Pneumetic Punching Machine PPN

Automatic Pneumatic Punching machine

Module 1ABSTRACT

Presses are used in industries for a wide variety of uses, including blanking,

piercing and pressing. There are many different types of presses. The most popular

are pneumatic presses and hydraulic presses. These two models of presses are very similar

in function. But pneumatic presses are more preferable than hydraulic presses.

The greatest advantage of Pneumatic presses is their speed. Pneumatic presses are 10

times faster than hydraulic presses and they can perform many jobs faster and more

efficiently. They can also be stopped at any time by opening the valves to release the air.

Pneumatic presses are extremely flexible, that they can be placed in a factory in any required

position, even upside down.

The objective of our project is to MANUFACTURE THE PNEUMATIC

PUNCHING MACHINE of 2 tonne capacity and to make a U-Bend of 1mm thickness sheet

made of Galvanized Iron.

1Dept. Of Mechanical Engineering


1.1 SPECIFICATIONS OF PNEUMATIC

PRESS: The acting load is 2 tonne.

Cylinder Bore is 160mm. Stroke length is 170mm.

Diameter of Piston Rod is 63mm. Punch diameter is 24mm.

Die diameter is 24mm.

Volume of working plate is 540 x 465 x 50 mm3

By using this, the overall working time is reduced compared to other presses and hence,

the overall productivity increases.



Module 2INTRODUCTION

A power press is a machine that supplies force to a die used to blank, form, or shape

metal or nonmetallic material. Thus, a press is a component of a manufacturing system that

combines the press, die, material, and feeding method to produce a part. Presses are

composed of frame, bed, or bolster plate and a reciprocating member called a ram or slide,

which exerts force upon work material through special tools mounted on the ram and bed.

Energy stored in the rotating flywheel of a mechanical press (or supplied by a hydraulic system

in a hydraulic press, or supplied by pneumatic cylinder in a pneumatic press) is transferred to

the ram to provide linear movement.

Power presses can be classified according to:

1. Energy Supply

- Mechanical presses- Hydraulic presses- Pneumatic presses- Steam presses- Electromagnetic presses

2. Function

- Energy-producing machines- Force-producing machines- Stroke-controlled machines

3. Construction

- C-frame presses or gap-frame- Closed-frame presses or O-frame- 2-Pillar type- 4-Pillar type

4. Operation

- Single-Action Press- Double-Action Press- Triple-Action Press- Multi-slide Press



2.1 Pneumatic Presses

These type employs pressurized air using compressor as actuator and several valves to

generate a high compressive force acting on the male element it’s look like the hydraulic presses

but it deal with lower pressure requirements i.e. it generate lower acting forces.

2.2 C-Frame Presses or Gap-Frame

C-frame construction is often used with smaller-capacity presses. Their main advantage

lies in the easily accessible work area, which accounts for shorter setup and adjustmenttimes.

This advantage is perhaps outweighed by their faults, mostly attributable to theshape of their

frame, whose construction is likely to suffer from deflection under load.However, in current

machine building, ribs, back plate and other reinforcements are used tosecure the machine’s

sturdiness and accuracy.



Module 3PRINCIPLE OF PROJECT

Punching is a metal forming process that uses a punch press to force a tool, called a

punch, through the workpiece to create a hole via shearing. The punch often passes through the

work into a die. A scrap slug from the hole is deposited into the die in the process. Depending on

the material being punched this slug may be recycled and reused or discarded. Punching is often

the cheapest method for creating holes in sheet metal in medium to high production volumes.

When a specially shaped punch is used to create multiple usable parts from a sheet of material

the process is known as blanking. In forging applications the work is often punched while hot,

and this is called hot punching

Punch tooling (punch and die) is often made of hardened steel or tungsten carbide. A die

is located on the opposite side of the workpiece and supports the material around the perimeter of

the hole and helps to localize the shearing forces for a cleaner edge. There is a small amount of

clearance between the punch and the die to prevent the punch from sticking in the die and so less

force is needed to make the hole. The amount of clearance needed depends on the thickness, with

thicker materials requiring more clearance, but the clearance is always less than the thickness of

the workpiece. The clearance is also dependent on the hardness of the workpiece. The punch

press forces the punch through a workpiece, producing a hole that has a diameter equivalent to

the punch, or slightly smaller after the punch is removed. All ductile materials stretch to some

extent during punching which often causes the punch to stick in the workpiece. In this case, the

punch must be physically pulled back out of the hole while the work is supported from the punch

side, and this process is known as stripping. The hole walls will show burnished area, rollover,

and die break and must often be further processed. The slug from the hole falls through the die

into some sort of container to either dispose of the slug or recycle it

This Pneumatic hole Punching machine Have Pneumatic cylinder, 5/2 solenoid valve, Tool

Arrangements , bolts Nut Supporting pillar.

When The air from compressor, it will be taking a decision to move the tool down.

Also it will up and down movement when the obstacle crossing time that will also press sheet

with the help of pneumatic cylinder, and it will be given to the solenoid valve and then it will


Automatic Pneumatic Punching machinemove up or down depends upon the air speed. The tool movement and Up, down can be done

with the help of pneumatic cylinder.

This machine are mostly used in Industrial use to Mass Production It can punch hole rapidly and

Multi size Jobs.

