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PNEUMATIC FOUR AXIS MATERIALS HANDLING ROBOT
Thesis · October 2019
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ABSTRACT
Pneumatics is one of the most used systems in these days. Today equipment and
system use this type of actuating because it is a very safe, economic and ease to
implement. Another advantage that recommends this type of actuating is the reduced loss
of heat during the actuating process. Material handling systems are characterised by
repetitive movements, speed and displacement control and precision, requirements that
recommend pneumatics driving. Certain characteristics of compressed air have made this
medium quite suitable to be used in modern manufacturing and production industries. It is
therefore important that technicians and engineers should have a good knowledge of
pneumatic system, air operated valves and accessories.
A pneumatic system consists of a compressor plant, pipe lines, control valves, drive
members and related auxiliary appliances. The air is compressed in an air compressor;
and from the compressor plant, the flow medium is transmitted to the pneumatic cylinder
through a well laid pipe line system. To maintain optimum efficiency of pneumatic
system, it is of vital importance that pressure drop between generation and consumption
of compressed air is kept very low. Pneumatic material handling system is used to move
the components from one place to another with a maximum weight of 2 kg. It is used in
the following places: Chemical laboratories, Welding, Foundry etc.
The experimental setup consists of four double acting pneumatic cylinders. One of
these cylinders is used to actuate rack & pinion assembly such that piston rod of the
cylinder is connected to rack meshed with the pinion. By operating the cylinder, rack &
pinion assembly turns the whole assembly through nearly 260°. The turning angle of the
assembly can be altered by varying the length of the rack. Another cylinder i.e. vertical
cylinder is used to increase the height of the setup; the height is limited by the piston rod
length of the cylinder. Horizontal cylinder is used to increase the arm length; the working
area of the arm is limited by the piston rod length. Gripper cylinder is used to actuate the
gripper that holds the materials.
Department of Mechanical Engineering, RIT, Bangalore Page 1

Table of Contents
TOPIC PAGE NO.
ACKNOWLEDGEMENT
ABSTRACT
INTRODUCTION ............................................................................................................... 4
1.1 Introduction to Materials Handling ........................................................................ 4
1.2 Automation in Materials Handling ........................................................................ 6
LITERATURE SURVEY .................................................................................................... 8
2.1 Pneumatic System ................................................................................................ 11
2.3 Selection of Pneumatics ....................................................................................... 14
2.4 Components of Materials Handling Equipment .................................................. 15
2.5 Rack and Pinion Assembly .................................................................................. 22
PROBLEM FORMULATION........................................................................................... 24
SCOPE OF PRESENT WORK ......................................................................................... 25
METHODOLOGY ............................................................................................................ 26
5.1 Preparation of Project Plan .................................................................................. 26
5.2 Design Calculations and 3D Modeling ................................................................ 26
5.3 3D Modeling ........................................................................................................ 32
EXPERIMENTAL DETAILS AND PROCEDURE ......................................................... 38
6.1 Fabrication and Testing........................................................................................ 38
6.2 Description of Assembly...................................................................................... 39
6.3 Process Chart ....................................................................................................... 40
6.4 Materials of Components ..................................................................................... 41
RESULTS AND DISCUSSION ........................................................................................ 42
7.1 Applications ......................................................................................................... 43
7.2 Advantages ........................................................................................................... 43
7.3 Limitations ........................................................................................................... 44
CONCLUSIONS................................................................................................................ 45
SCOPE FOR FUTURE WORK ........................................................................................ 46
REFERENCES

LIST OF FIGURES
FIGURE PAGE NO.
Figure 1: Components of a Pneumatic System 14

Figure 2: Air Compressor 16
Figure 3: Specification of Air Compressor 16
Figure 4: Pressure Gauge (0-10 bar) 17
Figure 5: Direction Control Valve (5/2 DCV) 18
Figure 6: Schematic of 5/2 DCV 18
Figure 7: Double Acting Pneumatic Cylinder 21
Figure 8: Sectional View of Double Acting Cylinder 21
Figure 9: Rack & Pinion 23
Figure 10: 5/2 DCV Valve 32
Figure 11: Pneumatic Cylinder 32
Figure 12: Sectional Views of Frame (all dimensions in cm) 33
Figure 13: Pictorial View of Frame 33
Figure 14: Top View of Frame with Cylinder and Rack & Pinion Assembly 34
Figure 15: Isometric View of Assembly of Arms, Cylinder and Rack & Pinion 34
Figure 16: Pictorial colored View of the Assembly 34
Figure 17: Different Views of the Full Assembly 35
Figure 18: Side View of the Full Assembly 35
Figure 19: Front View of the Whole Assembly 36
Figure 20: Top View of the Whole Assembly 36
Figure 21: View of Turned Position of the Full Assembly 37
Figure 22: Pictorial View of the Full Assembly 37
Figure 23: Schematic Diagram of Assembly of Equipment Functioning 39
Figure 24: Fabricated Assembly of the Equipment 39
Figure 25: Testing of Equipment 42

CHAPTER 1
INTRODUCTION
1.1 Introduction to Materials Handling

Material handling is a necessary and significant component of any productive activity.
It is something that goes on in every plant all the time. Material handling means providing
the right amount of the right material, in the right condition, at the right place, at the right
time, in the right position and for the right cost, by using the right method. It is simply
picking up, moving, and lying down of materials through manufacture. It applies to the
movement of raw materials, parts in process, finished goods, packing materials, and
disposal of scraps. In general, hundreds and thousands tons of materials are handled daily
requiring the use of large amount of manpower while the movement of materials takes
place from one processing area to another or from one department to another department
of the plant. The cost of material handling contributes significantly to the total cost of
manufacturing. Handling and storing materials involve diverse operations such as
hoisting tons of steel with a crane; driving a truck loaded with concrete blocks; carrying
bags or materials manually; and stacking palletized bricks or other materials such as
drums, barrels, kegs, and lumber. The efficient handling and storing of materials are vital
to industry.
The primary objective of a material handling system is to reduce the unit cost of
production. The other subordinate objectives are reduction in manufacturing cycle time,
delays and damage, Promotes the safety and improve working conditions, maintain or
improve product quality Promote productivity, reduces tare weight, control inventory,
promote increased use of facilities.

