FABRICATION OF MOTORIZED TRI-CYLINDER AIR COMPRESSOR

SYNOPSIS

The compressor is mechanical equipment which is used to increase the

pressure with the help of the piston. Need to improve the performance of
compressor by several methods. The main aim of the project is to make tri-cylinder
air compressor to generate large amount of air with less power and low vibration.
In tri cylinder air compressor the three cylinders are kept at 120 degree to each
other. The three cylinders are placed radically and equally apart such that the
cylinder opening tends to meet on a common triangular compression chamber. The
three pistons are made to compress air simultaneously on to common tri angular
chamber over shorter stroke and the isothermal efficiency will be better than single
cylinder with one piston. The motor is connected to the chain drive to drive the
three crank shaft which is used to move the piston. If space is smaller the pressure
will be more and bigger the lower. If compressor is made to work at 1400 rpm air
taken will be147.18 × 1400 = 206052 litters at 7 atmospheres pressure .The
advantage with triangular compressor will be low vibration, smaller unit giving
more output and so cheaper to make, ideal for air compressor is Air conditioning
and Refrigeration, Vacuum pumps and general purpose usage.
CHAPTER 1
1.1 Introduction
The compressor is mechanical equipment which is used to increase the
pressure with the help of the piston.
We need to improve the performance of compressor by several methods.
Such as designs shape and construction are known and screw type compressor is
the latest design as on date. The power required to compressor air to a known
pressure is given in the attached tables. One cubic root of air equals approximately
28 litters its volume we brought of a novel idea to design the triangular compressor
as per the attached sketches or diagrams with this. It is three cylinder compressors
placed radically and equally apart such that the cylinder openings tend to meet on a
common triangular compression chamber that has one inlet and outlet value to a
tank for receiving air in the compressed state. As an example let us take a 100cc
displacement single cylinder compressor, e.g. that will have a bore of 50 mm and
stroke 50mm.Now all 3 pistons are made to compress air simultaneously on to
common triangular chamber over shorter stroke and so the isothermal efficiency
will be better than the single cylinder one of 50cc p ton also there will be no
vibration due to triangle force acting towards the middle at the same time.

1.2 Types of air compressor

According to the design and principle of operation
1. Reciprocating compressor
2. Rotary screw compressor
3. Turbo compressor
1.3 Positive displacement