It Have 10 bar maximum Pressure capacity . It can clamp 1 mm to 2mm thickness work pieces.

It cost also less, high efficiency, work loading time is less.



Module 4PNEUMATICS

Pneumatics is that branch of technology, which deals with the study and application of use of

pressurized air to affect mechanical motion.

“Pneumos” means “Air” and “Tics” means “Technology”.

The compressed air is used as the working medium, normally at a pressure of 6-

8bars(also can be extended up to 15bar) and a maximum force up to 50KN can be

obtained.Pneumatics is used extensively in industry as well as in many everyday applications. It

has many distinct advantages in terms of energy consumption, cost and safety.Pneumatic power

is used in industry, where factory machines are commonly plumbed for compressed air

(other compressed inert gases can also be used). Pneumatics also has applications in dentistry,

construction, mining, and other areas.

4.1 GASES USED IN PNEUMATIC SYSTEMS

Pneumatic systems in fixed installations such as factories use compressed air because a

sustainable supply can be made by compressing atmospheric air. The air usually has moisture

removed and a small quantity of oil added at the compressor, to avoid corrosion of mechanical

components and to lubricate them.


Automatic Pneumatic Punching machine4.2 ADVANTAGES OF PNEUMATICS

Simplicity of Design and Control

- Machines are designed using standard cylinders and other components. Control is as

easy as ON-OFF type.

Reliability

- Pneumatic systems tend to have long operating lives and require very little

maintenance.

- Because gas is compressible, the equipment is less likely to be damaged by

Storage

- Compressed Gas can be stored, allowing the use of machines when electrical power is lost.

Safety

- Very low chance of fire (compared to hydraulic oil).

- Machines can be designed to be overload safe.


Automatic Pneumatic Punching machine4.3 PNEUMATIC SYSTEMS

Pneumatics is something that we probably know very little about, yet come across every

day without even realising it. Some examples of everyday pneumatic systems are shown below.

.

Fig#1 Example of a pneumatic system

Pneumatics is also used a lot in industry and you would expect to see pneumatic systems in

factories, production lines and processing plants. It can be used to do lots of different jobs such

as moving, holding or shaping objects.

Fig # 2 Operations done by Pneumatic System


Automatic Pneumatic Punching machineEvery one of these pneumatic systems makes use of compressed air. Compressed air is quite

simply the air that we breathe forced or squashed into a smaller space. We can use the energy

stored in this compressed air to do things.

4.4 PREPARATION OF AIR

For a pneumatic system, we need the pressurized air which is free from dust, moisture and

smoke. To remove these pollutants, air is filtered. During the filtration, the dust, moisture and

smoke are eliminated about 90%. Then the pressurized air passes through the air dryer to remove

the moisture and make the air dry. Then it passes through another filter, where a complete free

air is available for the system. This pressurized air goes to the FRL unit, then to the system.

Fig # 3 Basic Pneumatic System

To understand how compressed air is able to do things, let’s think of a ball. If we blow up

the ball so that it is full, it will contain a lot of compressed air. If we bounce the ball, it will

bounce very high. However, if the ball is burst then the compressed air will escape and the ball

will not bounce as high. Quite simply, the ball bounces because it is using the energy stored in

the compressed air.



Fig # 4 Example of Pneumatic Systems

4.5 ADVANTAGES OF PNEUMATICS

There are usually lots of different ways to carry out a task, so it is important to understand

some of the reasons for choosing pneumatic systems.

Clean:

Pneumatic systems are clean because they use compressed air. We know already that this

is just the air we breathe forced into small spaces. If a pneumatic system develops a leak, it will

be air that escapes and not oil. This air will not drip or cause a mess and this makes pneumatics

suitable for food production lines.

Safe:

Pneumatic systems are very safe compared to other systems. We cannot, for example, use

electronics for paint spraying because many electronic components produce sparks and this could

cause the paint to catch fire.

It is important, however, that we look after and maintain the different components. It is also

important that we follow the correct safety rules.

Reliable:

Pneumatic systems are very reliable and can keep working for a long time. Many

companies invest in pneumatics because they know they will not have a lot of breakdowns and

that the equipment will last for a long time.

Economical:


Automatic Pneumatic Punching machineIf we compare pneumatic systems to other systems, we find that they are cheaper to run.

This is because the components last for a long time and because we are using compressed air.

Many factories already have compressed air for other reasons.

Flexible:

Pneumatic systems are easy to install and they do not need to be insulated or protected

like electronic systems.



4.6 SUPPLYING COMPRESSED AIR

We know already that pneumatic systems need compressed air to make them work. A

bicycle pump can produce compressed air. This is all right for inflating the tyres of the bicycle,

but can you imagine trying to blow up all the tyres on a lorry using this? You would soon

become tired, exhausted even.

In order to supply pneumatic systems with compressed air we use a machine called a

compressor. Compressors come in lots of different shapes and sizes but they all work in the same

way.

Fig # 5 Compressor

A pump that is driven by a motor, sucks-in air from the room and stores it in a tank called

the receiver. We will be able to hear the compressor when it is running. Sometimes though, it

will stop because the receiver is full.



Fig # 6 ON/OFF positions for air flow

4.7 SAFETY RULES

Safety rules help to keep us safe. They highlight dangers and this helps to prevent accidents.

When we are using pneumatics we must follow these rules.

