIGURES
FIGURE
NUMBER TITLE PAGE NO
1 AIR COMPRESSOR 17
3 5 PIN CONFIGURATION 26
4 SOLENOID VALVE 34
3
ABSTRACT
4
CHAPTER I
INTRODUCTION
5
1. INTRODUCTION
Full automation.
Semi automation.
6
CHAPTER II
LITERATURE REVIEW
7
2. LITERATURE REVIEW
PNEUMATICS
The word ‘pneuma’ comes from Greek and means 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.
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.
The compressibility of the air was first investigated by Robot Boyle in 1962
and that found that the product of pressure and volumes of particular quantity of
gas.
8
The usual written as
In this equation the pressure is the absolute pressured which for free is about
14.7Psi 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:
PNEUMATIC POWER:
9
THE ADVANTAGES OF PNEUMATICS:
2. Pneumatic pressures are quite low due to compressor design limitations(less that
250 psi).
10
CHAPTER III
DESCRIPTION OF EQUIPMENTS
11
CHAPTER III
DESCRIPTION OF EQUIPMENTS
3.1.COMPRESSOR
Compressor is the air producing machine. They collect the airs from the
atmosphere are in the running of machine are engine. Air compressors are utilized
to raise the pressure of a volume of air. Air compressors are available in many
configurations and will operate over a very wide range of flow rates and pressures.
Compressed air was expelled by primitive man to give glowing embers sufficient
oxygen to allow them to flare up into a fire. During the compression process, the
temperature increases as the pressure increases. This is known as polytypic
compression. The amount of compression power also increases as the temperature
increases. Compressors are staged thereby reducing the temperature rise and
improving the compression efficiency. The temperature of the air leaving each
stage is cooled prior to entering the next stage. This cooling process is called
intercooling. Volumetric efficiency also increases with multi-stage compression
since the pressure ratio over the first stage will be decreased.
Selection of the air compressor is only the first step in designing an efficient
and reliable compressed air system. The air exiting the compressor is saturated
with moisture and will have compressor lubricants (lubricated compressors only).
Other chemicals that may have been drawn into the compressor intake may also be
present. This contamination is harmful to many processes, pneumatic tools,
instruments and equipment. Air purification equipment, filters, air dryers,
breathing air purifiers, monitoring equipment, used alone or in combination will
remove these contaminants. Selection and purchase of the compressor and
necessary purification equipment can be easily done on the Compressed air site.
12
Our application engineers are ready to answer all of your questions and to assist
you in placing your order. And it work in the process of rotating the fan and the
piston movement with the help of current supply.
13
3.2.1A) SINGLE ACTING CYLINDER
The normal escape of air is out off by a cushioning piston before the end of
the stroke is required. As a result the sit in the cushioning chamber is again
compressed since it cannot escape but slowly according to the setting made on
reverses. The air freely enters the cylinder and the piston strokes in the other
direction at full Force and velocity.
3.3 VALVES
SOLENOID VALVE
14
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.
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.
15
PARTS OF A 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. Coils are rated in various
voltages such as 115 volts AC, 230volts AC, 460volts Ac, 575 Volts AC.6Volts
DC, 12Volts DC, 24 Volts DC, 115 Volts DC &230Volts DC. They are designed
for such Frequencies as 50Hz to 60Hz.
2. Frame
3. Solenoid plunger
The solenoid plunger is the mover mechanism of the solenoid. The plunger
is made of steel laminations which are riveted together under high pressure, so that
there will be no movement of the lamination with respect to one another. At the top
of the plunger a pin hole is placed for making a connection to some device. The
solenoid plunger is moved by a magnetic force in one direction and is usually
returned by spring action.
16
Solenoid operated valves are usually provided with cover either the solenoid or the
entire valve. This protects the solenoid from dirt and other foreign matter, and
protects the actuator. In many applications it is necessary to use explosion proof
solenoids.
Position-1
When the spool is actuated towards outer direction port ‘P’ gets
Connected to ‘B’ and ‘S’ remains closed while ‘A’gets connected to ‘R’.
Position-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’
Gets connected to each other and ‘B’ to ‘S’ while port ‘R’remains closed.
The control valve is used to control the flow direction is called cut off valve or
solenoid valve. This solenoid cutoff valve is controlled by the electronic control
unit.In our project separate solenoid valve is used for flow direction of vice
cylinder. It is used to flow the air from compressor to the single acting cylinder.
17
Flow control valve:
In any fluid power circuit, flow control valve is used to control the speed of
actuator. The flow control can be achieved by varying the area of flow through
which the air in passing.
3.4 Hoses:
Connectors
In our system there are two type of connectors used. One is the Hose
connector and the other is the reducer. Hose connectors normally comprise an
adopt hose nipple and cap nut. These types of connectors are made up of brass (or)
aluminum (or) hardened pneumatic steel.