Positive-displacement air compressors are the type of compressor executed

by forcing air into a chamber whose volume is decreased to compress the air.
Piston-type air compressors use this principle by pumping air into an air chamber
through the use of the same motion of pistons. This type of compressor uses one-
way valves to guide air into a chamber, where the air is compressed. Rotary screw
compressors also utilizes positive-displacement compression by matching two
helical screws that, when turned, guide air into a chamber, whose volume is
increased as the screws turn. Vane compressors use a slotted rotor with varied
blade placement to guide air into a chamber and compress the volume. This type of
Compressor delivers a fixed volume of air at high pressures. The types of positive
displacement compressors include piston compressors and rotary screw
compressors.
1.4 Negative displacement
Negative-displacement air compressors consist of the centrifugal
compressors. This type of compressor use centrifugal force generated by a
spinning impeller to accelerate and then decelerate captured air, which pressurizes
the air.
1.5 Cooling
The result of adiabatic heating, air compressors require some type of disposing
of waste heat for the better performance. Generally the cooling is some form of air-
or water-cooling, although some (particularly rotary type) compressors may be
cooled by oil (that is then in turn air- or water-cooled).and the atmospheric changes
also included during cooling of compressors.
1.6Tri-cylinder air compressor
We need to improve the performance of compressor by several methods. Such
as designs shape and construction are known and screw type compressor is the
latest design as on date. The power required to compressor air to a known pressure
is given in the attached tables. One cubic root of air equals approximately 28 litters
its volume we brought of a novel idea to design the triangular compressor as per
the attached sketches or diagrams with this. It is three cylinder compressors placed
radically and equally apart such that the cylinder openings tend to meet on a
common triangular compression chamber that has one inlet and outlet value to a
tank for receiving air in the compressed state. As an example let us take a 100cc
displacement single cylinder compressor, e.g. that will have a bore of 50 mm and
stroke 50mm.Now all 3 pistons are made to compress air simultaneously on to
common triangular chamber over shorter stroke and so the isothermal efficiency
will be better than the single cylinder one of 50cc pton also there will be no
vibration due to triangle force acting towards the middle at the same time.
Adiabatically also this will be advantages since 3 cylinders displacement is pushed
at the same velocity and force on the common chamber because the three piston
move at equal velocity driven by one chain to achieve this 3 compressors cranks
sprockets as teeth. For every rotations of crank each pistons will move once from
TDC to BDC and BDC to TDC two strokes. Therefore theoretically 147.18cc of air
will be taken in and compressed to the volume of smaller space is the common
compression chamber.
1.7 Belt drive
A belt is a closed loop of flexible material used to mechanically link two or
more rotating shafts, most often parallel. Belts may be used as a source of motion,
to transmit power efficiently, or to track relative movement. Belts are looped over
pulleys and may have a twist between the pulleys, and the shafts need not be
parallel. In a two pulley system, the belt can either drive the pulleys normally in
one direction (the same if on parallel shafts), or the belt may be crossed, so that the
direction of the driven shaft is reversed (the opposite direction to the driver if on
parallel shafts). As a source of motion, a conveyor belt is one application where the
belt is adapted to continuously carry a load between two points.
1.8. Material selection
1.8.1 Compressor head
The material chosen for the body of the compressor head is high grade
aluminium alloy IS4250. The head is of triangular shape with an angle of 60º to
each side. First an Aluminium rod of 80mm diameter and length of is taken and it
is turned and faced in Lathe as a triangular shape of required dimension. Then
groove is taken on the three sides in order to fix the cylinder block to it. Then
Central drill of diameter of 12.7mm is done in its length and the 3 drills of 15mm
diameter are done from exactly centre of the side to the central drill.
1.8.2 Cast iron cylinder heads
Used for both racing and passenger vehicles, cast iron cylinder heads are
generally considered more durable and believed to make more power due to the
fact that the chamber holds in heat. As one would guess from the material used in
manufacturing, cast iron cylinder heads are heavier than their aluminium
counterparts which usually weigh at least 50% less than the cast iron cylinder
heads. Cast iron cylinder heads are often preferred by day-to-day drivers who find
them to be cheaper and less expensive to maintain as they tend to have fewer
cracks and blown gaskets. On the down side, when cast iron cylinder heads do
require attention it can be not only time consuming but expensive to repair. Despite
being preferred by day-to-day drivers looking for an inexpensive and durable
cylinder head, cast iron cylinder heads are also used in racing vehicles. In fact,
certain race tracks are mandated as “iron only”.
1.8.3 Aluminium cylinder heads
Aluminium cylinder heads are popular among much of the racing set as they
are lightweight, and produce more torque than cast iron cylinder heads. Despite the
issue of dissipating heat, aluminium cylinder heads are usually easier (less
expensive) to repair than cast iron cylinder heads. Close attention must be paid to
certain areas such as fastener tightening procedures and issues with valve lash that
result from the expansion of aluminium under normal operating temperatures. In
general both types of cylinder heads can be beneficial depending on what type of
performance you are expecting from your vehicle. Understanding how each work
and the benefits and drawbacks will help you better determines which type of
cylinder head will best suit your needs.
1.8.4 Cylinder block
The material for cylinder block is Cast Iron. The Cylinder Block is first cast
and then machined and also required surface are finished with suitable methods
like boring and honing. The outer diameter was turned. and facing of the top and
bottom surfaces are done in a lathe. When boring is done in boring machine, care
should be taken to machine it with accurate dimension.
1.8.5 Connecting rod
The material chosen for connecting rod is mild steel. It is hardened to
withstand the pressure of 7 bar. First the template is made with the actual
dimension and then gas cutting is done on the mild steel plate for the template
dimension and then machined.
1.8.6 Crankshaft assembly
The Crankshaft is of solid type made of cast iron to withstand the pressure
developed by the bearing and the compressor components. The Crank shaft is
turned, hardened, grand and the ends are tapered. All the made tapers are checked
using ring gauge. Up to 30º taper angle is provided.
 Figure 1.8.6 - Piston assembly
The web is separately machine and welded. The end bearings are restricted
between the web and end cover. The main connecting rod with its centre bearing is
fitted with interference fit to the eccentric crank shaft assembly. The Crankshaft
has its centre of gravity off set from the axis of rotation of the Crankshaft. Hence it
acts as balancing weight.
1.8.7End bearings
The thrust ball bearings are provided on the cover plate to safe guard the
Crankshaft. The bearing takes up the variable loads at the reasonable speeds. Care
should be taken while placing the bearing in the cover in the centre portion of the
body thickness plate.
1.8.8 Stand
The stand for the Compressor is made in mild steel to withstand all the loads
of the Compressor and motor assembly.
CHAPTER-2

2.1 PNEUMATICS:

The word ‘pneuma’ comes from Greek and means breather wind. The word
pneumatics is the study of air movement and its phenomena is derived from the
word pneuma. Today pneumatics is mainly understood to means the application of
air as a working medium in industry especially in driving and controlling of
machines and equipment.

Pneumatics has been considered to be used to carry out simple mechanical

tasks. But, in today’s world it is playing an important role by becoming one of the
major sources for automation, and the recent developments in this field has made it
a useful technology in the field of complex automated applications.

Pneumatic systems operate on a supply of compressed air which must be

available in sufficient quantity and at a pressure to suit the capacity of the system.
When the pneumatic system is being adopted for the first time, however it will
indeed be necessary to deal with the section of compressed air supply.

The key part of any pneumatic machine is supply of compressed air is by

means reciprocating compressor. A compressor is a machine that takes in air, gas
at a certain pressure and delivers the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered.

And the volume expressed is that of the air at intake conditions namely at
atmosphere pressure and normal ambient temperature.
2.2 PNEUMATIC ACTUATOR:

Physical processes proceeding in drives are submitted to the gas laws. The
gas laws are a set of laws that describe the relationship between thermodynamic
temperature (T), pressure
(P) and volume (V) of gases. Three of these laws, Boyle’s law, Charles’s law, and
Gay-Lussac’s law, may be combined to form the combined gas law
P1V1 = P2V2
T1 T2

Which with the addition of Avogadro’s law later gave way to the ideal gas
law. Other important gas laws include Dalton’s law of partial pressures. The
kinetic theory of gases, Graham’s law of effusion and root mean square velocity
explains how individual molecules act in a gas and their relation to pressure,
volume, and temperature. A gas that obeys these gas laws is known exactly as an
ideal gas (or perfect gas). An ideal gas does not exist; however, some gases follow
the laws more closely than the others in given standard conditions.

