PNEUMATIC CONTROLLED BAR FEEDING MECHANISM

Submitted in the partial fulfillment of the requirement for the award of

DIPLOMA

IN MECHANICAL ENGINEERING

SUBMITTED BY:

1. G.K. MANIGANDAN 2. B. KARTHIKEYAN 3. P. BALASUBRAMANI

4. J. DHANAJEYAN 5. D. DURAIVEL 6. L. PRABHU

Under guidance of Mr. V.K. RAJENDRAN,M.E. APRIL 2010. DEPARTMENT OF MECHANICAL ENGINEERING

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE CHEM BARAMBAKKAM, CHENNAI 602 103

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE CHEM BARAMBAKKAM, CHENNAI 602 103

BONAFIDE CERTIFICATE
This is to certify that this Project work on

PNEUMATIC CONTROLLED BAR FEEDING MECHANISM submitted by . Reg. No. in partial fulfillment for the award of DIPLOMA IN MECHANICAL ENGINEERING This is the bonafide record of work carried out by him under our supervision during the year 2012 Submitted for the Viva-voce exam held on ..

HEAD OF THE DEPARTMENT

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the Principal Mr. A. VIJAY KISHORE ,MSc., M TECH, MISTE.,

encouragement and valuable advice.

we thank our Esquired Head of Department Mr R. RAJKUMAR, A.M.I.E, M.E. Phd, for presenting his felicitations on us. We are grateful on our Entourages Mr. .R RAJKUMAR, A.M.I.E, M.E,Phd., for guiding in various aspects of the project making it a grand success. We also owe our sincere thanks to all staff members of the Mechanical Engineering Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

TABLE OF CONTENTS
CHAPTER TITLE ACKNOWLEDGEMENT ABSTRACT LIST OF TABLES LIST OF FIGURES NOMENCLATURE 1 INTRODUCTION 1.1 OBJECTIVES AND SCOPE 2 3 LITERATURE SURVEY BAR REEDING MACHANISM 3.1 BAR FEEDING MECHANISM 3.2 WORKING PRINCIPLE 3.3 CONSTRUCTION 3.3.1. BASE 3.3.2. MOVABLE V BLOCK 3.3.3. FIXED V BLOCK 3.3.4. GUIDE ROD 4. CYLINDER 6 2 4 4 4 4 4 5 5 1 PAGE NO Iii iv vii viii ix

4.1 CYLINDER 4.2 TYPES OF CYLINDERS 4.2.1. SINGLE CYLINDER PUMP 4.2.2. DOUBLE CYLINDER PUMP 4.2.3. TRIPLE CYLINDER PUMP 4.2.4. DUPLEX DOUBLE ACTING PUMP 4.2.5. QUINTUPLEX PUMP CHAPTER TITLE 4.3 SINGLE ACTING CYLINDER 4.4 DOUBLE ACTING CYLINDER 5. 4.5. SPECIFICATION HAND OPERATING VALVE 5.1 HAND OPERATING VALVE 6. 5.2 TYPES OF HAND OPERATING VALVE POWER HACKSAW MACHINE 6.1. POWER HACKSAW MACHINE 6.1.1. TYPES OF POWER HACKSAW MACHINE 6.1.2. SPECIFICATION OF MACHINE 7. 8. 9. 6.1.3. SPECIFICATION OF MOTOR TEAM SPLIT COST ESTIMATION CONCLUSION APPENDIX 1 : Base Plate (M.S) APPENDIX 2: R.H.V- Block (M.S) APPENDIX 3: Moving V- Block (M.S) APPENDIX 4 : L.H. V Block APPENDIX 5 : Cylinder MTG bracket (M.S. WELD) APPENDIX 6 : Guide Bush & Guide Rod APPENDIX 7 : Stopper Screw & Nut APPENDIX 8 : Stopper Plate APPENDIX 9 : Isometric view APPENDIX 10 : Photographic view REFERENCE

6 6 6 6 7 7 7

PAGE NO

LIST OF TABLES
TABLE 4.1 6.1 6.2 8.1 LABLE Specification of Cylinder Machine Specification Motor Specification Cost Estimation PAGE NO

