ACTUAL COMPONENTS USED IN OUR PEOJECT

1.PNUEMATIC CYLENDER

2.HACKSAW BALDE AS CUTTER

3.DC 5/2 PNUEMATIC VALVE

4.DC MOTOR

5.ROLLER

6.ARDUINO BORAD

7.ULTASONIC SENSOR

8. POWER SUPPLY

9.MOTOR DRIVER
PHOTOS OF COMPONETS USED IN PROJECT MODEL
1.PNUEMATIC CYLINDER

SPECIFICATION OF PNUEMATIC CYLENDER

1.Body material : Aluminum die cast /Aluminum alloy

2.TYPE : DOUBLE ACTING

3. Seal material : TPE-U ( PU) or equivalent

4. Power : Pneumatic

5. Stroke : 100 mm

6 BORE : 50 MM

6. Piston diameter : 35

7. Piston rod thread : M16x1.5 ( male ) for Type:1 M20x1.5 ( male) for Type:2

8. Theoretical force at 6 bar pressure : 1500N or higher

9. Mode of operation : Double acting

10. Pressure range : up to 12 bar or higher

11. Temperature Range : Up to 50oC or higher

12. Cushioning : Pneumatic cushioning adjustable at both end

13. Assembly position : Any

14. Pneumatic connection : 3/8″

Pneumatic cylinder(s) (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, something 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 sometimes prefer to use pneumatics because they are quieter, cleaner, and do
not require large amounts of 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 Disney TIKI ROOM, pneumatics are
used to prevent fluid from dripping onto people below the puppets
2.DC SOILNOID VALVE

1. Type of actuation : Electrical

2. Valve function : 5/2 mono stable

3. Working pressure : Up to 10 bar or higher

4. Nominal flow rate : 2000 lpm or higher

5. Design structure : Piston slide

6. Type of reset : Mechanical spring

7. Sealing principal : Soft

8. Assembly position : Any

9. Manual override : Pushing /screw driver type

10. Type of piloting : Piloted

11. Pilot air supply : Internal

12. Flow direction : Non reversible

13. Pneumatic connection : G3/8

14. Material for seal : NBR or equivalent

15. Material for body : Aluminum die cast or equivalen

1. Mounting position : Any

2. Material : Duroplast, copper, steel

3. Electrical connection : 3 pin

4. Permissible voltage fluctuations : ±10%

5. Operating voltage : 24 V DC

6. Frequency : 50Hz

7. Degree of protection : IP 65

Solenoid working principles

Solenoids are the most important components used in solenoid valves to control the
flow of liquids and gases. Solenoids are electromechanical devices that convert AC or
DC electrical energy into linear motion. They usually consist of a helical coil wound
concentrically around a movable cylinder, called the armature, made from a
ferromagnetic material such as iron or steel. Most solenoid valves have a replaceable
coil and can be used with coils with different voltages.

When current flows through the coil, it generates a magnetic field inside the coil which
attracts the armature towards the center of the solenoid using the same basic principles
as ordinary electromagnets. Since the armature is drawn towards the center of the
solenoid regardless of the polarity of the current, an opposing force is needed to return
the armature into the starting position when the coil is not energized. This is achieved
by using a spring mechanism. Under ideal conditions, in order to actuate the solenoid,
the force generated by the solenoid must be larger than the combined forces of the
spring, and the hydraulic pressure, as well as friction.

By lifting the armature, a small port in the valve is opened that allows the flow of the
media. The flow through the valve can be controlled by energizing or de-energizing the
coil. While there are several types of solenoid valves which differ in their mechanical
construction, the basic idea of a solenoid actuator acting on a control surface remains
the same in all solenoid valve types.

The polarity of the electrical contacts is not important with AC and DC solenoid valves.
With AC valves, this might be obvious because the current switches polarity twice per
period anyway. With DC valves the reasoning is that current passing through the coil
creates an electromagnet which produces an attractive force on the armature. When
current is applied through the coil, the armature will always be pulled towards the coil,
regardless of the contact and current polarity.

Differences between AC and DC solenoids

At the most basic level, the operation of DC solenoids is relatively straightforward - the
solenoid may be energized, allowing the magnetic force generated by the solenoid to
overcome spring resistance and moving the armature towards the center of the coil, or
de-energized, allowing the spring force to push the armature back to the starting
position.

With AC solenoids, the theory of operation is slightly more complicated. AC current can
be approximated using a sinusoidal waveform. As a consequence, twice per period the
current has a zero-crossing, meaning that the current flowing through the coil at that
point in time is equal to zero.

Since the magnetic force generated by the solenoid is in direct proportion to the current
flowing through the solenoid coil, the spring force will overcome the force generated by
the solenoid for a short period of time, twice per period. This is a problem which
manifests as a vibration of the armature, which produces a humming sound and can
cause stress on solenoid valve components. To avoid this issue, a simple conductive
ring, termed a shading ring, is installed near the coil around the armature. The shading
ring is usually made from copper. The function of a shading ring is to store magnetic
field energy and release it with a 90 degree phase difference.
The effect of a shading ring is that while the magnetic field generated by the primary coil
decreases towards zero, the magnetic field generated by the shading ring peaks,
effectively filling in the gap in the magnetic field amplitude during zero crossings,
eliminating the vibrations. Most solenoid valves that can be used with different coil
voltages have a built-in shading ring.