The most important gas law is the ideal gas law, which states that: PV = nRT

Other gas laws, such as vander Waals equation, seek to correct the ideal gas
laws to reflect the behaviour of actual gases. Van der Waals equation alters the
ideal gas law to reflect how actual gases function using a series of calculated
values called van der Waals constant Any gas can be used in pneumatic system but
air is the mostly used system now a days.
2.3 SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic is an attractive medium for low cost mechanizations
particularly for sequential (or) repetitive operations. Many factories and plants
already have a compressed air system, which is capable of providing the power
(or) energy requirements and the control system (although equally pneumatic
control systems may be economic and can be advantageously applied to other
forms of power).
The main advantage of a pneumatic system is it is economically cheap and
simple in design, also reducing maintenance costs. It can also have an out standing
advantage in terms of safety.
2.4 PNEUMATIC POWER

Pneumatic systems use pressurised gas to transmit and control

power. Pneumatic systems typically use air as the fluid medium because
air is safe, free and readily available.
2.4.1 Advantages of Pneumatics:

1. Air used in pneumatic systems can be directly exhausted in to the

surrounding environment and hence the need of special reservoirs and
no-leak system designs are eliminated.
2. Pneumatic systems are simple in design and economical.
3. Control of pneumatic systems is easier.

2.4.2 Disadvantages of Pneumatics:

1. Pneumatic systems exhibit spongy characteristics due to

compressibility of air.
2. Pneumatic pressures are quite low due to compressor design
limitations (less that 250 psi).
 3. CHAPTER-3

LITERATURE REVIEW

3.1 AUTO INDEXING GEAR CUTTING ATTACHMENT FOR SHAPING

MACHINE

M.V.N Srujan Manohar, S.Hari Krishna , University College of

engineering, JNTU Kakinada, A.P, INDIA(2012) :

They have been investigated to use pneumatic shaper for high production of
automatic gear cutting with auto indexing work piece. A small ratchet gear
structure has been thus devised to demonstrate the gear cutting attachment in
shaping machines.

The pneumatic source of power with control accessories is used to drive the
ram or the cylinder piston to obtain the forward and return strokes. By this
arrangement the forward/reverse stroke of the pneumatic cylinder is adjustable
type when compared with the conventional machines. We desired a shaping
machine which will automatically index the job and gives automatic tool feed to
the pneumatic cylinder
3.2 DESIGN & FABRICATION OF PNEUMATICALLY OPERATED
PLASTIC INJECTION MOULDING MACHINE

Poonam G. Shukla, Gaurav , P. Shukla Nagpur, India (2013) :

This project intends to use of plastic is increased now days in many

industries like automobile, packaging, medical, etc. The reason behind this is that
the plastic made things are quiet easier to manufacture, handle and reliable to use.
So the plastic goods manufacturing industries are striving hard to produce good
quality products at large scale and cheaper cost. The hydraulically operated
machines solve the problem, but they are too costlier for small scale and medium
scale industries. This paper deals with design and fabrication of pneumatically
operated injection plastic moulding machine.
3.3 DESIGN AND DEVELOPMENT OF SEMI-AUTOMATIC
CUTTING MACHINE FOR YOUNG COCONUTS

Satip Rattanapaskorn , Kiattisak Roonprasang , King Mongkut’s Institute of

Technology Ladkrabang, Bangkok 10520, Thailand (2008) :
The purpose of this research is to design, fabricate, test, and evaluate the
prototype of a semi-automatic young coconut fruit cutting machine. The design
concept is that fruit cutting is accomplished by pneumatic press on a young
coconut sitting on a sharp knife in a vertical plane. The machine consists of 5 main
parts: 1) machine frame,
2) cutting base,
3) knife set,
4) pneumatic system,
5) tanks receiving coconut juice and cut fruits. The machine parts contacting
edible parts of the fruit are made of food-grade stainless steel. In operation, a
young coconut is placed on the cutting base and the pneumatic control is
switched on. The coconut is automatically moved to the pressing unit and
cut in half by a knife set. The coconut juice flows down to the tank while the
cut fruits are separated and moved into the other tank.

3.4 PNEUMATIC AUTO FEED PUNCHING AND RIVETING MACHINE

A.S. Aditya Polapragada, K. Sri Varsha, University College of

engineering, JNTU Kakinada, A.P, INDIA:
This projects intends to pneumatic system has gained a large amount of
importance in last few decades. This importance is due to its accuracy and cost.
This convenience in operating the pneumatic system has made us to design and
fabricate this unit as our project. This unit, as we hope that it can be operated easily
with semi-skilled operators.
The pneumatic press tool has an advantage of working in low pressure, that
is even a pressure of 6 bar is enough for operating the unit. The pressurized air
passing through the tubes to the cylinder, forces the piston out whose power
through the linkage is transmitted to the punch. The work piece thus got is for
required dimensions and the piece can be collected through the land clearance
provided in the die. The die used in this is fixed such that the die of required shape
can be used according to the requirement. This enables us to use different type
punch dies resulting in a wide range of products. Different types of punch as
requirement can be thus got. According to the work material the operating pressure
can be varied
3.5CRITICAL REVIEW:
1).The above specified projects are work for only specified operations
only.
2).On those machines numbers of operations are not performed.
3).Those machines are not made for multi-purpose.
4).Even similar operations also not performed on those machines,
they are meant for single operations only.