1.1.1 Definition and Scope

Expressed in simple words, materials handling involves the short-distance movement,
protection, storage and control of materials and products within the confines of a building
or between a building and a transportation vehicle. As a process, it uses a wide range of

manual, semi-automated, and automated equipment and includes consideration of the
protection, storage, and control of materials throughout their manufacturing,
warehousing, distribution, consumption, and disposal. As a consequence, unfortunately,
there is no universally accepted definition of materials handling. One of the definition
adopted way back by the American Materials Handling Society is: Materials handling is
the art and science involving the moving, packaging and storing of substances in any
form. Some of the other definitions are:
• Materials handling is the movement and storage of materials at the lowest
possible cost through the use of proper methods and equipment.
• Materials handling is the moving of materials or product by any means,
including storage, and all movements except processing operations and
inspection.
• Materials handling is the art and science of conveying, elevating, positioning,
transporting, packaging and storing of materials.
Functional scopes of materials handling within an industry covers the following:

• Bulk materials as well as unit materials handing. Bulk handling is particularly
relevant in the processing, mining and construction industries. Unit materials
handling covers handling of formed materials in the initial, intermediate and
final stages of manufacture.
• Industrial packaging of in-process materials, semi finished or finished goods,
primarily from the point of view of ease and safety of handling, storage and
transportation. However, consumer packaging is not directly related to
materials handling.
• Handling of materials for storage or warehousing from raw materials to
finished product stage.

1.1.2 Importance of Materials Handling

In the modern era of competition, this has acquired greater importance due to growing
need for reducing the manufacturing cost. The importance of material handling function
is greater in those industries where the ratio of handling cost to the processing cost is
large. Today material handling is rightly considered as one of the most potentially
lucrative areas for reduction of costs. A properly designed and integrated material
handling system provides tremendous cost saving opportunities and customer services
improvement potential. The foremost importance of materials handling is that it helps
productivity and thereby increases profitability of an industry. In many instances it is seen
that competing industries are using same or similar production equipment, and one who
uses improved materials handling system stays ahead of their competitors. A well-
designed materials handling system attempts to achieve the following:
• Improve efficiency of a production system by ensuring the right quantity of
materials delivered at the right place at the right time most economically.
• Cut down indirect labour cost.
• Maximise space utilization by proper storage of materials and thereby reduce
storage and handling cost.
• Reduce damage of materials during storage and movement.
• Reduce overall cost by improving materials handling.
• Improve customer services by supplying materials in a manner convenient for
handlings.
1.2 Automation in Materials Handling

This is an era of automation where it is broadly defined as replacement of manual
effort by mechanical power in all degrees of automation. The operation remains an
essential part of the system although with changing demands on physical input as the
degree of mechanization is increased. Automation may be either full automation or semi-
automation. In full automation, manual effort is fully replaced by mechanical power
whereas in semi-automation, a combination of manual effort and mechanical power is
required whereas in full automation human participation is very negligible.

Need For Automation

Automation plays an important role in mass production. It accomplishes what can not
be done manually. It reduces the labour costs and hence increases the labour productivity.
In addition, it improves the worker safety and product quality. Automation can be
achieved through computers, hydraulic system, pneumatic system & robotics etc. Out of
these sources, pneumatics form an attractive medium for low cost automation. The main
advantages of all pneumatic systems are economy and simplicity.

CHAPTER 2
LITERATURE SURVEY
It is to be noted that pneumatic system; which uses pressurized gases to transmit and
control power for required mechanical actions; forms comparatively simple, economical
and attractive medium for automation in materials handling. An efficient materials
handling system must have three primary attributes; namely the ability to perform its
intended function, adequate service life, and the capability of being produced at
reasonable cost. The review summarizes the study of materials handling system with
pneumatic system and the previous effort on the design and fabrication of pneumatic
system based materials handling equipment. There were a lot of works being carried out
on the development of pneumatic materials handling system. Here, few books and papers
referred in this project and listed below are described in the following sections.
Anthony Esposito [1] This book (Fluid Power with Applications) presents the details of
pneumatics such as properties of air, compressors, air control valves, pneumatic actuators
etc. and many more. It describes the preparation of compressed air with compressors.
Different parts of the compressors along with their functions have also been discussed.
The book also describes the pneumatic circuit design considerations and their
applications. The selected portions of the book were studied and understood. The basic
ideas for the system were developed after studying the book. The review of the book
formed the basis for the pneumatic based materials handling system.
EurIng Ian C. Thrner [2] This book (Engineering Applications of Pneumatics and
Hydraulics) presents the detail concepts of control valves, their types and principles of
operation; pneumatic actuators, pneumatic circuits and arrangement of components. The
important portions of the book were reviewed. The understanding of the concepts of
pneumatics was developed. The review of the book also helped in selecting suitable
control valves such as directional control valves required in the pneumatic system. It also
provided the information about the pneumatic circuits and arrangement of the
components.

Siddhartha Ray [3] This book is focused on the materials handling. It describes the
materials handling, its classification and automation in materials handling. The book also
describes the robotic handling of materials. The automation in materials handling with
pneumatic system is also discussed. The selected portions of the book were studied and
hence the understanding of concept of the materials handling with pneumatics along with
its advantages over other systems was developed.
S. Premkumar, K. Surya Varman, R. Balamurugan [4] This paper mainly focuses on

the design and implementation of multi handling pick and place robotic arm. Robotic arm
consists of revolute joints that allowed angular movement between adjacent joint. Three
double acting cylinders were used to actuate the arm of the robot. Robot manipulators are
designed to execute required movements. By using this collaborated mechanism the
success rate of pick and place robots are increased. The rack and pinion is welded with
piston of the double cylinder, by actuating the hand lever valve the vertical arm will attain
its 360 degrees rotary moment. While the angular moment of the horizontal arm is
actuated by the double acting cylinder and 3/2 hand lever valve. The material handling
equipments such as gripper and vacuum suction cup are mounted over the arm. The to
and fro movement of the gripper is actuated by a separate double acting cylinder and
gripper is operated by using BO motor. The robots contain two vacuum suction cups
which generate vacuum with the help of vacuum generator. Compressor continuously
delivers the air to the cylinder with help of the cylinders all the parts of the robot were
operated. By using gripper and vacuum suction cup both the flat and irregular shaped
materials were handled.
Nilesh Bodkhe, Sanghshil L. Kanekar and Tushar G. Bhore [5] This paper presents
the designs of pneumatic transfer systems (whether push or pull) that requires careful
consideration of a number of important considerations:
• Material considerations include particle attributes such as particle size, size
distribution, particle shape, density, hardness and friability. Physical properties
such as density, compressibility, permeability, and cohesion and other properties
such as toxicity, reactivity, and electrostatic effects.

