Fab Pneumatc SAW Mc 2012

7/30/2019 Fab Pneumatc SAW Mc 2012

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Submitted in the partial fulfillment of the requirement for the award

DIPLOMA IN MECHANICAL ENGINEERING

SUBMITTED BY:

1. V.PRADEEP RAJU 4. K. JOHNSON

2. A.VELAUTHAM 5. A. WILSON

3. S.BABU 6. P. DINAKARAN

Under guidance of

S.N. SUNDAR, M.E.

APRIL 2009

DEPARTMENT OF MECHANICAL ENGINEERING


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A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI- BANGALORE ROAD

SEMBARAMBAKKAM

CHENNAI 602103

BONAFIDE CERTIFICATE

This is to certify that this Project work on

AUTOMATIC PNEUMATIC SAW MACHINE

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 2009

Submitted for the Viva-voce exam held on ..

PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER


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ACKNOWLEDGEMENT

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

Principal Mr. R.J. KUMAR, M.E.F.I.E, M.I.S.T.E for encouragement and

valuable advice.

we thank our Esquired Head of Department Mr. R. RAJKUMAR, M.E.

for presenting his felications on us.

We are grateful on our Entourages Mr. S.N. SUNDAR, M..E. 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

Department and Foundry Department.

Ultimately, we extend our thanks to all who had rendered their co-

operation for the success of the project.


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INTRODUCTION

In our technical education the project work plays a major role. Every

students is put in to simulated life particularly where the student required to

bring his knowledge, skill and experience of the project work.

It helps how to evolve specifications under given constrains by

systematic approach to the problem a construct a work device. Project work

thus integrates various skills and knowledge attainment during study and

gives orientation towards application.

As the students solve the various problems exposed by the project

work, the students get the confidence to overcome such problems in the

future life. It helps in expanding the thinking and alternatives for future

applications.


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Chapter No. TITLE

1. SYNOPSIS

2. CONSTRUCTION

3. WORKING PRINCIPLE

4. MECHANICAL ASSEMBLY DIAGRAM

5. PNEUMATIC CIRCUIT DIAGRAM

6. MECHANICAL SPARE PART DETAILS

7. PNEUMATIC COMPONENT DETAILS

8. FINISHING AND PAINTING

9. COST ESTIMATION

10. CONCLUSION

11. BIBILOGRAPHY

12. PHOTO VIEW


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.


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SYNOPSIS

To increase the productivity and to overcome skilled labour

shortage, most of the manufacturing industries are going for automation.

The main arm for us to select the project work is to acquire practical

knowledge in the field of automation using PNEUMATIC SYSTEM.

We selected DESIGN AND FABRICATION OF PNEUMATIC

SAW as our project work and we used principles of Mechatronics in

developing this project work, reciprocating mechanism is achieved by

reciprocating the double acting cylinders which controlled by single

solenoid operated 5/2 way DC valve which is actuated through the relays

and timers.

The operating pressure required for this system is 5 to 6 bar.The

maintenance required for this system is less than the other systems.


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The project consist of

1. M.S. Stand

2. Pneumatic system

3. hacksaw frame with blade

4. Electric panel

1. M.S.STAND:

The M.S.Stand is shown in figure. It is made in square channel

2mm thickness and 450 mm height. The cylinder is mounted at the top. The

HACKSAW frame with blade is mounted at the end of piston rod.

2. PNEUMATIC SYSTEM:

In pneumatic system, the piston rod in cylinder is moved by the

supply of compressed air which is supplied through the 5/2 way solenoid

operated directional control valve. The cylinder A and B ports are connected

to the 5/2 way D.C. Valve with 6/8mm PVC tube. The 6mm connector is

used to connect this cylinder port and D.C valve. The minimum air pressure

required is 5 to 6bar. The figure shows the cross section view of double

acting cylinder.

3. ELECTRICAL PANEL:


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A 230V A.C Supply is required to operate this solenoid valve.

For this separate switch is provided to ON/OFF this solenoid valve.


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WORKING PRINCIPLE

The Pneumatic circuit diagram for the pneumatic saw Machine is shown.

Before starting the machine set the pressure 5 Bar

in the FRL unit and connect air supply to the 5/2 way Solenoid


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operated directional control valve at the pressure port.

Now, Press the ON Switch after placing the job in the

Worktable, Here the material to be cut is feeded manually in the worktable

and the hacksaw frame is screwed to end rod of the double acting

cylinder. The solenoid valve allows the pressurized air to the double acting

cylinder, the blade fixed in the cylinder rod cut the work piece over the

worktale.. The automatic operation of reciprogaing motion of cylinder is

control by a electronic control system.