3.6 OBJECTIVE:

The main aim of the project is to make tri -cylinder air compressor to
generate large amount of air with less power and low vibration. In tri cylinder air
compressor The three cylinders are kept at 120 degree to each other. The three
cylinders are placed radically and equally apart such that the cylinder opening
tends to meet on a common triangular compression chamber.

CHAPTER-4

DESCRIPTION OF EQUIPMENT

4.1 PRODUCTION OF COMPRESSED AIR:

Pneumatic systems operate on a supply of compressed air, which must be

made available in sufficient quantity and at a pressure to suit the capacity of the
system.
The key part of any p neumatic system for supply of compressed air is by
means using reciprocating compressor. A compressor is a machine that takes in air,
gas at a certain pressure and delivers it at a higher pressure. Compressor capacity is
the actual quantity of air compressed and delivered. And the volume expressed is
that of the air at intake conditions namely at atmosphere pressure and normal
ambient temperature.
Clean condition of the suction air is one of the factors, which decides the
life of a compressor. Warm and moist suction air will result in increased
precipitation of condense from the compressed air.

Positive displacement compressors are most frequently employed for

compressed air plant and have proved highly successful for pneumatic control
application.

The different types of positive compressors are:

1. Reciprocating type compressor
2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
application unless built in multistage designs and are seldom encountered in
pneumatic service.

4.1.1 RECIPROCATING COMPRESSORS:

Built for either stationary (or) portable service the reciprocating compressor
is by far the most common type. Reciprocating compressors deliver more than 500
m³/min. In single stage compressor, even if the air pressure is of 6 bar, the
machines can discharge pressure of 15 bars. Discharge pressure in the range of 250
bars can be obtained with high pressure reciprocating compressors that of three &
four stages. Single stage and 1200 stage models are particularly suitable for
pneumatic applications , with preferences going to the two stage design as soon as
the discharge pressure exceeds 6 bar, because it in capable of matching the
performance of single stage machine at lower costs per driving powers in the range

Fig 4.1.A Air Compressor

4.2 PNEUMATIC CONTROL COMPONENT:

4.2.1 PNEUMATIC CYLINDER

An air cylinder is an operative device in which the state input energy of
compressed air i.e. pneumatic power is converted in to mechanical output power,
by reducing the pressure of the air to that of the atmosphere.
4.2.2 DOUBLE ACTING CYLINDERS:
A double acting cylinder is employed in control systems with the full
pneumatic cushioning and it is essential when the cylinder itself is required to
retard heavy loads. This can only be done at the end positions of the piston stock.
In all intermediate positions a separate externally mounted cushioning device must
be provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end of
the stock is required. As a result the sit in the cushioning chamber is again
compressed since it cannot escape but slowly according to the setting made on
reverses.
The air freely enters the cylinder and the piston stokes in the other direction at
full force and velocity.

Fig 4.2.2 Double Acting Cylinder

4.2.3 SINGLE ACTING CYLINDER:

Single acting cylinder is only capable of performing an operating
medium in only one direction. Single acting cylinders are equipped with one inlet
for the operating air pressure, and can be produced in several designs. Single
cylinders develop power in one direction only.

Therefore no heavy control equipment should be attached to them, which is

required to be moved on the piston return stoke. Single action cylinder requires
only about half the air volume consumed by a double acting for one operating
cycle.

Fig 4.2.3 Single Acting Cylinder

4.2.4 GENERALLY USED MATERIALS FOR CYLINDERS:

Table 4.2.4 End Cover Materials

S.N LIGHT
O DUTY MEDIUM DUTY HEAVY DUTY
Aluminium
stock Aluminium stock
1. (Fabricated) (Fabricated) Hard tensile Castings
Brass stock Brass stock
2. (Fabricated) (Fabricated)
Aluminium, Brass,
Aluminium
3. Castings iron or steel Castings.
 Cylinder Tube Materials

S.N LIGHT
O DUTY MEDIUM DUTY HEAVY DUTY
Hard drawn brass
1. Plastic tube Hard drawn brass tube.
Hard drawn
Aluminium
2. tube Aluminium Castings Hard drawn steel tube
Hard drawn Brass, bronze, iron or
3. Brass tube castings, welded steel tube
Table 4.2.4 Piston
Materials

S.NO LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium Castings Aluminium Forgings,
Aluminium
Castings Brass (Fabricated) Aluminium Castings.
2.
Bronze (Fabricated) Bronze (Fabricated)
3. Iron and Steel Brass, Bronze, Iron or
Castings Steel Castings.

Table 4.2.4 Mount

Materials

S.N
O LIGHT
DUTY MEDIUM DUTY HEAVY DUTY

Aluminium Aluminium, Brass High Tensile

1.
Castings And Steel Castings Steel Castings

Light Alloy High Tensile

 2. (Fabricated) Steel Fabrication

Table 4.2.4 Piston Rod Materials

S.NO MATERIAL FINISH REMARKS

Ground and polished

MILD STEEL hardened, Generally preferred chrome
1. ground and polished. Plated

STAINLESS
2. STEEL Ground and Polished Less scratch resistant than
chrome plated piston rod

4.3 VALVES:

4.3.1 SOLENOID VALVE:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow
in the pneumatic system. The directional valve does this by changing the
position of its internal movable parts.

