A TYPICAL 3-D VIEW OF

PNEUMATIC BUTTON TESTING MC

 INTRODUCTION
Need:- we are going to make a machine for AUTOMATION WORK INDUSTRY
and make it multipurpose & should be used as pneumatically operated automatic
stamping cum embossing machine. The machine is simple to maintain and easy
to operate. Hence we tried our hands on “ PNEUMATIC BUTTON TESTINGFOR
AUTOMATION work”
With the increasing of demand for factory automation, the application of
pneumatic actuators have been extending widely in many fields since 1960s,
because of cleanness, low-cost, little maintenance, etc. However, when the world
neared the end of the 20th century, energy efficiencies of all kinds of driving
systems were discussed and compared at the background of facing the problem
of energy and environment in the world. As a result, it was reported that the
energy efficiency of pneumatic systems is very poor compared with electrical
systems and hydraulic systems, and it is even lower than 20%.
Today, most of users are making efforts in cutting down the air consumption in
their plants such as avoiding air leakages, adjusting operating pattern of devices
and so on. At the same time, pneumatic equipments manufacturers are
accelerating the development of products that can save energy. However, with
regard to the research of pneumatic technology, there is not any clear method to
calculate the available energy of compressed air, and it is not clarified how much
energy are lost in supply pipes or at actuators.
Because of air compressibility, heat transfer, etc., it is difficult to establish a
method to have an energy assessment for pneumatic systems. Among
pneumatic equipments, it is considered that actuator and air compressor result in
the low energy. Hence this energy can accurately be used for automation work.
 CHAPTER-02
CONSTRUCTION

Pneumatic systems use the potential energy stored in compressed air to do

work. By controlling the release of the air to pneumatic cylinders, Pneumatic
components are arranged in circuits - much like electronic circuits - using
symbols for each component. You need to be familiar with the operation of two of
most common pneumatic components - a single-acting cylinder with a three-port
valve, and a double-acting cylinder with a five-port valve. You also need to
understand how time-delayed pneumatic circuits and pneumatic logic
circuits work.

Finally you need to know how to work out the force output from a cylinder.

Pneumatic actuator
A pneumatic actuator converts energy (in the form of compressed air, typically)
into motion. The motion can be rotary or linear, depending on the type of
actuator. Some types of pneumatic actuators include:

 Tie Rod Cylinders

 Compact Air Cylinders
 Rotary Actuators
 Grippers
  Escapement mechanisms
 Rodless Actuators with Magnetic linkage
 Rodless Actuators with Mechanical linkage
 Specialty actuators that combine rotary and linear motion--frequently used
for clamping operations
 Vacuum Generators

A robotic sculpture that uses a pnuematic actuator was created by artist Jim
Pallas and motorer Jim Zalewski in 1990. This artwork, the Nose Wazoo, senses
movements of people around it and, using the pnuematic actuator (cylinder) to
change its center of gravity, gimbals thru several different movements as shown
in a short video.

There are a number of different manufacturers of pneumatic equipment. Some

examples are:

 Kirloskar pneumatics [1]

 Chikago Pneumatics (holeman &khosla) [2]
 Norgren Pneumatics [3]
 Bimba Manufacturing Company [4]
 Festo [5]

Pneumatic cylinder
Pneumatic cylinders or air cylinders are mechanical devices used to impart a
force from a fluid, typically compressed air.

Pneumatic cylinders are available in a variety of styles, including tie rod,

compact, round body, rotary, gripper, escapement, guided, and rodless cylinders.
Other features of pneumatic actuators include the ability to have multiple strokes
or a full stroke with intermediate stopping points, adjustments to control the
amount of extension or retraction of a given actuator, and locks that can serve as
safety mechanisms in case the machine experiences a loss of air pressure.

A typical pneumatic cylinder consists of a piston, piston rod, and a body or tube.
Compressed air enters at one end of the tube, imparting force on the piston,
which is then displaced (moves) in order to balance the force exerted on the
piston. Air cylinders, or actuators as they are also called, are available in a
variety of sizes, shapes, and have varying strokes. Typical cylinder sizes range
from a small 2.5mm air cylinder, which might be used for picking up a small

transitor or other electronic component, to 400mm diameter air cylinders which

would impart enough force to lift a BUTTON TESTING. Some pneumatic
cylinders reach 1000mm in diameter, and are used in place of hydraulic cylinders
for special circumstances where leaking hydraulic oil could impose an extreme
hazard.

Air Cylinders are available in a variety of styles. Some examples include: Single
acting cylinders--cylinders that use the force imparted by air to move in one
direction, and a spring to return to the "home" position. Double acting cylinders--
cylinders that use the force of air to move in both extend and retract strokes.
Rotary air cylinders--actuators that use air to impart a rotary motion Rodless air
cylinders--actuators that use a mechanical or magnetic coupling to impart force,
tyically to a table or other body that moves along the length of the cylinder body,
but does not extend beyond it.The pneumatic power is converted to straight line
reciprocating motions by pneumatic cylinders. According to the operating
principle, air cylinders can be sub-divided as (i) single acting and (ii) double
acting cylinders.