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INTRODUCTION TO

PNEUMATICS


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INTRODUCTION TO PNEUMATICS

In engineering field may Machines make use of a fluid or compressed air to

develop a force to move or hold an object

A system which is operated by compressed air is known as Pneumatic

System. It is most widely used the work Piece turning drilling sawing etc.

By the use of Pneumatic System the risk of explosion on fire with

compressed air is minimum high working speed and simple in construction.


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PNEUMATIC COMPONENTS

In engineering field, many machines make use of fluid for developing

a force to move or hold an object. A number of fluid can be used in

devices and system. Two commonly used fluids are oil and compressed

air. A system which is operated by compressed air. A system which is

operated by compressed air is know as pneumatic system.

AIR COMPRESSOR

Compressor is a device which gets air fro the atmosphere and

compresses it for increasing the pressure of air. Thus the compressed air.

Thus the compressed air used for many application.

The compression process requires work in put. Hence a compressor is

driven by a prime mover. Generally an electric motor is used as prime

mover. The compressed air from compressor is stored in vessel called

reservoir. Fro reservoir it be conveyed to the desired place through pipe

lines.


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2. FLTER

In pneumatic system, an air filter is used to remove all foreign matter.

An air filter dry clean air to flow without resistance various materials are

used for the filter element. The air may be passed thorugh a piece metal, a

pours stone felt resin impregnated paper. In some filters centrifugal action

or cyclone action is used to remove foreign matters.

3. PRESSURE REGULATOR

Constant pressure level is required for the trouble free operation of a

pneumatic control., A pressure regulator is fitted downstream of the

compressed air filter. It provides a constant set pressure at the outlet of the

outlet of the regulator. The pressure regulator is also called as pressure

reducing valve or pressure regulating valve.

4. LUBRICATOR

The purpose of an air lubricator is to provide the pneumatic

components with sufficient lubricant. These lubricants must reduce the wear

of the moving parts reduce frictional forces and protect the equipment from

corrosion.

Care should be taken to ensure that sufficient lubrication is provided.

But excessive lubrication should be avoided.


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.

5. FLR Package (or) FRL Package

The air service unit is a combination of following units.

1. Compressed air filter

2. Compressed air regulator

3. Compressed air lubricator

Air Filter, regulator and lubricator are connected together with close

nipples as one package. This unit is know as FLR (Filter, regulator,

lubricator.)

6. PRESSURE CONTROL VALVE :

Each hydraulic system is used to operate in a certain pressure range.

Higher pressure causes damage of components. To avoid this pressure

control valves are fitted in the circuits.

7. Direction control valve :

Directional control valves are used to control the direction of flow.

The design principle is a major factor with regard to service life actuating

force switching times etc.

8. Piston and Cylinder

single acting pneumatic cylinder;


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PNEUMATIC CITCUIT SYMBOL FORSINGLE ACTING PNEUMATIC

CYLINDER;

Pneumatic cylinders (sometimes known as air cylinders) are mechanical

devices which produce force, often in combination with movement, and are

powered by compressed gas (typically air).
http://en.wikipedia.org/wiki/Mechanical_devicehttp://en.wikipedia.org/wiki/Mechanical_devicehttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Motion_(physics)http://en.wikipedia.org/wiki/Compressed_gashttp://en.wikipedia.org/wiki/Compressed_airhttp://upload.wikimedia.org/wikipedia/commons/d/db/Kolv_(pneumatisk).PNGhttp://en.wikipedia.org/wiki/Mechanical_devicehttp://en.wikipedia.org/wiki/Mechanical_devicehttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Motion_(physics)http://en.wikipedia.org/wiki/Compressed_gashttp://en.wikipedia.org/wiki/Compressed_air


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To perform their function, pneumatic cylinders impart a force by converting

thepotential energy ofcompressed gas into kinetic energy. This is achieved

by the compressed gas being able to expand, without external energy input,

which itself occurs due to the pressure gradient established by the

compressed gas being at a greaterpressure than the atmospheric pressure.

This air expansion forces a piston to move in the desired direction. The

piston is a disc or cylinder, and the piston rod transfers the force it develops

to the object to be moved.