This valve was selected for speedy operation and to reduce the manual effort
and also for the modification of the machine into automatic machine by means
of using a solenoid valve.
A solenoid is an electrical device that converts electrical energy into
straight line motion and force. These are also used to operate a mechanical
operation which in turn operates the valve mechanism. Solenoids may be push
type or pull type.
 The push type solenoid is one which the plunger is pushed when the
solenoid is energized electrically. The pull type solenoid is one is which the
plunger is pulled when the solenoid is energized.

Fig 4.3.1 5/2 WAY Solenoid Valve

4.3.2 PARTS OF A SOLENOID VALVE:

4.3.2.A. COIL:
The solenoid coil is made of copper wire. The layers of wire are separated
by insulating layer. The entire solenoid coil is covered with a varnish that is not
affected by solvents, moisture, cutting oil or often fluids. Coils are rated in various
voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts
DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are designed
for such frequencies as 50 Hz to 60 Hz.
4.3.2.B. FRAME:
The solenoid frame serves several purposes. Since it is made of laminated
sheets, it is magnetized when the current passes through the coil. The magnetized
coil attracts the metal plunger to move. The frame has provisions for attaching the
mounting. They are usually bolted or welded to the frame. The frame has
provisions for receivers, the plunger.
4.3.2.C. SOLENOID PLUNGER
The Solenoid plunger is the mover mechanism of the solenoid. The plunger
is made of steel laminations which are riveted together under high pressure, so that
there will be no movement of the lamination with respect to one another. At the top
of the plunger a pin hole is placed for making a connection to some device. The
solenoid plunger is moved by a magnetic force in one direction and is usually
returned by spring action.
Solenoid operated valves are usually provided with cover over either the
solenoid or the entire valve. This protects the solenoid from dirt and other foreign
matter, and protects the actuator. In many applications it is necessary to use
explosion proof solenoids.

4.3.3 WORKING OF SOLENOID VALVE:

The solenoid valve has 5 openings. This ensures easy exhausting of 5/2
valve. The spool of the 5/2 valve slide inside the main bore according to spool
position; the ports get connected and disconnected. The working principle is as
follows
POSITION-1
When the spool is actuated towards outer direction port ‘P’ gets connected to
‘B’ and ‘S’ remains closed while ‘A’ gets connected to ‘R’
POISITION-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets
connected to each other and ‘B’ to ‘S’ while port ‘R’ remains close

Fig 4.5 5/2 Way Soleniod Valve Sectional View

4.3.4 SOLENOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve
or solenoid valve. This solenoid cut off valve is controlled by the electronic control
unit.In our project separate solenoid valve is used for flow direction of vice
cylinder. It is used to flow the air from compressor to the single acting cylinder.
4.3.5 FLOW CONTROL VALVE:

In any fluid power circuit, flow control valve is used to control the speed of
the actuator.The flow control can be achieved by varying the area of flow through
which the air in passing.When area is increased, more quantity of air will be sent to
actuator as a result its speed will increase. If the quantity of air entering into the
actuator is reduced, the speed of the actuator is reduced.Flow control valves
facilitate high precision adjustment of flow volumes and are used to precisely
control the piston speed of a drive.For adjustable speed via exhaust air flow
control. The piston moves between air cushions created through freely flowing
supply air and restricted exhaust air. The benefit is improved operating behaviour,
even in the event of load changes

Fig 4.3.5 Flow Control Valve For Pneumatic Cylinder

4.4 HOSES
Hoses used in this pneumatic system are made up of polyurethane. These
hose can with stand at a maximum pressure level of 10 N/m². Polyurethane
combines the best properties of both plastic and rubber. It offers abrasion and tear
resistance, high tensile and elongation values, and low compression set.
Polyurethane is naturally flexible and exhibits virtually unlimited flexural
abilities. Combining good chemical resistance with excellent weathering
characteristics sets polyurethane apart from most other thermoplastics. It has
exceptional resistance to most gas lines, oils, kerosene, and other petroleum based
chemicals, making it an ideal choice for fuel lines (although additives in today’s
gasoline and petroleum products warrant field testing).

Fig 4.4 Poly Urathane Tubes

4.5. APPLICATIONS OF PU TUBE

• Any time condensation can occur with small actuators, air grippers and air
operated valves. Condensation in a pneumatic system will cause operating
failure and affect the life of pneumatic equipment.
• Manufacturers of electrical components.
• When you need to eliminate water condensation but you can not use a
membrane or desiccant dryer (as you cannot use a fast exhaust).
4.5.1 BENEFITS OF PU TUBE:

• Longer life of other pneumatic equipment.

• Prevents operational failure of small actuators, air grippers and pilot
operated valves due to condensation.
• Avoids corrosion in other pneumatic equipment.
• Diffuses water vapour in the piping to the outside before it liquefies, so we
avoid problems such as dried grease or ozone when using other types of
dryers.
• Easy mounting.
4.6 CONNECTORS:
In our system hose connectors are used . Hose connectors normally comprise
an adoptee hose nipple. These types of connectors are made up of brass (or)
Aluminium (or) hardened pneumatic steel. For these type hose connectors no need
of hose clamp these are self-locking hose connectors. a Multi way four way hose
connecter
The universal combination at an attractive price. Can be widely used thanks
to resistant materials. Easy to install thanks to optimised bending radii. Limited
reset effect. Attractively priced: the universal solution for metal fittings. Perfect for
standard pneumatic applications – in many different fields. Wide range of variants
Over 1000 types for maximum flexibility in standard applications. Hydrolysis
resistant For applications in damp environments or in contact with water at up to
60 °C. Resistant to pressure Secure connection when used with pressure ranges of
up to 14 bar. Economical for pneumatic installations in the high pressure ranges.