1. Never blow compressed air at anyone, not even yourself.

2. Never let compressed air come into contact with your skin, as this can be very dangerous.

3. Always wear safety goggles when you are connecting and operating circuits.

4. Check that all airlines are connected before turning on the main air supply.

5. Always turn off the main air supply before changing a circuit.

6. Keep your hands away from moving parts.

7. Avoid having airlines trailing across the floor or where someone could trip or become

entangled.



Module 5 PARTS OF PNEUMATIC SYSTEM

5.1 PNEUMATIC CYLINDERS:

Pneumatic equipment can be split up into two basic categories of cylinders and valves.

Cylinders are the ‘muscles’ of pneumatic systems as they are used to move, hold and lift objects.

They can even be used to operate other pneumatic components. Cylinders are operated by

compressed air and they covert the stored energy in the compressed air into linear motion.

Fig # 7 Pneumatic Cylinders Linear motion is motion in a straight line: an apple falling from a tree or a sliding door closing is

an example of linear motion. We can represent linear motion by arrows like the ones below.

There are two types of cylinder that we will be using:

Single-Acting Cylinders

Double-Acting Cylinders


Automatic Pneumatic Punching machine5.2 Single-Acting Cylinder:

The symbol for a single-acting cylinder is shown below.

Fig # 8 Single Acting Cylinder

A single-acting cylinder requires only one air supply. If we supply compressed air to a

single-acting cylinder, the air pushes against the piston inside the cylinder and causes it to

outstroke. When the piston has fully outstroked it is said to be positive.

Fig # 9 Outstroke of the Piston

If we stop the supply of air then the spring inside the cylinder causes the piston to

instroke to its starting position and the piston is said to be negative. As this happens, the air

inside the cylinder is pushed back out.

Fig # 10 Instroke of the Piston


Automatic Pneumatic Punching machineSingle-acting cylinders are easy to use and control but they do not produce very big

forces. This means that we need to be careful of what we use them for.

5.3 Double-Acting Cylinder

A double-acting cylinder has no spring inside to return it to its original position. It needs two

air supplies, one to outstroke the piston and the other to instroke the piston.

The symbol for a double-acting cylinder is shown below.

Fig # 11 Double Acting Cylinder

To outstroke a double-acting cylinder we need compressed air to push against the piston

inside the cylinder. As this happens, any air on the other side of the piston is forced out. This

causes the double-acting cylinder to outstroke. When the piston has fully outstroked it is said to

be positive.

Fig # 12 Outstroke of the Piston

To instroke a double-acting cylinder we need to reverse this action. We supply the

compressed air to the other side of the piston. As the air pushes the piston back to its original

position, any air on the other side is again forced out. This causes the piston to instroke and it is

said to be negative.

Fig # 13 Instroke of the Piston


Automatic Pneumatic Punching machineDouble-acting cylinders are used more often in pneumatic systems than single-acting

cylinders. They are able to produce bigger forces and we can make use of the outstroke and

instroke for pushing and pulling.

Sizes:

Air cylinders are available in a variety of sizes and can typically range from a small 2.5

mm air cylinder, which might be used for picking up a small transistor or other electronic

component, to 400 mm diameter air cylinders which would impart enough force to lift a car.

Some pneumatic cylinders reach 1000 mm in diameter, and are used in place of hydraulic

cylinders for special circumstances where leaking hydraulic oil could impose an extreme hazard.

Materials: The pneumatic cylinders designed for educational use typically have transparent outer

sleeves (often plexi glass), so students can see the piston moving inside.

The pneumatic cylinders designed for cleanroom applications often use lubricant-free Pyrex

Glass pistons sliding inside graphite sleeves.

In general, the material used for a pneumatic cylinder is ST-52 (Steamless Tube).

5.4 VALVES: Valves control the flow of compressed air to a cylinder. They can be used to turn the air

on or off, change the direction in which the air is flowing or even slow down the airflow. The

most common type of valve is the 3/2 valve.

3/2 valve:

A 3/2 valve gets its name because it has three ports and two states. A port is where we

can connect a pipe and a state is simply a position that the valve can be in. The ports are

numbered to help us make the right connections. The numbers will be stamped onto the casing of

the valve.

Port 1 – Main Air

This port is connected to main air. Remember that our main air is supplied through a

manifold. Main air is identified by this symbol:


Automatic Pneumatic Punching machinePort 2 – Output Connection

This port lets us make connections to other components. Remember, the purpose of valves is

to control the flow of air to other components, usually cylinders.

Port 3 – Exhaust This port allows air trapped in the circuit to escape or exhaust. Remember, for our cylinders

to instroke and outstroke, they need the air on the other side of the piston to escape.

The 3/2 valve has two states of operation. One state prevents air from being supplied to other

components and the other allows the air to flow freely.

State 1 – Off/Unactuated State: In this state, the main air supply through the valve is blocked and so air is unable to reach

other components, such as cylinders. However, any air within the cylinder is able to exhaust

through the valve and this will allow the cylinder to return to its original position.

The symbol below represents the air flow through the valve in OFF state.

State 2 – On/Actuated State: In this state, the main air supply is able to flow freely through the valve and supply

components, such as cylinders, with air.

The symbol below represents the air flow through the valve in OFF state.