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 airuse

mounting method
http://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Energy_conversionhttp://en.wikipedia.org/wiki/Potential_energyhttp://en.wikipedia.org/wiki/Compressed_gashttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Spontaneouslyhttp://en.wikipedia.org/wiki/Pressurehttp://en.wikipedia.org/wiki/Atmospheric_pressurehttp://en.wikipedia.org/wiki/Pistonhttp://www.horrorseek.com/home/halloween/wolfstone/Pneumatics/pnucyl_PneumaticCylinders.html#ActionTypes%23ActionTypeshttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Energy_conversionhttp://en.wikipedia.org/wiki/Potential_energyhttp://en.wikipedia.org/wiki/Compressed_gashttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Spontaneouslyhttp://en.wikipedia.org/wiki/Pressurehttp://en.wikipedia.org/wiki/Atmospheric_pressurehttp://en.wikipedia.org/wiki/Pistonhttp://www.horrorseek.com/home/halloween/wolfstone/Pneumatics/pnucyl_PneumaticCylinders.html#ActionTypes%23ActionTypes


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Types

Although pneumatic cylinders will vary in appearance, size and function,

they generally fall into one of the specific categories shown below. However

there are also numerous other types of pneumatic cylinder available, many

of which are designed to fulfill specific and specialised functions.

Single acting cylinders

Single acting cylinders (SAC) use the pressure imparted by compressed air

to create a driving force in one direction (usually out), and a spring to return

to the "home" position


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Pressure, radius, area and force relationships

Although the diameter of the piston and the force exerted by a cylinder are

related, they are not directly proportional to one another. Additionally, thetypical mathematical relationship between the two assumes that the air

supply does not become saturated. Due to the effective cross sectional area

reduced by the area of the piston rod, the instroke force is less than the

outstroke force when both are powered pneumatically and by same supply of

compressed gas.

The relationship, between force on outstroke, pressure and radius, is as

follows:

This is derived from the relationship, between force, pressure and effective

cross-sectional area, which is:

F = p A\,

With the same symbolic notation ofvariables as above, but alsoA represents

the effective cross sectional area.

On instroke, the same relationship between force exerted, pressure and

effective cross sectional area applies as discussed above for outstroke.

However, since the cross sectional area is less than the piston area the
http://en.wikipedia.org/wiki/Relation_(mathematics)http://en.wikipedia.org/wiki/Directly_proportionalhttp://en.wikipedia.org/wiki/Air_compressorhttp://en.wikipedia.org/wiki/Air_compressorhttp://en.wikipedia.org/wiki/Saturationhttp://en.wikipedia.org/wiki/Cross_sectional_areahttp://en.wikipedia.org/wiki/Symbolhttp://en.wikipedia.org/wiki/Variable_(mathematics)http://en.wikipedia.org/wiki/Relation_(mathematics)http://en.wikipedia.org/wiki/Directly_proportionalhttp://en.wikipedia.org/wiki/Air_compressorhttp://en.wikipedia.org/wiki/Air_compressorhttp://en.wikipedia.org/wiki/Saturationhttp://en.wikipedia.org/wiki/Cross_sectional_areahttp://en.wikipedia.org/wiki/Symbolhttp://en.wikipedia.org/wiki/Variable_(mathematics)


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relationship between force, pressure and radius is different. The calculation

isn't more complicated though, since the effective cross sectional area is

merely that of the piston less that of the piston rod.

For instroke, therefore, the relationship between force exerted, pressure,

radius of the piston, and radius of the piston rod, is as follows:

Where:

Frepresents the force exerted

r1 represents the radius of the piston

r2 represents the radius of the piston rod

ispi, approximately equal to 3.14159.

VALVE CONNECTORS;
http://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Pihttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Pi


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POLYURETHANE TUBE ; shortly say PUN tube;

Manual operations involving heavy lifting. Pushing or pulling

motions can be firing for the operations and can induce a monotony which

results in lowered production. Cylinders have been designed to carry out

these movements with a pre determined force and stroke and can be fitted

to synchronize with operation cycles of many machines it is worth wile to

examine the existing plan and methods of movement and to consider the

numberous mechanical applications which the range of pneumatic cylinders

make possible. Quality is to keynote of air cylinder. Engineer them into


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you production setup to get the last ounce of power, speed and efficiency to

save time, space and money.

Piston is cylinder part which moves in a cylinder have corresponding

hole on it. To make the strokes effective there is no gap between them or

with a very tiny gap, part of the micron. The cylinder and its piston have a

glazing surface where there is a contact between them for easy motion of

piston and avoiding wear and tear of both. The outer side of the cylinder

have mountings consists of plate and studs attached with it. But the of these

mountings, the cylinder and piston assembly can fitted on any place of the

piston have threads on it for fastening theother parts (or) accessories

according the operating performed and the application required. We can fit

holding devices, Clamping materials or other metal cutting and forming

ports with which can be movable with the piston.