Fig 4.6Hose Connector

The powerful combination for applications involving pressure ranges up to
16 bar For example, for applications with the pressure booster Robust, flexible and
reliable connection for the automotive industry. Fulfils the requirements Heat
resistant For reliable compressed air supply in high temperature ranges. Whether
with 10 bar at 80 °C or 6 bar at 150 °C – always delivers maximum process
security.Anti-static Electrically conductive tubing combined with a solid-metal
fitting Approved for the food Industry Food and Drug Administration certification
for use in the food industry:
 Fig 4.6 Four way hose connector

The hydrolysis-resistant combination with increased functions. Designed to

meet the highest demands, This combination shines in applications which require
the highest possible hygiene standards for food. The cost-effective alternative to
stainless steel, perfect for e.g. critical environments such as the splash zone:
resistant to practically all common cleaning agents, with maximum corrosion
protection. Resistant to media Completely resistant to all cleaning agents and
lubricants and even permits the transportation of acids and lyes without any
problems.
Flame-retardant Safe in areas where there is a risk of fire thanks to flame-
retardant properties to Resistant to welding Spatter The economical combination
for applications not in close proximity to welding applications. Also reliable for
applications in direct proximity to welding splatter Double-sheathed tube and
special fitting.
4.7 CONTROL UNIT

A pneumatic multipurpose device is an air-operated device used for many

small operations. It is a portable one. Compressed air is the source of energy for
this device. The compressed air is allowed to pass through the nozzle in such a way
that the rotation obtained is utilized for machining.
The nozzles welded to the fan can be rotated in either direction. The rpm and
torque of the shaft depends upon the pressure of the air admitted so by varying the
pressure, the RPM and torque can be varied. Thick tubes interconnect the parts.
The Clamps are used at the connecting parts to prevent leakage. In thread parts
seals are used to prevent leakage.
The compressed air from the compressor first enters the control unit. In the
control unit the pressure of the air is controlled and sent to the barrel to rotate the
fan in the required direction. The gate valve controls the pressure and volume of
air. Then the pressure is read by a pressure gauge. Later the air is admitted to the
barrel, a shaft is placed and it carries the fan.
The shaft is supported by bearing. The bearings are placed in the
couplings, which covers the end of barrel.
 CHAPTER-5

DESIGN OF EQUIPMENT AND DRAWING

5.1 Pneumatic Components And Its Specification
The pneumatic auto feed multi operation machine consists of the following
pneumatic components:
1. Double acting pneumatic cylinder
2. Single acting pneumatic cylinder
3. Solenoid Valve
4. Flow control Valve
5. Connectors
6. Hoses

5.1.1.Double acting pneumatic cylinder:

Stroke
length : 160 mm = 0.16 m

Piston
diameter : 50 mm
Piston rod : 15 mm
Quantity : 1
Nitride (Buna-N)
Seals : Elastomer
End cones : Cast iron
Piston : EN – 8
Air
Media :
Temperatur
e : 0-80 º C

Pressure
Range: : 8 N/m²
Fig 5.1.1 Double Acting Cylinder Drawing
 5.1.2.single acting pneumatic cylinder:

Stroke
length : 175 mm = 0.175 m

Piston
diameter : 35 mm
Piston rod : 15 mm
Quantity : 1
Nitride (Buna-N)
Seals : Elastomer
End cones : Cast iron
Piston : EN – 8

Media : Air
Temperatur
e : 0-80 º C

Pressure
Range: : 8 N/m²

Fig 5.1.2 Single Acting Cylinder Drawing

5.1.3 5/2 way solenoid valve

Size : 0.635 x 10 ¯² m
: G 0.635 x 10 ¯² m
Part size

Max pressure range : 0-10 bar

Quantity : 10

Fig 5.1.3 solenoid valve

5.1.4 Flow Control

Valve
0.635 x 10 ²
Port size : m
Pressure : 0-8 bar
Media : Air

Quantity : 4
5.1.5. Hose Connectors

Max working pressure : 10 bar

5.1.6. Hoses:
Temperature : 0-100 º C
Max pressure : 10 bar
Fluid media : Air
8 mm =
Material : Brass Outer 8 x 10
diameter : ¯ ³m
Diameter : 08 mm 3 mm =
Self- Inner 3 x 10
Locking : locking diameter : ¯ ³m
Poly
urathen
Material : e
5.2 GENERAL MACHINE SPECIFICATIONS :
5.2.1 Barrel unit

Short capacity : 0.635 x 10-² m

40 mm = 40 x 10¯
Barrel diameter (ID) : ³m

Drill capacity : 1.5-10mm

5.2.2 Clamping unit

Clamping : Manual clamping

Max Clamping Size : 100 mm = 0.1m
5.2.3 Pneumatic unit
Double acting
Type of cylinder : cylinder
Flow control valve
Type of valve : &
solenoid valve
Max air pressure : 8 bar

CHAPTER-6
LIST OF MATERIALS
6.1FACTORS DETERMINING THE CHOICE OF MATERIALS:

The various factors which determine the choice of material are discussed
below.
6.1.1. Properties:

The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface finish,
rigidity, ability to withstand environmental attack from chemicals, service life,
reliability etc.
The following four types of principle properties of materials decisively
affect their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical

The various physical properties concerned are melting point,

Thermal Conductivity, Specific heat, coefficient of thermal expansion,
specific gravity, electrical Conductivity, Magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

compressive shear, bending, torsional and buckling load, fatigue resistance,
impact resistance, elastic limit, endurance limit, and modulus of elasticity,
hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are.