• System attributes include the resistance of pipe and fittings to chemical reactivity
and abrasion, the efficient design or routing of the system to transfer materials
from and to multiple points, and the maintenance of adequate airflow over the
range of conditions expected. These considerations can be complex and it is
recommended that you consult with a qualified and experienced engineer to assure
that your system is properly designed.
In these topics, different parameters like air velocity, pressure, particle size and shape,
distance to be conveyed, which govern the design of the system, are described.
Catrina CHIVU [6] This paper is focused on pneumatics used in material handling
system, underling the limitation or the specific application of concrete actuators. The
most used pneumatic actuator in material handling applications is the pneumatic cylinder,
especially the double-acting cylinder. In the last years, researchers, tried to prove that a
replacement of the cylinder is the pneumatic muscle, that may be used in almost all
application dominated by the pneumatic cylinder. There are many comparing points of
view regarding the two actuating systems: stiffness, stroke, costs, force, speed, etc. In the
present paper there are compared from stroke, dynamic parameters of simulation and
force point of view.
Santosh C, Manoj C S, Akshay Peddarajula and Abhishek R Shetty [7] This paper
presents the design and fabrication of pneumatic arm for pick and place of cylindrical
objects. The designed pneumatic arm consists of two cylinders, a shaft works with lead
screw mechanism capable of converting motion of piston to rotational motion of arm with
help of using compressed air. The designed processes are carried out based on integrated
information of kinematics dynamics and structural analysis of the desired robot
configuration as whole. The highly dynamic pneumatic arm model can be easily set at
intermediate positions by regulating the pressure using the flow control valve. It can be
used in loading and unloading of goods in a shipping harbour as the movement of goods
is done from lower plane to higher plane.

2.1 Pneumatic System

2.1.1 Basics of Pneumatic System
Pneumatics has long since played an important role as a technology in the performance
of mechanical work. It is also being used in the development of automation solutions.
Pneumatic systems are similar to hydraulic systems but in these systems compressed air is
used in place of hydraulic fluid.
A pneumatic system is a system that uses compressed air to transmit and control
energy. Pneumatic systems are used extensively in various industries. Most pneumatic
systems rely on a constant supply of compressed air to make them work. This is provided
by an air compressor. The compressor sucks in air from the atmosphere and stores it in a
high pressure tank called a receiver. This compressed air is then supplied to the system
through a series of pipes and valves.
2.1.2 Pneumatics in Materials Handling

Pneumatic systems usually operate at much lower pressure than hydraulic systems do,
pneumatics holds many advantages that make it more suitable for many applications.
Because pneumatic pressures are lower, components can be made of thinner and lighter
weight materials, such as aluminium and engineered plastics, whereas hydraulic
components are generally made of steel and ductile or cast iron. Hydraulic systems are
often considered rigid, whereas pneumatic systems usually offer some cushioning, or
“give.” Pneumatic systems are generally simpler because air can be exhausted to the
atmosphere, whereas hydraulic fluid usually is routed back to a fluid reservoir.
Pneumatics also holds advantages over electromechanical power transmission methods.

Electric motors are often limited by heat generation. Heat generation is usually not a
concern with pneumatic motors because the stream of compressed air running through
them carries heat from them. Furthermore, because pneumatic components require no
electricity, they don’t need the bulky, heavy, and expensive explosion-proof enclosures
required by electric motors. In fact, even without special enclosures, electric motors are

substantially larger and heavier than pneumatic motors of equivalent power rating. Plus, if
overloaded, pneumatic motors will simply stall and not use any power.
Electric motors, on the other hand, can overheat and burn out if overloaded. Moreover,
torque, force, and speed control with pneumatics often requires simple pressure- or flow-
control valves, as opposed to more expensive and complex electrical drive controls. And
as with hydraulics, pneumatic actuators can instantly reverse direction, whereas
electromechanical components often rotate with high momentum, which can delay
changes in direction.
2.1.3 Automation with Pneumatic System
Automation can be achieved by pneumatic system that uses pressurized gases to

transmit and control power. As the name implies, pneumatic systems typically use air as
fluid medium because air is a safe, low cost and readily available fluid. It is particularly
safe environments where an electrical spark could ignite leaks from the system
components. There are several reasons for considering the use of pneumatic system
instead of hydraulic system. Some of them are the followings:
• The air used in pneumatic devices is dried and free from moisture so that it does
not create any problem to the internal parts of the system.
• Liquid exhibits greater inertia than gases and hence in the hydraulic system, the
weight of the oil is a potential problem.
• Initial cost is less; hydraulics equipment cost as much as twice the price of
pneumatic equipment.
• A pneumatic water treatment automation system reduces the costs of installation
and operation compared with conventional electrical installations. For opening
and closing of underwater valves, pneumatic systems work well because they can
sustain overload pressure conditions.
• Pneumatic actuators also have long life and perform well with negligible
maintenance requirement throughout their life cycle.

2.1.4 Operation of Pneumatic System

In order to affect mechanical motion, pneumatics employs compression of gases, based
on the working principles of fluid dynamics in the concept of pressure. Any equipment
employing pneumatics uses an interconnecting set of components: a pneumatic circuit
consisting of active components such as gas compressor, transition lines, air tanks, hoses,
open atmosphere, and passive components. Compressed air is supplied by the compressor
and is transmitted through a series of hoses. Air flows are regulated by valves and the
pneumatic cylinder transfers the energy provided by the compressed gas to mechanical
energy. Aside from compressed air, inert gases are also applied particularly for self-
contained systems. Pneumatics is applied in a wide range in industries, even in mining
and dentistry. The majority of industries use gas pressures of about 80 to 100 pounds per
square inch.
Over pneumatics, hydraulics is capable of moving heavier loads and having greater
force. But at the same time pneumatics are cleaner; the system uses no return lines and
gases are exhausted to the atmosphere. Thus leaks will be of less concern since the
working fluid of pneumatics is air, unlike oil in hydraulics. Its working fluid is also
widely available and most factories are pre-plumbed for compressed air distribution,
hence pneumatic equipment is easier to set-up.
To control the system, only ON and OFF are used and the system consists only of
standard cylinders and other components, making it simpler than hydraulics. Pneumatic
systems require low maintenance and have long operating lives. Lastly the working fluid
of the pneumatic system absorbs excessive force, leading to less frequent damage to
equipment. Compressible gases are also easy to store and safer; no fire hazard is
presented and machines could be made to be overload safe.
2.2 Components of Pneumatic System

The main components of the compressed air production, transportation, and distribution
system consist of air compressor, electric motor and motor control centre, pressure
switch, check valve, storage tank, pressure gauge, auto drain, air dryer, filters, air
lubricator, pipelines, and different types of valves. The main components of air

consuming system consist of intake filter, compressor, air take off valve, auto drain, air
service unit, directional valve, actuators, and speed controllers. Basic components of the
pneumatic system are as shown in the figure.
Figure 1: Components of a Pneumatic System
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 mechanization 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 an all pneumatic system are usually economic
and simplicity the latter reducing maintenance to a low level. It can also have outstanding
advantages in terms of safety.