(i) Single acting cylinder:- In a single acting cylinder, the compressed air is
fed only in one direction. Hence this cylinder can produce work in only one
direction. The return movement of the piston is effected by a built-in spring or by
application of an external force.
(ii) Double acting cylinder :-Here we have used double acting cylinder It is the
pneumatic actuator, which is actuated using compressed air. The Force exerted
by the compressed air moves the piston in two directions in a double acting
cylinder. In principle, the stroke length is unlimited, although buckling and
bending must be considered before we select a particular size of piston diameter,
rod length and stroke length.
The double acting cylinder consists of-
1) Cylinder tube, 2) Piston unit, 3) double cup packing on piston, rod packing of
‘O’rings, 4) bronze rod guide, piston rod, 6) end covers (flanges) 7) port
connection, 8) cushion assembly
The cylinder is manufactured from aluminium solid bar with central bore on lathe
machine. It is then made smooth internally using method of honing and lapping. It
contains piston and piston rod, which reciprocates to and froe with the application
of high pressure air. The piston is fitted with the piston ring which is made of
Teflon rubber to make perfect compression of the air. The material used for
various parts differs for different types of cylinders depending upon applications.

DOUBLE ACTING CYLINDER

 3) 5/2 Direction control SOLIONID operated valve:-
Its basic symbol is as shown below:-

Fig.1.3 D.C. Valve symbol

To control the to and fro motion of a pneumatic cylinder, the air energy has to be
regulated, controlled, and reversed with a predetermined sequence in a
pneumatic system. Similarly one has to control the quantity of pressure and flow
rate to generate desired level of force and speed of actuation.
To achieve these functions, valves are used to-
(i) start and stop pneumatic energy,
ii) control the direction of flow of compressed air,
iii) control the flow rate of the compressed air and
iv) control the pressure rating of the compressed air.
A direction control valve has two or three working positions generally. They are:
1. Neutral or zero position
2. Working position
The positions are mostly numbered as 0,1,2. Direction control valves are
designated to indicate both the number of ways as well as the number of working
positions such as 4/2, 3/2,5/2 means 5 ways /2positions.
Here we have used 5/2 direction control valve. In this design of direction control
valve, 5 openings are provided .This ensures easy exhausting of the valve along
with the two positions i.e. ON and OFF.
Here the spool slides inside the main bore and according that the spool position
is made ON or OFF due to the fact that the spool gets connected to the open
side or the closed side of the air opening.

5/2 DIRECTION CONTROL VALVE

4) Air circulating devices:
The compressed air is stored in an air receiver from which air is drawn out in
to the consumer point by means of pipe line.
While laying out the pipeline for the system, one should take sufficient
BUTTON TESTINGe and pay attention to see that the pressure drop from the
generating point to the point of consumption remains as low as possible. For
economical reason, it is always better if the total drop of pressure is kept limited
to a maximum value of 0.1 bar or even less. The following factors are taken into
account while selecting pneumatic pipeline and other air- line installations:-
1) Pressure of compressed air in the lines.
2) Total flow rate per unit time through the line.
3) Permissible pressure drop in the line.
4) Types of tube material and types of line fitting.
5) Length and diameter of tube or other pipelines.
6) Working environment.
Considered the above factors we have selected the flexible hose tubes of
1/8”diameter.
PNEUMATIC FILTER

A pneumatic filter is a device which removes contaminants from a compressed

air stream. This can be done using a number of different techniques, from using
a "media" type that traps particulates, but allows air to pass through to a venturi,
to a membrane that only allows air to pass through.

Usage

It is now common to have various stages of filtration employed in a filter-

regulator-lubricator form factor, usually with the different filter housings
connected. Air filtration applications are diverse and include end-user sectors
such as cleanroom environments, biomedical, analytical instrumentation, food
processing, marine and aviation, agriculture, manufacturing, food and beverage
packaging and a host of other uses.

Primary filters

Typical commercial pneumatic filters will remove particles as small as 5

micrometres (microns) from the air. The filters protect pneumatic devices from
damage that would be caused by these contaminants. These contaminants
include lubricant particles ejected by the compressor, dirt particles and small
water droplets.

Secondary filters
Secondary filters are used for a variety of applications and can remove particles
as small as 50 nanometres in size. These secondary filters can remove fumes,
odors, vapor, mist, moisture, oil, and tiny particles from the air stream. In addition
special air dryer devices are used to condense moisture from humid air and
deliver a clean, dry supply of air, mostly used with sensitive equipment such as
fine printing and laboratory use.
1) Frame Base :- It forms the robust support to stand the machine vertically. It
holds the weight of the vertical post and supports the direction control valve. It is
made of mild steel channels of size (40 x 75 x 5)mm cross section and 285 x
385mm of rectangular base with the vertical post and the horizontal channel at
the top.
PNEUMATIC CIRCIT CYLINDER I
PNEUMATIC CIRCIT FOR CYLINDER II