The complete symbol for a 3/2 valve combines both states and is usually drawn in the

OFF/Unactuated state. The complete symbol is shown below.


Automatic Pneumatic Punching machine5.5 T-PIECE

A T-piece or T-connector is a very simple component that lets us split or divide airflow.

It can be very useful if you want two cylinders to operate at the same time.

Fig # 14 T-Connector

On circuit diagrams, the T-piece is identified by a dot.

5.6 COMPRESSORS

An air compressor is a machine which takes in air at a certain pressure and delivers the air at

a higher pressure. Everything on earth is subjected to the absolute atmospheric pressure(pa), this

pressure cannot be felt. The prevailing atmospheric pressure is therefore regarded as the base and

any deviation is termed "gauge pressure".

Absolute pressure = Atmospheric pressure + gauge pressure

Absolute pressure is approximately one bar greater than the gauge pressure. Characteristics of

interest on a compressor are, Delivery volume or capacity of the compressor, Compression ratio.

Compressor capacity is usually expressed as air volume at ambient conditions at the compressor

intake, namely in units of meter cube per minute or litres per minute.

Compression ratio is expressed by the discharge pressure measured in the generally accepted

unit of bars. Compressors should be installed in a separate room. Special care is required to

ensure that the compressors will be able to take in air that is preferably cool but above all dry and

substantially dust-free. At locations where clean suction air is not available, the installation of a

separate intake filter can answer this requirement. Piping leading from the filter to the


Automatic Pneumatic Punching machinecompressor intake should be amply dimensioned. In this way it is also possible for clean suction

air to be supplied to a multiple number of compressors via a common intake duct.

5.7 FRL Unit

It is a device that conditions air for use in pneumatic systems. An FRL is a combination

filter-regulator-lubricator.frl units have semi-auto-drain function and the body is made of die

casting aluminum alloy, thus making them sturdy to operate in industrial environments.

Fig # 15 FRL Unit The FRL units are used in various industries such as food processing, paper and packaging,

pharmaceutical and textile. Offered at economical prices, FRL units are robust in design,

construction and are ideal to be used in tough working conditions.

Specifications:

Medium: Compressed air

Mounting position: Vertical ± 5°

Pressure range max.: 10 Bar

Temperature nominal: -10 to + 60°



5.8 COMPONENTS USED

Double acting cylinder

Pneumatic hand operated valve

High speed steel blade

SPECIFICATIONS

PNEUMATIC CYLINDER

Stroke length = 150mm

Diameter = 50mm

Pressure = 10bar


Automatic Pneumatic Punching machine5.9 PNEUMATIC CYLINDER

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which

use the power of compressed gas to produce a force in a reciprocating linear motion.

Like hydraulic cylinders, pneumatic cylinders use the stored potential energy of a fluid,

in this case compressed air, and convert it into kinetic energy as the air expands in an attempt to

reach 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. Engineers prefer to use pneumatics sometime because they are quieter, cleaner, and

do not require large amounts or space for fluid storage.

Because the operating fluid is a gas, leakage from a pneumatic cylinder will not drip out

and contaminate the surroundings, making pneumatics more desirable where cleanliness is a

requirement. For example, in the mechanical puppets of the DisneyTiki Room, pneumatics are

used to prevent fluid from dripping onto people below the puppet.

Figure (i)

DOUBLE-ACTING CYLINDER


Automatic Pneumatic Punching machineDouble-acting cylinders (DAC) use the force of air to move in both extend

and retract strokes. They have two ports to allow air in, one for out-stroke and one

for in-stroke. Stroke length for this design is not limited, however, the piston rod is

more vulnerable to buckling and bending. Addition calculations should be

performed as well by using design data hand book using some relations between

cylinder and pressure we can accurately find out bending and buckling of tie rod.

2D VIEW:

Figure (ii)


http://en.wikipedia.org/wiki/File:Doppelwirkender_Zylinder_Funktionsprinziep.gif

Automatic Pneumatic Punching machine5.10 TWO WAY DIRECTIONAL VALVE

A two-way directional valve consists of two ports connected to each other withpassages,

which are connected and disconnected. In one extreme spool position, portA is open to port B;

the flow path through the valve is open. In the other extreme,the large diameter of the spool

closes the path between A and B; the flow path isblocked. A two-way directional valve gives an

on-off function.

(Flow path open and Flow path closed).

Figure (iii)

5.11 HIGH SPEED STEEL BLADE:

A blade is used to cut the sheet metal in a desired dimension. Here we are using high speed steel

blades to cut the sheet metal.


Automatic Pneumatic Punching machine5.12 PNEUMATIC TRANSMISSION OF ENERGY:

The reason for using pneumatics, or any other type of energy transmission on amachine,

is to perform work. The accomplishment of work requires the applicationof kinetic energy to a

resisting object resulting in the object moving through adistance. In a pneumatic system, energy

is stored in a potential state under the formof compressed air. Working energy (kinetic energy

and pressure) results in apneumatic system when the compressed air is allowed to expand. For

example, atank is charged to 100 PSIA with compressed air. When the valve at the tank outletis

opened, the air inside the tank expands until the pressure inside the tank equals theatmospheric

pressure. Air expansion takes the form of airflow.

To perform any applicable amount of work then, a device is needed which cansupply an

air tank with a sufficient amount of air at a desired pressure. This deviceis positive displacement

compressor.