2.4 Components in Materials Handling Equipments

The major components of the pneumatic four axis materials handling equipment are:
• Air Compressor
• Pressure Gauge
• Pneumatic Control Valves
• Pneumatic Cylinders
• Rack and Pinion Block
• Connecting Hoses
2.4.1 Air Compressor

An air compressor is a device that converts power using an electric motor, diesel or
gasoline engine etc. into potential energy stored in pressurized air i.e., compressed air. By
one of several methods, an air compressor forces more and more air into a storage tank,
increasing the pressure. When tank pressure reaches its engineered upper limit the air
compressor shuts off. The main function of the air compressor is to compress the air up to
the required pressure. This is a two stages or two-cylinder reciprocating air compressor.
The two cylinders are for low and high compression. The air pressure is measured at
various places by the use of pressure gauges. V-belt and pulley are used to drive the
compressor.
Compressors can be broadly classified into two groups: Positive Displacement

Compressor and Dynamic Compressor. In positive displacement air compressor,
successive volumes of air are isolated and then compressed to a higher pressure. There
are essentially two forms of positive displacement compressor: reciprocating and rotary.
Reciprocating positive displacement compressor is widely used air compressor. In
dynamic air compressor, a high speed rotating element accelerates the air and converts the
resulting velocity head into pressure.
Positive displacement compressors work on the principle of increasing the pressure of a

definite volume in an enclosed chamber. Dynamic (turbo) compressor employs rotating

vanes or impellers to impart velocity and pressure to the flow of the air being handled.
The pressure comes from the dynamic effects such as centrifugal force.
Figure 2: Air Compressor
Figure 3: Specification of Air Compressor
2.4.1.1 Selection Criteria for Compressor
A numer of factors are involved in the selection criteria of a suitable air compressor.
These are briefly explained below:
• Pressure
First of all, the pressure needed must be determined. Most air operated system and
tools are designed to operate at a pressure from 6000 to 7000 N/m². A compressor
of normal make and type would normally be suitable if this can assure a pressure
6000 N/m² in the distribution line laid down for a pneumatic tools and system.
• Capacity
Another important factor in compressor selection is the capacity or volume of air
required. This factor is sometimes extremely difficult to evaluate. Obviously, the
unit selected should be large enough to supply all the air devices, which will be
operating at any given time. If all the air operation is continuous, the capacity
required is simply the sum of air compression of each individual tool.
2.4.2 Pressure Gauge

Pressure gauge is used for measuring the outlet pressure of air from the compressor. The
gauge used is Bourdon type pressure gauge. The gauge is fitted at the outlet of the air
compressor. The gauge selection is done based on the working pressure of the equipment.
Figure 4: Pressure Gauge (0-10 bar)
2.4.3 Pneumatic Control Valves

The pneumatic cylinder is regulated and controlled by pneumatic valves. These valves are
actuated manually, mechanically, electrically, pneumatically, and by various combined
mode of actuation. Direction control valves are needed to control the to and fro motion of
cylinder, the fluid energy has to be regulated, controlled and reversed with a
predetermined sequence in a pneumatic system. Similarly, one may have to control the
quantity of pressure and flow rate to generate the desired level of force and speed of
actuators. To achieve these functions, valves are used. Valves are fluid power elements
used for controlling and regulating the working medium. The main functions of the
pneumatic control valves are:
• Start and stop the fluid energy
• Control the direction of flow of compressed air
• Control the flow rate of the fluid

• Control the pressure rating of the fluid
Although various types of valves are available, they are mainly classified as: Direction
control valves, Direction control check valves, Flow control valves, Pressure control
valves etc, the main purpose of a valve in a pneumatic circuit is to control outputs. Valves
can be divided into a number of groups according to what they control.
2.4.3.1 Direction Control Valves

Directional control valves are one of the most fundamental parts in pneumatic machinery
as well as in hydraulic machinery. They allow fluid flow into different paths from one or
more sources. They usually consist of a spool inside a cylinder which is mechanically or
electrically controlled. The movement of the spool restricts or permits the flow, thus it
controls the fluid flow.
Figure 5: Direction Control Valve (5/2 DCV)
Figure 6: Schematic of 5/2 DCV
A 5/2 way direction control valve, from the name itself has 5 ports equally speed and 2
flow positions. It can be used to isolate and simultaneously bypass a passage way for the
fluid which for example shoud retract or extend a double acting cylinder. There are

variety of ways to have this valve actuated. A solenoid valve is commonly used, a lever
can be manually twist or pinch to actuate the valve, an internal or external hydraulic or
pneumatic pilot to move the shaft inside, sometimes with a spring return on the other end
so it will go back to its original positions when pressure is gone, or a combination of any
of mention above.
In the Illustration given, a single solenoid is used and a spring return is installed in the
other end. The inlet pressure is connected to (P)1. (A)2 could possibly be connected to
one end of the double acting cylinder where the piston will retract while (B)4 is
connected to the other end that will make the piston extend. The normal position when the
solenoid is deenergized is that the piston rod is blocking (B)4 and pressure coming from
(P)1 passes through (A)2 that will make the cylinder normally retracted. When the
solenoid is energized, the rod blocks (A)2 and pressure from (P)1 passes through (B)4
and will extend the cylinder.and when the solenoid is deenergized, the rod bounces back
to its original position because of the spring return. (E)3 and (E)5 is condemned or used
as exhaust.
2.4.3.2 Flow Control Valves

These are used to control the rate of flow of a fluid through the valve. A directional
control valve on the receipt of some, external signal, which might be mechanical,
electrical or a fluid pilot signal, changes the direction of stops, or starts the flow of fluid
in some part of the pneumatic/hydraulic circuit. They can be used to carry out such
functions as:
• Controlling the direction of motion of an actuator
• Selecting alternative flow paths for a fluid.
• Stopping and starting the flow of fluid.
A pneumatic system, energy that will be used by the system and transmitted through the
system is stored as potential energy in an air receiver tank in the form of compressed air.
A pressure regulator is positioned after a receiver tank and is used to position out this
stored energy to each leg of the circuit. A pressure regulator is a normally open valve.
With a regulator positioned after a receiver tank, air from the receiver can expand through
the valve to a point downstream. As pressure after the regulator rises, it is sensed in an
internal pilot passage leading to the underside of the piston. This piston has a large
surface area exposed to downstream pressure and for this reason is quite sensitive to
downstream pressure fluctuations.
When downstream pressure nears the present level, the piston moves upward pulling the
poppet towards its seat. The poppet, once it seats, does not allow pressure to continue
building downstream.
2.4.4 Pneumatic Actuators
A pneumatic actuator converts energy typically in the form of compressed air into
mechanical motion. The motion can be rotary or linear, depending on the type of actuator.
Linear pneumatic actuators are used to move an object or apply a force in a straight line.
Pneumatic cylinder is a pneumatic actuator which can be divided into two types: Single
Acting Cylinder and Double Acting Cylinder. A single acting cylinder is powered by
fluid for the movement of the piston in one direction with it being returned in the other
direction by an internal spring or an external force; a double acting cylinder is powered
by fluid in both directions. Rotary actuators are used to move an object in a circular path.
Rotary actuators are the fluid power equivalent of an electric motor.
2.4.4.1 Pneumatic Cylinders