• Cast ability,
• weld ability,
 • Brazability,
• Forge ability,
• merchantability,
• surface properties,
• shrinkage,
• Deep drawing etc.
6.1.2. Manufacturing Case:
Sometimes the demand for lowest possible manufacturing cost or surface
qualities obtainable by the application of suitable coating substances may demand
the use of special materials.
6.1.3. Quality Required:
This generally affects the manufacturing process and ultimately the
material. For example, it would never be desirable to go for casting of a less
number of components which can be fabricated much more economically by
welding or hand forging the steel.
6.1.4. Availability of Material:
Some materials may be scarce or in short supply. It then becomes
obligatory for the designer to use some other material which though may not be a
perfect substitute for the material designed.
The delivery of materials and the delivery date of product should also be
kept in mind.

6.1.5. Space Consideration:

Sometimes high strength materials have to be selected because the
forces involved are high and the space limitations are there.

6.2 LIST OF METERIALS USED

Table 6.2 List Of Materials Used

SNO DESCRIPTION QUANTITY MATERIAL

 DOUBLE ACTING
PNEUMATIC
1 3 Aluminium
CYLINDER
5/2 WAY SOLENOID 3
2 VALVE Aluminium

6
3 HOSE COLLAR Brass

1
4 MOTOR M.S

1
5 3 WAY CONNECTOR PU

5mtr
6 PU TUBES Polyurethane

BASE FRAME 1
7 &STRUCTURE Iron

1
8 AIR COMPRESSOR

FLOW CONTROL
9 VALVES 4 Brass

10 TAP SET H.S.S

1
11 BROACHING BIT SET H.S.S
1
12 BOLTS & NUTS 30 Iron

6.3 Single Pole Double Throw switches (SPDT)

 It is one of the electical switch. It is used as a ON/OFF switches. Direction
of current cant be controlled. It is operated manually. It is used for operating the
light, motor etc., This switch has 1 input and 2 output.

Fig. 6.3 –SPDT circuit Fig. 6.3 –SPDT Switch

6.4 Specifciation
Pole and Throw: Single Pole Double Throw
Actuator Type: Raised Handle
Voltage: 12V
Current Rating : 5A

6.5 Electrical Motor

Fig. 6.14 –Classification of Electric Motor

6.6 DC Motor with speed controller:

It consist of 2 sets of coil one is known as armature winding and another one is or
set of permanent magnet is called as stator. By applying a voltage in armature
winding torque is generated so the motion is obtained.

6.7 Stator
It is a statioary part
It is a permanent magnet with two or more poles
Electromagnet create the alternativly magnet field
6.8 Rotor
It is inner part which rotate
It consist of armature winding which is connected extermally
Stator and rotor is made up of ferromagnetic materials

Fig. 6.8 –DC motor

6.9 Winding
It is made up of series and parallel connection
A winding is made up of series or parallel connection of coils.
It is made up of copper .
For speed reduction worm and worm wheel arrngement is attached.

6.9.1 Specifciation
Type: Shunt
Speed: 300 Rpm
Voltage: 12V
Current Rating : 3A

6.10 AC Motor
The single-phase induction motor is used for refrigerators, drills, washing,
compress ors, water pumps and etc.

Fig. 6.10 –AC motor

There are two coils one is primary coil and another one is starting coil. These are
connected in perpendicularly. The stator is made up of laminated iron

6.10.1Specifciation
Type: single phase induction
Speed:1440 Rpm
Voltage: 220-240 V
Current Rating : 3A

CHAPTER 7
FABRICATION

7.1 METHOD OF FABRICATION:

The stand (or) base carries the whole machine. The whole machine is
installed on the foundation .A circular column having length of 90cm about one
third part of its length is in the foundation the remains part is above the
foundation, from the upper end of the vertical column 50cm is machined by
performing turning operation, a bush with having length 7.5cm is machined and
slides over the machining parts of rod.
The horizontal rod is slider over the, vertical column by means of bush. A
double acting cylinder is connected to horizontal column by using clamp for
feeding of the machine.
A Pneumatic motor with chuck is connected to the horizontal column
normally. A 5/2 way solenoid value is connected to control the double acting
cylinder to upward &downward motion.
The tri cylinder air compressor with common compression chamber can be
improved in Following areas, Lubrication method to be reduce wear and tear. Inter
cooling can be used to reduce the work done when multistage compression is used.
Pressure rise can be increased by reducing the clearance volume.

CHAPTER 8
8.1 WORKING PRINCIPLE

This triangular air compressor with common compression chamber consists

of three cylinders placed at 120 to each other cylinder. The main aim if this
compressor is to generate large amount of air compared with existing compressor
with less power input and with low vibration. For this compressor contain three
cylinders having their own piston, connecting rod, crank shaft and their drive.
Chain drive was preferred to overcome slipping.

When the motor drives the crank shaft all the three piston will move in phase
from BDC to TDC, when the piston reaching TDC compression takes place and
discharge is done and when reaches the BDC suction condition are obtained and
suction takes place.
8.2Plan of experiments

8.2.1 Electrical connection

The electrical power supply must be connected to the motor through starter.
Start the unit momentarily and observe the direction of rotating the rotor. The
direction should be clockwise. If the direction of rotation is not correct change the
direction by interchanging the two places in the starter.