What a Positive Displacement Compressor Consists of

A positive displacement compressor basically consists of a movable member insidea

housing. The compressor has a piston for a movable member. The piston isconnected to a

crankshaft, which is in turn connected to a prime mover (electricmotor, internal combustion

engine). At inlet and outlet ports, valves allow air toenter and exit the chamber.

How a Positive Displacement Compressor Works:

As the crankshaft pulls the piston down, an increasing volume is formed within

thehousing. This action causes the trapped air in the piston bore to expand, reducing itspressure.

When pressure differential becomes high enough, the inlet valve opens,allowing atmospheric air

to flow in. With the piston at the bottom of its stroke, inletvalve closes. The piston starts its

upward movement to reduce the air volume whichconsequently increases its pressure and

temperature. When pressure differentialbetween the compressor chamber and discharge line is

high enough, the dischargevalve opens, allowing air to pass into an air receiver tank for storage.


Automatic Pneumatic Punching machine5.13 Control of Pneumatic Energy:

Working energy transmitted pneumatically must be directed and under completecontrol at

all times. If not under control, useful work will not be done and machineryor machine operators

might be harmed. One of the advantages of transmittingenergy pneumatically is that energy can

be controlled relatively easily by usingvalves.

Control of Pressure:

Pressure in a pneumatic system must be controlled at two points - after thecompressor

and after the air receiver tank. Control of pressure is required after thecompressor as a safety for

the system. Control of pressure after an air receiver tankis necessary so that an actuator receives

a steady pressure source without wastingenergy.

Control of Pressure after a Compressor:

In a pneumatic system, energy delivered by a compressor is not generally

usedimmediately, but is stored as potential energy in air receiver tank in the form ofcompressed

air.

In most instances, a compressor is designed into a system so that it operates intermittently. A

compressor usually delivers compressed air to a receiver tank untilhigh pressure is reached, then

it is shut down. When air pressure in the tankdecreases, the compressor cuts in and recharges the

tank. Intermittent compressoroperation in this manner is a power saving benefit for the system.

A common way of sensing tank pressure and controlling actuation and de-actuationof relatively

small (2-15 HP) compressors, is with a pressure switch.



Module 6MECHATRONICS

Mechatronics is a multidisciplinary field of engineering that includes a combination of

mechanical engineering, electrical engineering, telecommunications engineering, control

engineering and computer engineering. As technology advances the subfields of engineering

multiply and adapt. Mechatronics' aim is a design process that unifies these subfields. Originally,

mechatronics just included the combination of mechanics and electronics, hence the word is a

combination of mechanics and electronics; however, as technical systems have become more

and more complex the word has been broadened to include more technical areas.

The word "mechatronics" originated in Japanese-English and was created by Tetsuro

Mori, an engineer of Yaskawa Electric Corporation. The word "mechatronics" was registered as

trademark by the company in Japan with the registration number of "46-32714" in 1971.

However, afterward the company released the right of using the word to public, and the word

"mechatronics" spread to the rest of the world. Nowadays, the word is translated in each

language and the word is considered as an essential term for industry.


http://en.wikipedia.org/wiki/Trademark

http://en.wikipedia.org/wiki/Yaskawa_Electric_Corporation

http://en.wikipedia.org/wiki/Wasei-eigo

http://en.wikipedia.org/wiki/Engineering

http://en.wikipedia.org/wiki/Technology

http://en.wikipedia.org/wiki/Computer_engineering

http://en.wikipedia.org/wiki/Control_engineering

http://en.wikipedia.org/wiki/Control_engineering

http://en.wikipedia.org/wiki/Telecommunications_engineering

http://en.wikipedia.org/wiki/Electrical_engineering

http://en.wikipedia.org/wiki/Mechanical_engineering

http://en.wikipedia.org/wiki/Multidisciplinary

Automatic Pneumatic Punching machineFrench standard NF E 01-010 gives the following definition: “approach aiming at the

synergistic integration of mechanics, electronics, control theory, and computer science within

product design and manufacturing, in order to improve and/or optimize its functionality".

Many people treat "mechatronics" as a modern buzzword synonymous with "electromechanical

engineering". However, other people draw a distinction between an "electromechanical

component"—does not include a computer; an electro-mechanical computer (such as the Z4)—

does not include an electronic computer; vs. a "mechatronic system"—a computer-controlled

mechanical system, including both an electronic computer and electromechanical components.


http://en.wikipedia.org/wiki/Z4_(computer)

http://en.wikipedia.org/wiki/Mechanical_computer#Electro-mechanical_computers

http://en.wikipedia.org/wiki/Electromechanical_engineering

http://en.wikipedia.org/wiki/Electromechanical_engineering

INPUTAC

SUPPLY

REGULATEDIC

STEP DOWNTRANSFORMER

RECTIFIERCIRCUIT

FILTERCIRCUIT


Module 7ELECTRONIC CONTROL

7.1 POWER SUPPLY

Power supply is the first and most important part of our project. In the proposed project the

power supply circuit is used to provide the regulated supply to the IC`s used in the project.

Power supply circuit consists of step down transformer, rectifier circuit, filter circuit and

regulator IC.