Pneumatic cylinders are the one, which offers the rectilinear motion to mechanical
elements. Cylinders are classified as light, medium, and heavy duty with respect to their
application.
Double acting cylinder is considered to be as a main actuator in any pneumatic
systems. Double acting cylinders are more expensive than single acting cylinders, but
double acting cylinders are superior than the single acting cylinders by any other
important measure. Double acting cylinders are faster and stronger.
In industrial applications, single acting cylinders are also used if possible, but when speed
and force are important double acting cylinder are employed. Applications include

opening and closing doors, taking things off conveyor belts and putting things on
conveyor belts.
Figure 7: Double Acting Pneumatic Cylinder
Figure 8: Sectional View of Double Acting Cylinder
Air Seal
Air seal is used to prevent the leakage of air pressure from the cylinder. Normally it is
made up of neoprene rubber. If there are any air leakages in the system, it will reduce the
efficiency.
Wiper Seal
Wiper seal is provided at the entrance of the cylinder to avoid dust materials from the
environment. It is made up of neoprene rubber.

Circlip
Circlip is used to protect the out coming of air seal and wiper seal from the cylinder. It is
made up of steel.
“O” Ring
The “O” rings are fitted into the grooves of piston to maintain perfect seal between the
piston and the cylinder wall. They are mostly made up of neoprene rubber.
Cylindrical Technical Data

• Barrel
It is made of cold drawn aluminimum honed to 25mm.
• Piston Rod
M.S. hard Chrome plated
• Seals
Nitrile (Buna – N) Elastomer
• End Covers
Cast iron graded fine grained from 25mm to 300mm
• Piston
Aluminium
• Cushions
Adjustable standard on 400mm bore and above
2.5 Rack and Pinion Assembly

A rack and pinion is a type of linear actuator that comprises a pair of gears which convert
rotational motion into linear motion. A circular gear called "the pinion" engages teeth on
a linear "gear" bar called "the rack"; rotational motion applied to the pinion causes the
rack to move relative to the pinion, thereby translating the rotational motion of the pinion
into linear motion. The block is the central part of the unit as it houses the rack and
pinion. This rack and pinion attachment gives the rotary motion to the pneumatic
material-handling device. This block converts linear motion into rotary motion. Pinion is
a gear wheel which is provided to get mesh with rack to convert the linear motion into
rotary motion. It is made up of cast iron.

In rack, rack teeth are cut horizontally about the required length to get the accurate
turn of 360 degrees. It is made up of Cast iron.
Figure 9: Rack & Pinion

CHAPTER 3
PROBLEM FORMULATION
Pneumatic system uses pressurized gases to transmit and control power. As the name
implies, pneumatic systems typically use air as fluid medium, because air is a safe, low
cost and readily available fluid. It is particularly safe environments where an electrical
spark could ignite leaks from the system components. There are several reasons for
considering the use of pneumatic system instead of hydraulic system. Liquid exhibits
greater inertia than gases. Therefore, in hydraulic system the weight of the oil is a
potential problem. To design and development a material handling system for
automation/semi-automation of industries by using pneumatic control system, which is
used for low cost automation.
From the literature survey, it is clear that proper control on fluid flow through the
pneumatic system plays a major role in the controlling the mechanical actions required
for the materials handling system. Specifications of the components of the pneumatic
system based on the design and analysis are very important to obtain the desired
materials handling task at expected rate. The working pressure from the compressor also
plays an important role in rate of mechanical actions required in the materials handling.
Though there are many works done on the design and fabrication of the pneumatic system
based materials handling, less work has been done on the improvement of the pneumatic
system based materials handling automation with the minimum number of axes. The
project aims at the development of the pneumatic four axis materials handling equipment.
Objectives:
The main objective of our project work is,
• To study the various materials handling equipments.
• To design and fabricate pneumatic four axis materials handling equipment.
• To perform the testing on the fabricated equipment.

CHAPTER 4
SCOPE OF PRESENT WORK

Present work has been carried out on the development of the four axis materials handling
equipment which is capable of handling the materials for pick and place purpose.
Following steps are involved in the current work:

1. Carrying out an extensive literature survey in the required field.
2. Design of the components of materials handling system along with the selection of
appropriate materials and specifications.
3. Carrying out the fabrication works and experiment to determine how much weight
the equipment can handle.
4. To do proper experimentation for the satisfactory job by the materials handling
system.
5. To improve the equipment by modifying the system with different parameters.
To carry out the above mentioned steps, it is important to develop a proper methodology
and follow the guidelines properly. This is important for the smooth going of the analysis
to follow the methodology. The methodology for this work is defined in the next chapter.

CHAPTER 5
METHODOLOGY
The methodogy behind the current project work involves the preparation of the project
plan, selection of pneumatics, selection of components with appropriate materials, design
calculations & 3D modeling and fassembly of the equipment.
5.1 Preparation of Project Plan

In this stage we started preparing the machine design and the concept. The way our Arm
would look was decided and studied thoroughly. The first conceptual plan is as shown
and various changes were made to improve the performance and to make cost effective.
5.2 Design Calculations and 3D Modeling

Calculations were carried out for design of pneumatic cylinders & pistons: horizontal
cylinder, vertical cylinder, rotary cylinder & gripper cylinder etc and design of rack &
pinion assembly. Accordingly 3D model of the components and the assembly were
prepared using Modeling Software SolidWorks and CATIA. The 3D model of
components and the Assembly model gave the dimensional pictorial view of the
components which were to be fabricated.
5.2.1 Design of Components

5.2.1.1 Design of Pneumatic Cylinders
Horizontal, vertical, rotary cylinders & arm lifting cylinder are of same design and
selected from the pneumatic product catalogue. Cylinders are of double acting type.
According to the applications the forward and return stroke of the piston has to be
controlled with some time interval. So, double acting cylinders are preferred. This time
interval can not be achieved by single acting cylinders.
1. Design of Horizontal, Vertical & Rotary Cylinders

Force to be Exerted is 50 N
Force(F)=Pressure(P)×Area(A)

Pressure in the Cylinder, P=0.5×105 N/m² (working pressure)

Area of the Piston, A=(πd2)/4= Force/Pressure=50/50000=0.001 m²
Bore Diameter, d=(0.001×4/π)1/2=0.03568 m=35.68 mm

From pneumatic products catalogue, we have selected 40 mm as bore diameter of the
horizontal, vertical and rotary cylinders.
For Forward Stroke:

For 40 mm bore diameter,
Corresponding Piston Rod diameter, dr=16 mm
Area of the piston, A=(πd2)/4=(π×402)/4=1256.64 mm²
Force (modified) exerted in the forward stroke,
i.e. Extending Force, Fe=Pressure(P)×Area(A)
i.e. Fe=0.5×105×1256.64×10-6=62.83 N
For Return Stroke:

On the return stroke, when the pressure is applied to the reverse direction, the force on the
piston due to the pressure is, Fr =Pressure(P)×Net Area(A-a)
where,
P=Pressure in the cylinder (in N/m2)=0.5×105 N/m2 (working pressure)
A=Area of the piston (in m2)
a=Cross sectional area of the piston rod (in m2)
Therefore,
a= π×dr2/4=π×162/4=201.06 mm2
Net Area on the Piston Rod side, (A-a)=(1256.64-201.06) mm2
i.e. (A-a)=1055.58 mm2
Force (modified) exerted in the return stroke,
i.e. Retracting Force, Fr=Pressure×Net Area(A-a)
i.e. Fr=0.5×105×1055.58×10-6=52.78 N
Thus, for the working pressure of 0.5×105 N/m2

Extending Force=62.83 N
Retracting Force=52.78 N

2. Design of Arm Lifting Cylinder

Force to be Exerted is 40 N
Force(F)=Pressure(P)×Area(A)
Pressure in the Cylinder, P=0.5×105 N/m² (working pressure)

Area of the Piston, A=(πd2)/4= Force/Pressure=40/50000=0.0008 m²
Bore Diameter, d=(0.0008×4/π)1/2=0.03192 m=31.92 mm
From pneumatic products catalogue, we have selected 32 mm as bore diameter of the arm
lifting pneumatic cylinder.
For Forward Stroke:

For 32 mm bore diameter,
Corresponding Piston Rod diameter, dr=12 mm
Area of the piston, A=(πd2)/4=(π×322)/4=804.25 mm²
Force (modified) exerted in the forward stroke,
i.e. Extending Force, Fe=Pressure(P)×Area(A)
i.e. Fe=0.5×105×804.25×10-6=40.21 N
For Return Stroke:

On the return stroke, when the pressure is applied to the reverse direction, the force on the
piston due to the pressure is, Fr =Pressure(P)×Net Area(A-a)
where,
P=Pressure in the cylinder (in N/m2)=0.5×105 N/m2 (working pressure)
A=Area of the piston (in m2)
a=Cross sectional area of the piston rod (in m2)
Therefore,
a= π×dr2/4=π×122/4=113.10 mm2
Net Area on the Piston Rod side, (A-a)=(804.25-113.10) mm2
i.e. (A-a)=691.15 mm2
Force (modified) exerted in the return stroke,
i.e. Retracting Force, Fr=Pressure×Net Area(A-a)
i.e. Fr=0.5×105×691.15×10-6=34.56 N

Thus, for the working pressure of 0.5×105 N/m2

Extending Force=40.21 N
Retracting Force=34.56 N
5.2.1.2 Design of Pinion
From the Design Data Book,

Minimum diameter of the Pinion required is given by,
dmin=(0.59/σcmax)×{[Mt]/(1/E1+1/E2)2}1/3----------------------------------(I)
where,
σcmax=Maximum Contact Compressive Stress (in N/m2)
Mt=Nominal Twisting moment transmitted by the pinion (in Nm)
E1, E2=Young’s Moduli of Materials of Rack & Pinion (in N/m2)
E1=E2=80 GPa=0.8×1011 N/m2 (for cast iron)
Calculation of σcmax
Maximum Contact Compressive Stress is given by,
σcmax=BHN×Cb×Kl----------------------------------------------------------(II)
where,
BHN=Brinell Hardness Number of the Material of the Pinion (in kgf/mm2)
Cb=Coefficient depending on the Hardness
Kl=Life Factor
Kl={[1×107]/N}1/6-------------------------------------------------------------(III)
where,
N=Life in number of cycles=(n×T)×60
n=speed (in rpm)=10 rpm (required speed)
T=Life in hours=8000 hours
For cast iron (material of the pinion),
BHN=200
Cb=20
On substitution of n & T for N, we get
N=4.8×106 cycles
Substituting the values of N in (III), we get

Kl=1.130
Again, substituting the values of BHN, Cb & Kl in (II), we get
σcmax=4520 kgf/mm2=4607.54×105 N/m2
Calculation of Mt
Nominal Twisting moment transmitted by the pinion (in Nm) is given by,
Mt=9550×P0/n------------------------------------------------------------(IV)
where,
P0=Power to be transmitted (in kW)
n=Speed (in rpm)=10 rpm
Angular Velocity, ω=2πn/60=2×π×10/60=1.05 rad/s2
For calculation of Power,
Centrifugal Force, Fc=mω2r where, m=8 kg & r=1 m
i.e. Fc=8×1.052×1=8.82 N
Downward Force, Fd=mg
i.e. Fd=8×9.81=78.48 N
Total Force, Ft=Fc+Fd
i.e. Ft=8.82+78.48=87.30 N
Torque, T=Ft×r=87.30×1
i.e. T=87.30 Nm
Power, P0=Tω=87.30×1.05
i.e. P0=91.67 watts=0.09167 kW
Substituting the values of P0 and n in (IV), we get
Mt=9550×0.09167/10=87.545 Nm
[Mt]=1.4×87.545=122.563 Nm
Again, substituting the values of σcmax, [Mt], E1 & E2 in (I), we get
dmin={0.59/(4607.54×105)}×{122.563/(2/(0.8×1011))2}1/3
i.e. dmin=0.07439 m=74.39 mm
The minimum diameter of the pinion is calculated to be 74.39 mm.
We have selected the standard diameter of pinion as 75 mm.

Specification Of Pinion
Material: cast-iron
Outside Diameter: 75 mm
Circular Pitch: 4.7 mm
Tooth Depth: 3.375 mm
Module: 1.5 mm
Pressure Angle: 21°
Pitch Circle Diameter: 72 mm
Addendum: 1.5 mm
Dedendum: 1.875 mm
Circular Tooth Thickness: 2.355 mm
Fillet Radius: 0.45 mm
Clearance: 0.375 mm
5.2.1.3 Design of Rack
Pitch Circle Diameter of the pinion, d=72 mm

Circumference of the pinion is,
πd=π×72=226.19 mm
This is the dimension for the full rotation (360°) of the pinion.
For half of full rotation (180°),
Length of the rack for which the teeth are to be adjusted,
i.e. rack length=226/2=113 mm
Specification of Rack
Material: Cast-iron
Module: 1.5mm
Cross-section: 75×25mm
Teeth on the rack is adjusted for 113 mm