Pneumatics are used practically in every industry for a wide variety of

manufacturing process, pneumatics equipments are used for multiple

reasons. The best reason is that it is air powered ordinary air turns out to be

very excellent as a fluid power components.

Solenoid Valve :

In order to automate the air flow in our system we have to provide an

electrically controlled valves. Electrical devices can provide more effective


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control, less expensive interlocks having many additional safety features and

simplified automatic sequencing when a machine must operate in a

hazardous area, remote actuation is a desirable. The operator can provide

satisfactory control though electrical devices from a remote point with in a

safe area, uding a semi automatic system and these electrical flow control

devices are also in use in full automation by providing proper action signals.

Push and pull actuation can be priced b solenoids. These movements

are used to open and close the pop pet type valves. These actuations are

done according to the signals given to the solenoid coil when the decided by

the program. The outlet of solenoiud coil when the decided by the program,.

The outlet of solenoid valve is connected to a spray gun, which is going to

spray the paint.


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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


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the solenoid valve action. In the de energized condition, the plunger and the

valve spool position as shown in figure 1.


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5/2 WAY VALVE


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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.


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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.


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PNEUMATIC CIRCUIT DIAGRAM


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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.


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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


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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


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Quick response is achieved

Simple in constructions

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

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 kg/s)

Silencer may be used, to reduce the noise of compressed air

APPLICATION


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1) 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.

2) 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 application of this unit is limited to operations, which involves

moderate clamping forces.

3) TRANSFER OF JOBS BETWEEN WORK STATIONS:

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

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


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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.

4) 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.


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PNEUMATIC CIRCUIT

DIAGRAM

PNEUMATIC CIRCUIT DIAGRAM


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FEATURES OF THE

PNEUMATIC SAW

MACHINE


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FEATURES OF THE PNEUMATIC SAW

MACHINE

It is compact in size

It can be move

The electrical power consumption is very low

It can be utilized at our work shop

It is simple in construction

Low cost

Less weight and easy to handle

It reduces the man power

It is used in mass production


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FINISHING AND PAINTING


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JOB PREPARATION;

Before welding, remove any bend in the L angle with the sludge

hammer on the anvil block. Then it is cut to the required length with the

hacksaw blade and fabricated to required dimensional shape with arc

welding.

FINISHING OPERATION BEFORE PAINTING;

After welding, any slag on the welded area is removed with the

chipping hammer and cleaned with the metal wire brush. Then all the

surfaces are rubbed with the emery sheet.

Metalprimer is applied on the surfaces with the brush .After drying the

metal primer, the second coating is applied with the paint.


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COST ESTIMATION


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1. Double Acting Cylinder (1x1200)-------------- 1200.00

2. Solenoid Valve 5/2 Way (1x1600)------------ 1600.00

3. Valve Connectors (10x50) --------- ----------- 600.00

4. M.S Stand With plywood ---------------------- 1200.00

5. Switches, power supply ------------------ 400.00

6. Tube (5 Meters)---------------------------------- 100.00

7. ON/OFF relay control -------------------------- 800.00

8. Miscellanies charges ----------------------------- 100.00

-------------------6000.00

-------------------


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CONCLUSION


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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

is 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 pneumatic system.

We have successfully completed the project work on using

Pneumatics system at our Institute.

By doing this project work, we understood the working principle and

uses of various Cylinders, Valves, etc. .

It will be of no doubt that Pneumatics will be an integrated part of any

process in industry in the near future and we developed a through knowledge

in Automation with Pneumatics

Once again we express our sincere thanks to our staff members.


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BIBILOGRAPHY


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BIBILOGRAPHY

PRODUCTION TECHNOLOGY : R.K. JAIN & S.C. QUPTA

METAL FORMING PROCESS : R.S. KURMI

MANUFACTURING PROCESS : K. RAMACHANDRAN

MACHINE SHOP TECHNOLOGY : S.S. MANIAN &

RAJAGOPAL &

G. BALAJI SINGH

DESIGN OF MACHINE ELEMENTS : R.S. KURMI &

P.N. VENKATESAN

DESIGN OF MACHINE ELEMENTS : RAMACHANDRAN

DESIGN DATA BOOK : P.S.G. COLLEGE OFTECHNOLOGY

www.google.com


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PHOTO VIEW


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Fab Pneumatc SAW Mc 2012

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