BLOCK DIAGRAM OF POWER SUPPLY

CIRCUIT DIAGRAM OF THE POWER SUPPLY

Step Down Transformer


Automatic Pneumatic Punching machine Transformers are static device which convert the electrical energy from one

circuit to another circuit without any change in frequency and power. Step down transformer

means the transformer which reduces the supply voltage to the desired value. In our project we

need 12 volt DC supply, therefore in this project 12-0-12, 500mA transformer is used.

Rectifier Circuit

Rectifier is a circuit which converts the AC electrical energy into Dc electrical

energy. For operating of semiconductor devices used in this project we need regulated DC

supply. In this project we use centre tap full wave rectifier. Full wave rectifier circuit is capable

of converting sinusoidal input into a unidirectional output. The circuit diagram is as shown in the

figure.

Filter Circuit

It is seen that the output of the rectifier is not pure DC, because it contain

some amount of AC component which is called as ripple factor which gives the fluctuation and

hence to minimize the ripple in the output the filter circuit is used. This circuit is connected after

the rectifier circuit. In our project capacitor input filter is used. The circuit is as shown in the

figure. The capacitor is connected in parallel to minimize the ripple factor.

Regulator Circuit

In our project for the operation of IC we need +5 volt regulated supply is

necessary therefore a voltage regulator circuit is used. A voltage regulator is a circuit that

supplies constant voltages regardless of change in the load current. IC voltage regulators are

versatile and generally used. The 78xx series consist of three terminal positive voltage

regulators. These ICs are designed as fixed voltage regulator and adequate heat sink. It can be

deliver output current in access of 1A. These devices do not required external component.

These ICs has internal terminal overload protection and internal short circuit

and current limiting protection.


Automatic Pneumatic Punching machine7.2 VALVE CONTROLLER CIRCUIT


Automatic Pneumatic Punching machine7.3 WORKING OF ELECTONICS CONTROLLER

In this project automatic pnumetic valve controlled by the Micrcontroller.

Micrcontroller works on +5 Volt DC power supply. Program is dumped in the controller which

is written ic embedded c language and compiled in Keil Software.

When we powering the coontroller, mircontroller generate High pulse for 1 sec and low pulse for

1 sec as condition is written in the program.

We get this pulses at Pin 21 port2.0. this pin is connected to the BC547 NPN switching

transister. When high pulse is reaches at the base of transister then current flow from emmiter to

collector means transister is in on state cause current reaches to the coil of the relay it tend to

actuate the relay so current flow in pnumetic electonic valve.


Automatic Pneumatic Punching machine7.4 MICROCONTROLLER

AT89C52

AT89C52 is an 8-bit microcontroller and belongs to Atmel's 8051 family. AT89C52 has 8KB of

Flash programmable and erasable read only memory (PEROM) and 256 bytes of RAM.

AT89C52 has an endurance of 1000 Write/Erase cycles which means that it can be erased and

programmed to a maximum of 1000 times.

Though very slight difference between the features of AT89C51 and AT89C52, they are very

similar in their pin configurations* and operations. The differences between AT89C51 and

AT89C52 have been tabulated below.

AT89C52 AT89C51

RAM 256 Bytes 128 Bytes

Flash 8 KB 4 KB

Number of Timers/Counters 3 (16-bit each) 2 (16-bit each)

Number of Interrupt Sources 8 6

*The pin configuration of AT89C52 is exactly similar to that of AT89C51 except that the first

two pins, P1.0 and P1.1 are multiplexed to correspond to Timer2 operations as given in the

following table.

Existing Alternate Function

P1.0 T2 Timer/counter 2 External Count input

P1.1 T2 EX Timer/counter 2 Trigger input

While AT89C51 has two timers (Timer0 & Timer1), AT89C52 also has Timer2. Corresponding

to Timer2, there are extra SFRs (Special Function Registers) T2CON & T2MOD. Also there are

registers RCAP2H & RCAP2L to configure 16 bit Capture & Auto-reload modes of Timer2.

7805 Voltage Regulator


Automatic Pneumatic Punching machine7805 is a voltage regulator integrated circuit. It is a member of 78xx series of fixed linear

voltage regulator ICs. The voltage source in a circuit may have fluctuations and would not give

the fixed voltage output. The voltage regulator IC maintains the output voltage at a constant

value. The xx in 78xx indicates the fixed output voltage it is designed to provide. 7805 provides

+5V regulated power supply. Capacitors of suitable values can be connected at input and output

pins depending upon the respective voltage levels.

Pin Description:

Pin No Function Name

1 Input voltage (5V-18V) Input

2 Ground (0V) Ground

3 Regulated output; 5V (4.8V-5.2V) Output


Automatic Pneumatic Punching machine7.5 TRANSFORMER

A transformer is an apparatus for converting electrical power in an ac system at one voltage or

current into electrical power at some other voltage or current without the use of rotating parts.

Transformers have been an essential component in electrical as well as electronic circuits. Apart

from stepping up or stepping down the voltages, they are used for providing isolation, for

impedance mismatch and so on. Development of new technologies has reduced the usage of

transformers, but still they are quite vital in many applications.

Transformers are of many types and are used as per specific requirements. In addition to the

transformers used in power systems, in power transmission and distribution, a large number of

special transformers are in use in applications like electronic supplies, furnaces, traction, audio

applications, RF and microwave circuits, etc. Subsequent sections will present details about the

transformers.