5.3 3D Modeling
Based on the specifications obtained from the design, 3D model of the components and
the assembly were prepared using Modeling Software SolidWorks and CATIA. The 3D
model of components and the assembly model gave the dimensional pictorial view of the
components which were to be fabricated. The following figures are the 3D modelling of
the components of the pneumatic materials handling equipment:
Figure 10: 5/2 DCV Valve
Figure 11: Pneumatic Cylinder

Figure 12: Sectional Views of Frame (all dimensions in cm)
Figure 13: Pictorial View of Frame

Figure 14: Top View of Frame with Cylinder and Rack & Pinion Assembly
Figure 15: Isometric View of Assembly of Arms, Cylinder and Rack & Pinion
Figure 16: Pictorial colored View of the Assembly

Figure 17: Different Views of the Full Assembly
Figure 18: Side View of the Full Assembly

Figure 19: Front View of the Whole Assembly
Figure 20: Top View of the Whole Assembly

Figure 21: View of Turned Position of the Full Assembly
Figure 22: Pictorial View of the Full Assembly

CHAPTER 6
EXPERIMENTAL DETAILS AND PROCEDURE
6.1 Fabrication and Testing

The components of the equipment were fabricated based on the design specifications and
3D modeling. All of the components of the pneumatic materials handling equipment were
assembled and the assembly was subjected to the testing to ensure the proper functioning
of the equipment. In this chapter, the experimental details and procedure will be
explained.
6.1.1 Equipment Functioning

The experimental setup consists of four double acting pneumatic cylinders. One of these
cylinders is used to actuate rack & pinion assembly such that piston rod of the cylinder is
connected to rack meshed with the pinion. By operating the cylinder, rack & pinion
assembly turns the whole assembly through nearly 260°. The turning angle of the
assembly can be altered by varying the length of the rack. Another cylinder i.e. vertical
cylinder is used to increase the height of the setup; the height is limited by the piston rod
length of the cylinder. Horizontal cylinder is used to increase the arm length; the working
area of the arm is limited by the piston rod length. Gripper cylinder is used to actuate the
gripper that holds the materials.

Figure 23: Schematic Diagram of Assembly of Equipment Functioning
6.2 Description of Assembly

The assembly unit consists of a base block, cylinders, rack and pinion, base plate, tie rods,
solenoid valves and gripper. Cylinder1 is mounted on the base block with rack and pinion
assembly connected with tie rods. The vertical cylinder is mounted vertically over the
base plate to increase the height with a block and endplate provided at the end. The
horizontal cylinder is mounted on the block of the vertical cylinder horizontally to
increase length of the arm with a block and end plate provided at the end position. The
gripper cylinder is mounted on the horizontal cylinder block in an inclined position of
angle 30 to actuate the gripper. The piston rod of gripper cylinder is connected to the one
side of the gripper.
Figure 24: Fabricated Assembly of the Equipment

6.3 Process Chart

Table 6.1.3: PROCESS CHART
S. No. Component Materials Tools Machines Process Instruments

Name Used used Used
1 Piston rod MS Turning Lathe Turning Vernier
tool Grinding Caliper
Hard
chroming
2 Bracket MS Turning Lathe Turning Vernier
tool Caliper
3 Tie rod MS Turning Lathe Turning Vernier

tool Threadin Caliper
threading g Micrometer
tool
4 Piston rod MS Turning Lathe Turning Vernier
tool, Grinding Grinding Caliper
grinding machine Hard Micrometer
tool chroming
5 Rack CI Turning Lathe, milling Turning, Vernier
tool disc machine Teeth Caliper
cutter cutting Micrometer
6 Pinion CI Turning Lathe, milling Turning, Vernier

tool teeth machine Teeth Caliper
cutter cutting Micrometer
7 Square CI Turning Lathe Turning, Vernier

Block tool boring boring Caliper
bar

6.4 Materials of Components

Table 6.1.4: LIST OF MATERIALS & QUANTITY
SL.NO PARTS MATERIALS QUANTITY

1 HORIZONTAL CYLINDER M.S. 1
2 VERTICAL CYLINDER M.S. 1
3 ROTARY CYLINDER M.S. 1
4 ARM LIFTING CYLINDER M.S. 1
5 RACK C.I 1
6 PINION C.I. 1
7 BLOCK M.S. 2
8 FRAME M.S. 1
9 GRIPPER ARM M.S. 1
10 TIE ROD M.S. PIPE 1
11 NUTS & WASHERS M.S. -
12 D.C. VALVES ALUMINIUM 4
13 TUBES POLYURETHENE 10 METER
14 HOSE COLLAR AND HOSE CONNECTOR BRASS 20
Dimensional Details
Elements Specifications Dimensions
Frame Height 70.5cm
Width 51cm
Cross-Section 1 inch2
Arm Total Height 38 inch
Gripper Opening 6 inch
Miscellaneous Height base to frame 30 inch

CHAPTER 7
RESULTS AND DISCUSSION

The pneumatic four axis materials handling equipment was developed. The equipment
was tested to ensure satisfactory results as expected. The experimentation on the
equipment provided the output result of the equipment. The working of the equipment
was found to be satisfactory. However, the capacity of materials handling of the
equipment was less compared to the designed load handling capacity. The results or
outputs from the equipment can be summarized as:
➢ The equipment was able to handle the maximum load of 20-25 N whereas it was
designed to handle the maximum load of 40 N.
➢ The output torque of the equipment was unexpectedly low.
➢ The movement of the arm was sometimes too sensitive. This was so because of
fluctuation of working pressure and supply of same pressure to all the actuators
whose expected load carrying capacities are different.
➢ The gripper had better capability of holding flat objects compared to cylindrical or
any other irregular type of objects.
Figure 25: Testing of Equipment

7.1 Applications
The equipment may be used for the following applications:
• Discharge of Workpiece
The arm feed has a wide application in low cost automation industries. It can be
used in automated assembly lines to pick up the finished product from workstation
and place them in bins. it can also be used to pick raw material and place them on
the conveyor belts.
• Work Clamping
This unit can also be used in clamping. Operation in certain areas of mass
production where clamping and an clamping have to be done at high speeds. The
application of these units is limited to operations which involved moderate

clamping forces.
• Tool Changing Application

When the pneumatic arms are made smaller in size they can be used in automatic
tool changes in CNC turning and drilling machines, by attaching tool holding
device to the rotary cylinder.
• Chemical Laboratories, Welding and Foundry etc.

The equipment may be used in chemical laboratories to pick and place the
dangerous chemicals if the equipment is improved with respect to the gripper and
control of the motion. It may be also used in the manufacturing processes such as
welding and foundry to handle workpiece and materials whenever required.
7.2 Advantages
The followings are some major advantages of pneumatic materials handling equipment:
• The pneumatic arm is more efficient in the technical field
• Quick response is achieved
• Easy to maintain and repair

• Cost of the unit is less when compared to other robotics

• No fire hazard problem due to over loading
• Comparatively the operation cost is less
• The operation of arm is faster because the medium used to operate is air
• Continuous operation is possible without stopping
7.3 Limitations
The followings are the limitations of the pneumatic materials handling equipment:
• While working, the compressed air produces noise therefore a silencer may
be used.
• High torque can not be obtained.
• Load carrying capacity of this unit is not very high.