If dirt collects around the armature, the effect of the shading ring may be limited and
another solution is required. An example of another solution is the use of an electronic
circuit which filters the solenoid current, so that there are no zero-crossings. This
circuitry can be embedded into the solenoid valve coil itself or it can be built externally.
It is usually implemented using rectifier diodes and a filtering capacitor in a full-wave
rectifier topology.

Using AC coils with DC current and vice versa

In some cases, coils rated for AC current can be used with DC power supplies and vice
versa. However, there are some limitations to keep in mind.

Using a coil rated for AC current with a DC supply is possible, but the voltage (and the
current) must be limited or else the solenoid might burn out. The reason for this is that in
AC regime, coils have an inductive reactance that adds up with the electrical resistivity
of the coil. As a result, the impedance of a coil is several times higher in AC regime than
in DC regime. As an example, using a 24 VAC rated solenoid valve with a 24 VDC
power supply would most likely damage the solenoid because the effective current
flowing through the solenoid would be much higher with DC voltage.

Unfortunately, there is no fixed factor for derating the power supply voltage. The
effective current should be measured in AC regime, and that current should be set as a
target for DC regime as well. Some ways to achieve that target would be reducing the
supply voltage or using a current-limiting resistor.

Using a coil rated for DC current with an AC power supply, imposes the risk of
vibrations since DC solenoid valves might not contain a shading ring or a rectifier circuit.
These vibrations might damage the solenoid by stressing the components over time,
and they can contribute to noise levels in the room. This can be worked around by using
an external full-wave rectifier circuit with a capacitive filter.

Another problem is that the effective current will be several times lower in this case, and
the magnetic force generated by the coil might not be large enough to move the
armature from its resting position. A solution would be to use a larger voltage so that the
effective current matches the rated current of the solenoid.

AC vs. DC solenoid design considerations

Ideally, when a solenoid valve goes from OFF to ON state, the solenoid should initially
generate more force in order to overcome spring tension combined with hydraulic
pressure acting against the valve. Once flow is established, hydraulic forces acting on
the valve mechanism decrease, and the solenoid can decrease the generated force in
order to reduce power consumption and heating.

AC solenoids follow this ideal behaviour more closely than DC solenoids. In DC

solenoids, when the solenoid is turned on, the current rises asymptotically towards a
certain value depending on the resistivity of the coil. This translates to a lower initial
current (and lower initial force leading to slower valve opening). Once the valve is open,
the current draw remains at a constant value which is larger than needed to keep the
valve open. As a result, DC solenoids without any external circuitry will waste a
considerable amount of power in the open state.

For AC circuits, the impedance of a coil is calculated using the following formula:

Z=R+j2πfLZ=R+j2πfL

where Z is the impedance, R is the electrical resistance of the coil, j is a constant equal
to the square root of -1 which in this equation has an effect of shifting phase by 90
degrees, f is the frequency and L is the inductance of the coil. At first, the air gap is
large and as a result, the coil inductance is small, leading to a smaller impedance and a
larger current through the solenoid. Larger current equals higher magnetic force on the
armature.

As the valve opens, the air gap becomes smaller and smaller and the impedance of the
coil increases rapidly, decreasing the current through the coil. Reduced current through
the coil results in reduced power consumption and wasted heat. Because of this, AC
solenoids generate an initial spike in current, which enables a quicker, more powerful
opening of the valve. As soon as the valve is open, the current drops, which reduces
the power consumption.

Although AC solenoids are inherently more energy efficient, they come with some
possible drawbacks. One of them is power loss due to Eddy currents which form due to
electromagnetic induction in the armature. Another drawback is the risk of vibration,
which can be mitigated by using well-engineered solenoid valves which make use of
appropriate shading rings. In addition, modern control systems tend to provide easier
interfacing with DC outputs, so using AC solenoids with these systems can be more
cumbersome and require the use of additional relays.

DC solenoids can be made more efficient by using external circuits which can shape the
coil current in such a way that there is an initial current spike required to open the valve.
Once the valve opens, the current can be reduced to a maintenance current level, which
is just enough to reliably keep the valve open by pulling the armature against the spring
tension.

These external circuits can be as simple as connecting the coil in series with a parallel
connection of a resistor and a capacitor. In such a circuit, charging the capacitor
through the coil provides an initial coil current spike. After the capacitor is charged, the
current-limiting resistor passes all the current. The downside of such a simplistic
approach is that some of the power is wasted on heating the current-limiting resistor.

There are much more complex approaches involving switched power supplies which
provide a programmable current to the coil. These power supplies may work with both
AC and DC solenoid valves and power supplies. They ensure a good valve opening
spike and reduced power consumption while the valve is open, resulting in better power
efficiency, less heating and prolonged solenoid valv