What is a TRANSFORMER ?

A transformer is an electrical device that transfers electrical energy at one voltage from one

circuit to other at a different voltage merely by magnetic coupling; the transfer of energy doesn’t

involve any kind of motion.

Transformers are analogous to gear box (used to convert torque and hence speed). Transformers

step up or step down the voltage and therefore vary the current. As the product of speed and

torque remains constant, product of voltage and current also remains constant.

Transformers utilises the principle of electromagnetism given by Faraday’s law. A conductor

carrying changing current carrying sets up a changing magnetic field around it. When a second

conductor is placed in this varying magnetic field, voltage will be induced into it. Get a clearer

picture about transformers through exclusive images detailing about its internal structure and

windings at the transformer insight page.



When an AC voltage is applied to one (primary) coil, the varying magnetic field is set up around

the coil. By virtue of mutual induction, it creates an AC voltage in the other (secondary) coil. A

transformer can also be used with pulsating dc, but a pure dc voltage cannot be used, since only a

varying voltage creates the varying magnetic field which is the basis of the mutual induction

process.

An ideal transformer has infinite winding reactance, zero winding resistance, zero leakage

inductance and zero winding capacitances. Voltage ratio is equal to the turns ratio under all

loading conditions.


Automatic Pneumatic Punching machine7.6 Relay

A relay is an electrical switch that opens and closes under the control of another electrical circuit. In the original form, the switch is operated by an electromagnet to open or close one or many sets of contacts. It was invented by Joseph Henry in 1835. Because a relay is able to control an output circuit of higher power than the input circuit, it can be considered to be, in a broad sense, a form of an electrical amplifier.

Latching relay

A latching relay has two relaxed states (bistable). These are also called "impulse", "keep" or "stay" relays. When the current is switched off, the relay remains in its last state. This is achieved with a solenoid operating a ratchet and cam mechanism, or by having two opposing coils with an over-center spring or permanent magnet to hold the armature and contacts in position while the coil is relaxed, or with a remanent core. In the ratchet and cam example, the first pulse to the coil turns the relay on and the second pulse turns it off. In the two coil example, a pulse to one coil turns the relay on and a pulse to the opposite coil turns the relay off. This type of relay has the advantage that it consumes power only for an instant, while it is being switched, and it retains its last setting across a power outage. A remanent core latching relay requires a current pulse of opposite polarity to make it change state.

Relays are amazingly simple devices. There are four parts in every relay:

Electromagnet Armature that can be attracted by the electromagnet Spring Set of electrical contacts

The following figure shows these four parts in action:


http://en.wikipedia.org/wiki/Solenoid

http://en.wikipedia.org/wiki/Amplifier

http://en.wikipedia.org/wiki/Joseph_Henry

http://en.wikipedia.org/wiki/Magnet

http://en.wikipedia.org/wiki/Electrical_circuit

http://en.wikipedia.org/wiki/Electrical_circuit

http://en.wikipedia.org/wiki/Switch


In this figure, you can see that a relay consists of two separate and completely independent circuits. The first is at the bottom and drives the electromagnet. In this circuit, a switch is controlling power to the electromagnet. When the switch is on, the electromagnet is on, and it attracts the armature (blue). The armature is acting as a switch in the second circuit. When the electromagnet is energized, the armature completes the second circuit and the light is on. When the electromagnet is not energized, the spring pulls the armature away and the circuit is not complete. In that case, the light is dark.

When you purchase relays, you generally have control over several variables:

The voltage and current that is needed to activate the armature The maximum voltage and current that can run through the armature and the armature

contacts The number of armatures (generally one or two) The number of contacts for the armature (generally one or two -- the relay shown here

has two, one of which is unused) Whether the contact (if only one contact is provided) is normally open (NO) or normally

closed (NC)

Relay Applications

In general, the point of a relay is to use a small amount of power in the electromagnet -- coming, say, from a small dashboard switch or a low-power electronic circuit -- to move an armature that is able to switch a much larger amount of power. For example, you might want the electromagnet to energize using 5 volts and 50 milliamps (250 milliwatts), while the armature can support 120V AC at 2 amps (240 watts).


http://science.howstuffworks.com/electromagnet.htm

Automatic Pneumatic Punching machineRelays are quite common in home appliances where there is an electronic control turning on something like a motor or a light. They are also common in cars, where the 12V supply voltage means that just about everything needs a large amount of current. In later model cars, manufacturers have started combining relay panels into the fuse box to make maintenance easier. For example, the six gray boxes in this photo of a Ford Windstar fuse box are all relays:

In places where a large amount of power needs to be switched, relays are often cascaded. In this case, a small relay switches the power needed to drive a much larger relay, and that second relay switches the power to drive the load.


http://home.howstuffworks.com/light-bulb.htm

http://electronics.howstuffworks.com/motor.htm

Automatic Pneumatic Punching machine7.7 PUNCHING

Punching is a metal forming process that uses a punch press to force a tool, called a

punch, through the workpiece to create a hole via shearing. The punch often passes through the

work into a die.

Fig # 16 Punching

A scrap slug from the hole is deposited into the die in the process. Depending on the material

being punched this slug may be recycled and reused or discarded. Punching is often the cheapest

method for creating holes in sheet metal in medium to high production. When a specially shaped

punch is used to create multiple usable parts from a sheet of material the process is known as

blanking. In forging applications the work is often punched while hot, and this is called hot

punching.