CHAPTER 8
CONCLUSIONS
The design and fabrication of pneumatic four axis materials handling
equipment is completed with economic and effective considerations. Thus
we have developed a Pneumatic Four Axis Materials Handling Equipment
which helps to know how to achieve low cost automation. The capacity of
our material handling system is 20 N. The application of pneumatics
produces smooth operation. The work volume is produced within the angle
of 120°. This would boom the mass reduction industries having conveyors,
metal inert gas welding, tungsten inert gas welding and other applications.
The commercial production of this project is feasible economically. By using
more techniques, they can be modified and developed according to the
applications.

CHAPTER 9
SCOPE FOR FUTURE WORK

Based on the experiments and studies that were carried out in the present
work, there are many possible scopes for the future works that could be
carried out in the following fields with respect to the current works:
➢ Current work focuses on the development of materials handling
equipment based on the pneumatics. By using new techniques, the
functioning of equipment can be modified and improved according to
the applications.
➢ The gripper can be modified to pick and place the objects of shapes
other than flat objects.
➢ The mechanical actions or motions of the arms can be made smooth
and less sensitive by adding additional pneumatic valves.
➢ The weight of arms can be reduced by selecting more appropriate
materials which are of light weight but with great strength.
➢ As a part of output, the torque can be increased by techniques for
reducing external factors.
The above modifications and improvements can be carried out as a

continuation based on the current work that has been conducted. It can be
taken up in an attempt to continuously improve the materials handling
capacity of the equipment and hence efficiency of the equipment.

REFERENCES
[1] Anthony Esposito, Fluid Power with Applications, Fourth Edition, Prentice-Hall of
India Private Limited (1980), New Delhi. pp. 423-452 & 460-481.
[2] EurIng Ian C. Thrner, Engineering Applications of Pneumatics and Hydraulics,

Butterworth-Heinemann, Jordan Hill, Oxford. pp. 57-63, 72-76 & 87-93.
[3] Siddhartha Ray, Introduction to Materials Handling, New Age International (P)
Limited, Publishers; pp. 1-8 & 185-190.
[4] Design and Implementation of multi-handling Pick and Place Robotic Arm, S.
Premkumar, K. Surya Varman, R. Balamurugan, Volume 33, Number 3, International
Journal of Engineering Trends and Technology (IJETT)-March 2016.
[5] Design, Analysis & Fabrication of Pneumatic Materials Handling Systems, Nilesh
Bodkhe, Sanghshil L. Kanekar and Tushar G. Bhore, Volume 6, Issue 8, pp. 12-23,
International Journal of Engineering Trends and Technology (IJETT)-August 2015.
[6] Pneumatic Driving in Materials Handling Systems, Catrina CHIVU, Transilvania

University of Brasov, Romania, Volume 15, Number 3(43), pp. 155-159, November 2014
[7] Design and Fabrication of Pneumatic Arm for Pick and Place of Cylindrical Objects,
Santosh C, Manoj C S, Akshay Peddarajula and Abhishek R Shetty, Volume V, Issue VI,
June 2016 | ISSN 2278-2540, International Journal of Latest Technology in Engineering,
Management & Applied Science (IJLTEMAS)
[8] D.S. Kumar, Fluid Mechanics & Fluid Power Engineering, S. K. Kataria & Sons
[9] PSG Design Data Book for Engineers, published by Kalaikathir Achchagam,
Kalaikathir Buildings, Coimbatore-641 037, Tamil Nadu

[10] Festo Didactic KG – Fundamentals of control technology, Esslingen-1998, Festo

Pneumatic Catalogue, Festo Private Limited, Bangalore
[11] Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore

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PNEUMATIC FOUR AXIS MATERIALS HANDLING ROBOT

Thesis · October 2019

Royston CLEATUS Mascarenhas

The user has requested enhancement of the downloaded file.

Department of Mechanical Engineering, RIT, Bangalore Page 1

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Figure 1: Components of a Pneumatic System 14

Department of Mechanical Engineering, RIT, Bangalore Page 3

1.1 Introduction to Materials Handling

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1.1.1 Definition and Scope

or between a building and a transportation vehicle. As a process, it uses a wide range of

Functional scopes of materials handling within an industry covers the following:

Department of Mechanical Engineering, RIT, Bangalore Page 5

1.1.2 Importance of Materials Handling

1.2 Automation in Materials Handling

Department of Mechanical Engineering, RIT, Bangalore Page 6

Need For Automation

Department of Mechanical Engineering, RIT, Bangalore Page 7

Department of Mechanical Engineering, RIT, Bangalore Page 8

S. Premkumar, K. Surya Varman, R. Balamurugan [4] This paper mainly focuses on

Department of Mechanical Engineering, RIT, Bangalore Page 9

Department of Mechanical Engineering, RIT, Bangalore Page 10

2.1 Pneumatic System

2.1.2 Pneumatics in Materials Handling

Pneumatics also holds advantages over electromechanical power transmission methods.

Department of Mechanical Engineering, RIT, Bangalore Page 11

2.1.3 Automation with Pneumatic System

Automation can be achieved by pneumatic system that uses pressurized gases to

Department of Mechanical Engineering, RIT, Bangalore Page 12

2.1.4 Operation of Pneumatic System

2.2 Components of Pneumatic System

Department of Mechanical Engineering, RIT, Bangalore Page 13

Figure 1: Components of a Pneumatic System

2.3 Selection of Pneumatics

Department of Mechanical Engineering, RIT, Bangalore Page 14

2.4 Components in Materials Handling Equipments

2.4.1 Air Compressor

Compressors can be broadly classified into two groups: Positive Displacement

Positive displacement compressors work on the principle of increasing the pressure of a

Department of Mechanical Engineering, RIT, Bangalore Page 15

Figure 2: Air Compressor

Figure 3: Specification of Air Compressor

2.4.1.1 Selection Criteria for Compressor

2.4.2 Pressure Gauge

Figure 4: Pressure Gauge (0-10 bar)

2.4.3 Pneumatic Control Valves

Department of Mechanical Engineering, RIT, Bangalore Page 17

• Control the pressure rating of the fluid

2.4.3.1 Direction Control Valves

Figure 5: Direction Control Valve (5/2 DCV)

Figure 6: Schematic of 5/2 DCV

Department of Mechanical Engineering, RIT, Bangalore Page 18

2.4.3.2 Flow Control Valves

2.4.4 Pneumatic Actuators

2.4.4.1 Pneumatic Cylinders