8.2.2 Adjusting belt tension

The chain tension between the motor and Crankshaft flywheel must be
correctly adjusted with proper tension. Otherwise the Compressor will not run of
the required speed.

8.2.3 Starting procedure

The following are to be checked before starting the unit.

Check the oil level in the oil indicator if the level is the oil level indicator if the
level is below the minimum mark, add fresh oil to the correct grade.
Check the chain tension
Check the suction pipe air filler
Check that the unit rotates freely by hard and that there is no mechanical
obstructions
Start the unit and allow it to run for a few minutes

8.2.4 Checks during operation

Check whether the running sound is normal

Check the pressure developed by opening manometer safety device

If all the above preliminary checks are found satisfactory then the unit may be put
to regular use.

8.2.5 Comparison of conventional one with ours

 We know of several types of compressors made in many renowned
factories at Coimbatore for various applications piston type, screwed type value
type etc., but three pistons compressing air into a common compression chamber
is not known to be a existing and so we decide to make this novel design to prove
its superiority to others in cost and performance.
Any new product must be novel and useful it must be superior is
performance, reliable and dependable compared to known models. The cost of
making must be comparatively low and in the market it should be capable of
competating similar products, is every way, color appearance, value etc. Range
must be based on from perspective users and customers. However first working
model is only to prove superiority as per maker’s claims. When it is compared
with the existing ones it has very lesser vibration and lesser oil consumption and it
is more reliable than the connectional ones because of having less vibration and
also it is a Novel idea.

8.2.6 Calculation

For 100cc engine

Bore diameter d = 50mm
Stroke length l = 50mm
For replacing engine,
Bore diameter d = 50mm
Stroke length l = 50mm
Whereas three engines are involved
Area of 100cc engine = π/4 x d²
A = 1962.5 mm²
Area of replacing engine = π/4 x d²
A = 1962.5 mm²
The volume displaced is V = π /4 x d² x l
= π x 5² x 5
= 98.125cc
≈ 100cc.
For replacing engine,
The volume displaced is V = ƒÎ/4 x 52 x 5 x 1.5
Three Cylinders of 50cc each = 147.18cc
For three replaced engines,
Compressing area A = 3x 1962.5 mm2
= 5887.5 mm2.
When comparing the areas of the engines, the replaced engine has high
compressing area than 100cc
engine
Difference in area = (5887.5 -1962.5)
= 3925 mm2.
Therefore theoretically 49.06cc of air will be taken in and compressed to the
volume of smaller space in the
common compression chamber which we have made as to 1.5cm bore~7cm long
= 12.37cc or 7times the total
98cc volume = 7 atmospheric pressure.

8.3 Maintenance procedure

8.3.1 Lubrication

The Crankshaft and Connecting Rod assembly is lubricated by lubricating

oils as mentioned in the recommended lubricants charts. Oil should be filled in the
oil tank which sprays oil into cylinder during the suction stroke. Care should be
taken to see that the oil level is correctly maintained.

8.3.2 Daily

Check the oil level

Check the chain tension

8.3.3 Every two hours of operation

Clean the suction filter, to ensure long life for the values and the piston assembly.

8.3.4 Every 200 hours of operation

Check and adjust the chain tension.

Check all the bolts for tightness clean.
Check the developed pressure clean and adjust the safety valve if necessary.
Check the bearing sound.

8.3.5 Every 1000 hours

The suction and delivery valves should be removed and the valve seats
seating should be inspected for any score or damage. The valves may be lapped if
necessary in their respective seats using fine lapping compound. Dismantle the
crank shaft bearing and assemble it by new one or by applying grease.

8.4 Result and discussion

 The performance of the compressor was found to be satisfactory and the
output of the compressor is continuous it is up to the level expected. Further
improvements can be done on the radial compressor.

8.4.1 Advantages

1) Best suitable for low pressure application.

2) Less weight compared to other compressor.
3) Production cost is low.
4) Higher efficiency because of less power required.
5) High Durability.
6) Compactness of the compressor saves utilization space.
7) Easy to use and portable.
8.4.2 Applications :

1) Used in laboratories and pharmaceuticals.

2) Used for fabrication of plastic structure with hot gas.
3) Used for best control fumigation service.
4) Used for air agitation of photo film processing tanks, electroplating bath and in
chemical plants.
5) Used for cooling electronic circuits.
6) Used for inflating tyres and air mattresses.
7) Used for light duty spray painting.
8) Used to operate air driven hand tools such s Die-Polishers, Die-Grinders etc.,
9) Used in bore wells to deliver water from the well

CHAPTER 9
9.1 CONCLUSION:

The design and fabrication of triangular air compressor in the common

compression chamber have been
successfully completed and over all assembly of the compressor is drawn in this
report. The performance of the compressor was found to be satisfactory and the
output of the compressor is continuous it is up to the level expected. Further
improvements can be done on the radial compressor as dealt in
the previous chapter.
This project has also reduced the cost involved in the concern. Project has
been designed to perform the entire requirement task which has also been
provided.
9.2 FUTURE SCOPE:
The tri cylinder air compressor with common compression chamber can be
improved in following
areas,
1) Lubrication method to be improved to reduce wear and tear.
2) Inter cooling can be used to reduce the work done when multistage compression
is used.
3) Pressure rise can be increased by reducing the clearance volume.
4) The production cost can be reduced by casting the cylinder and the head
assembly into a
single piece.

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