Automatic Pneumatic Punching machinePneumatic hole punching helps to make the hole in sheet metal by using Compressed Air.

Pneumatic actuators controlled energy to the punch , so the Operator needs to provide only

modest effort regardless of conditions. Pneumatic Punching machine helps to make hole in

Various size by changing tool. As well, pneumatic Punch provides some feedback of forces

acting on the Sheet and Hole can Made in Sheet metal.

Pneumatic Hole punching machine is reduce Effort To Operator. Operator Need Very Less

amount of effort.

Pneumatic hole punching machine operated by compressed Air. Pneumatic clamp have

pneumatic Cylinder, 5/2 Flow control Hand Lever valve

Design Construction Depending on the job specification, there are multiple forms of body

constructions available :

Tie rod cylinders: The most common cylinder constructions that can be used in many

types of loads. Has been proven to be the safest form.

Flanged-type cylinders: Fixed flanges are added to the ends of cylinder, however, this

form of construction is more common in hydraulic cylinder construction.

One-piece welded cylinders: Ends are welded or crimped to the tube, this form is

inexpensive but makes the cylinder non-serviceable.

Threaded end cylinders: Ends are screwed onto the tube body. The reduction of material

can weaken the tube and may introduce thread concentricity problems to the system


Automatic Pneumatic Punching machine7.8 TOOL AND TOOL DESIGN PUNCH:

Punch is used to press the sheet metal, to the shape of DIE. The load from the cylinder is

impacted on to the punch, which bends the sheet metal.

Fig # 30 Punch Design

Punch tooling (punch and die) is often made of hardened steel or tungsten carbide. A die

is located on the opposite side of the workpiece and supports the material around the perimeter of

the hole and helps to localize the shearing forces for a cleaner edge. There is a small amount of

clearance between the punch and the die to prevent the punch from sticking in the die and so less

force is needed to make the hole. The amount of clearance needed depends on the thickness, with

thicker materials requiring more clearance, but the clearance is always less than the thickness of

the workpiece. The clearance is also dependent on the hardness of the workpiece. The punch

press forces the punch through a workpiece, producing a hole that has a diameter equivalent to

the punch, or slightly smaller after the punch is removed. All ductile materials stretch to some

extent during punching which often causes the punch to stick in the workpiece. In this case, the

punch must be physically pulled back out of the hole while the work is supported from the punch

side, and this process is known as stripping. The hole walls will show burnished area, rollover,

and die break and must often be further processed. The slug from the hole falls through the die

into some sort of container to either dispose of the slug or recycle it.



Module 8WORKING OF PNEUMATIC PRESS

The pneumatic press is provided with a 2 tonne capacity cylinder.

Compressor is a pump which stores up air at working pressure say 6 psi (pounds per

square inch) and compresses air, raising it to a higher pressure. The compressed air from the

compressor (in this case 6 psi) is delivered to the cylinder (160mm Bore) of the pneumatic press

(sometimes, can also be used to generate a vacuum).

When the lever is operated, the high pressure air in the cylinder is released, pushing the

piston and the rod attached to it, downwards.

The released air is free and non- toxic. Often the air is slightly modified by taking out

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

machines friendly by using FRL unit.

A 160mm (6.299 inches) diameter cylinder has an area of πr2. So if we have 6 psi air

pressure pushing on 3.14 square inches of surface. That cylinder has 6psi x 31.14 inch2 = 186.88

lbs of pressure.

This pressure pushes down the rod. Ram connected to the rod is forced downwards

which in turn pushes down the punch which is fixed to the ram. This punch, hits the metal

sheet placed on the die having a U-Groove. The pressure is applied until the part has been

formed to the proper angle.



Module 9 APPLICATIONS

Sheet metals are used in

Car bodies

Airplane wings

Medical tables

Roofs for buildings (Architectural) and many other things

Sheet metal of iron and other materials with high magnetic permeability, also

known as laminated steel cores, has applications in transformers and electric

machines.

Historically, an important use of sheet metal was in plate armor worn by cavalry,

and sheet metal continues to have many decorative uses, including in horse tack.



Module 10ADVANTAGES

Low cost

Less consumption of time

Easy to handle

Skilled labor is not required

Less maintainance

High accuracy

Good surface finish

Less floor space



Module 11FUTURE EXTENSION

We contemplate the following future features which can be incorporated into this project:-

A die to produce a washer of less than 1mm thickness.

Automation of pneumatic press.

Improvements in pneumatic press by adding components like timers, silencers etc.



Module 12 REFERENCES

http://www.ciri.org.nz/bendworks/bending.pdf

We made this project with our own idea with the help of

“HYDRAULIC AND PNEUMATIC SYSTEM” written by Srinivasan,

“TOTAL AUTOMATIVE TECHNOLOGY” written by Anthony E Schwaller,

“INDUSTRIAL ENGINEERING AND THE ENGINEERING DIGEST” written by Robert Thurston Kent, Charles MaccaugheySomes

WEBSITES:

www.pumpwork.in

www.wikipedia.com

www.howstuffworks,com


http://www.howstuffworks,com

http://www.wikipedia.com/

http://www.pumpwork.in/

Pneumetic Punching Machine PPN

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