18
3.5 PRESSURE GAUGE:
Pressure gauges are usually fitted with the regulators. So the air Pressure
adjusted in the regulator is indicated in the pressure Gauge, is the line pressure of
the air taken to the cylinder.
3.6.CONTROL UNIT
In our project the main device is a control unit. It is used to control the
whole unit of this project. In this we are using the solenoid valve to control the
pneumatic cylinder this equipment, the solenoid valves is connected through the
control unit. The control unit provides the instruction to the solenoid valve to
operate automatically. The control unit is connected with the battery to get the
power supply.
• Operates from 4 V to 30 V
19
• Less than 60-μA Current Drain
2 Applications
• Power Supplies
• Battery Management
• HVAC
• Appliances
3 Descriptions
The LM35 series are precision integrated-circuit temperature devices with an
output voltage linearly-proportional to the Centigrade temperature. The LM35
device has an advantage over linear temperature sensors calibrated in Kelvin, as
the user is not required to subtract a large constant voltage from the output to
obtain convenient Centigrade scaling. The LM35 device does not require any
external calibration or trimming to provide typical accuracies of ±¼°C at room
temperature and ±¾°C over a full −55°C to 150°C temperature range. Lower cost
is assured by trimming and calibration at the wafer level.
20
The low-output impedance, linear output, and precise inherent calibration of
the LM35 device makes interfacing to readout or control circuitry especially easy.
The device is used with single power supplies, or with plus and minus supplies. As
the LM35 device draws only 60 μA from the supply, it has very low self-heating of
less than 0.1°C in still air.
FIG: 3
21
5 Pin Configuration and Functions
22
CHAPTER IV
23
CHAPTER IV
2. Solenoid vale
4. Connectors
5. Hoses
6.Temperature sensor
7. control unit
Quantity : 1
Piston: EN-8
24
Media: Air
Temperature: 0-80°C
Media : Air
Quantity: 1
3. Connectors
Technical data
Temperature : 0-100°C
Material :Brass
4. Hoses
Technical data
25
Inner diameter : 3.5mm =3.5 x10-3m
Pneumatic unit
: 80.38cm2
: 80.38 X 10-4m2
Of cylinder.
26
27
FIG :5
28
FIG :6
29
FIG : 7
30
FIG : 8 SOLENOID VALVE
31
FIG : 9
32
FIG :10 AUTOMATIC PNEUMATIC VULCANZING MACHINE
33
CHAPTER V
WORKING PRINCIPLE
34
CHAPTER V
WORKING PRINCIPLE
Heat Sensor
Control Unit with Power supply
Solenoid Valve
Flow control Valve
Compressor
The heating coil is drawn power from the 230V a.c supply. The heating coil
temperature is changed by adjusting the variable resistor temperature value. So the
coil gets heated up to the particular temperature.
The tube is fixed on the base of the L-bracket. The Heating coil is fixed
bellow the L-bracket bed. The vulcanize tube side is kept above the heating coil.
The tube gets heated to the particular temperature. The control unit gives the
supply to the solenoid valve, so that the pneumatic cylinder is in forward stroke.
After reaching the setted temperature value, automatically the solenoid valve
supply is cutted by the sensor unit. The ram is release to the previous position after
vulcanization process completed. This machine is compact in size and semi-
automated one. Time consumption during the operation is very less when
compared to the manual operation.
35
CHAPTER VI
36
CHAPTER VI
MERITS
DEMERITS
37
CHAPTER VII
APPLICATIONS
38
CHAPTER VII
APPLICATIONS
Automobile Applications
Four wheeler and two wheeler applications.
39
CHAPTER VIII
LIST OF MATERIALS
40
CHAPTER VIII
LIST OF MATERIALS
The various factors which determine the choice of material are discussed
below.
1. PROPERTIES
The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied
Physical
Mechanical
From manufacturing point of view
Chemical
41
Compressive shear, bending, torsion and buckling load, fatigue resistance,
impact resistance, elastic limit, endurance limit, and modulus of elasticity,
hardness, wear resistance and sliding properties.
The various properties concerned from the manufacturing point of view are,
Cast ability
Weld ability
Surface properties
Shrinkage
Deep drawing etc.
2. MANUFACTURING CASE
3. QUALITY REQUIRED
This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of
components which can be fabricated much more economically by welding or hand
forging the steel.
4. AVAILABILITY OF MATERIAL
42
5. SPACE CONSIDERATION
6. COST
43
CHAPTER IX
COST ESTIMATION
44
CHAPTER IX
COST ESTIMATION
1. MATERIAL COST
2. LABOUR COST
3. OVERGHEAD CHARGES
= 3500 + 2000
= 5500
= 1100
4. TOTAL COST
45
CHAPTER X
CONCLUSION
46
CHAPTER X
CONCLUSION
47
BIBLIOGRAPHY
48
BIBLIOGRAPHY
49
PHOTOGRAPHY
50