LIST OF FIGURES
TABLE 4.1 4.2 5.1 6.1 A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 LABLE Single Acting Cylinder Double Acting Cylinder Hand Operating Valve Power Hacksaw Machine Base Plate (M.S) R.H.V. Block (M.S) Moving V- Block (M.S) L.H.V Block (M.S) Cylinder MTG bracket (MS WELD) Guide Bush & Guide Rod Stopper Screw & Nut Stopper Plate Isometric View Photographic View PAGE NO

NOMENCLATURE

NOTATIONS D A R N L Hs Hd V P

UNITS mm M2 mm rpm mm mm mm m
3

DESCRIPTION Diameter of the Cylinder Cross sectional area of the Cylinder Radius of crank Speed of Crank Length of Stroke Height of centre of the cylinder above the liquid surface, m Height of which the liquid is raised above the centre of the cylinder m Volume of liquid sucked during suction stroke Power required to drive the pump

kw

CHAPTER 1 INTRODUCTION
1.1 OBJECTIVE AND SCOPE :

The automatic bar feeding mechanism in the hacksaw machine. The bar is feed on the machine. When the machine is switched ON. A bar is automatically feed in the machine in ensure uniform length. When a number of pieces of same length are to be cut in this machine. The power operated hacksaws use on electric motor precutting metals by providing reciprocating motion to the through on eccentric. For this mechanical construction. We purchased components and after suitable modification and machining some parts. We have assembled them in addition to this we have provided some additional features in our machine as part of our project work. They are as follows a coolant pump coupled with main shaft which automatically supplies coolant whenever the machine is switched on a bar stops attachment to ensure uniformity in length when a number of pieces of same length are to be cut.

CHAPTER 2 LITERATURE SURVEY

Literature survey is the documentation of a comprehensive review of the published and unpublished work from secondary sources data in the areas of specific interest to the researcher. The Library is a rich storage base for secondary data and researchers used to spend several weeks and sometimes months going through books, journals, newspapers, magazines, conference proceedings, doctoral dissertations, masters these, government publications and financial reports to find information on their research topic. With computerized database now readily available and accessible the literature search is much speedier and easier and can be done without entering the Portals of a library building. The researcher could start the literature survey even as the information from the unstructured and structured interviews is being gathered. Reviewing the literature on the topic area at this time helps the researcher to focus further interviews more meaningfully on certain aspects found to be important is the published studies even if these had not surfaced during the earlier questioning. So the literature survey is important for gathering the secondary data for the research which might be proved very helpful in the research. The literature survey can be conducted for several reasons. The literature review can be in any area of the business.

The purpose of the literature survey is to identify information relevant to freshwater and pollutant discharges from the Rio Grande and Arroya Colorado and the potential and known impacts of these discharges within the project area, identify those areas where there is an absence or paucity of data, and make recommendations for future studies and planning efforts.

CHAPTER 3 BAR FEEDING MECHANISM

3.1.

BAR FEEDING MECHANISM Material feed and placement mechanisms for a steel cutting machine

result in a power saving and accurate clamping device. A work piece is moved into cutting position and clamped in place by the feed mechanism. After being cut by the cutting machine, the cut piece is slowly laid down by the placement mechanism. Not only can noise and vibration be eliminated, but also the safety of workers is improved, and machine life is extended. 3.2. WORKING PRINCIPLE When the hand operated lever is moved into forward position, then clamping cylinder 1 and 2 was released the clamping position and meanwhile feeding cylinder was moved backward. The lever moved into backward position then clamping cylinder hold the rod and after few second later feeding cylinder moves toward the forward. By using the stopper screw, we can adjust the length of the rod. So we can cut the rod by using power hacksaw machine. 3.3 CONSTRUCTION We are detail discuss about the construction of bar feeding mechanism as given below. 3.3.1. BASE It is made up of mild steel. It is used to fix all other components. 3.3.2. MOVEABLE V - BLOCK After release the clamping cylinder 1 &2, then feeding cylinder moves the backward position along with them movable V- block . It is made up of mild steel. 3.3.3. FIXED V- BLOCK

There are two fixed V- Block in bar feeder. One is fixed on left side and another one is on right side. Both the block support the work piece. It is made up of mild steel. 3.3.4. GUIDE ROD : It is used to guide the movable V-Block. It is made up of mild steel with good surface finishing.

CHAPTER 4 INTRODUCTION TO PNEUMATIC SYSTEM

INTRODUCTION TO PNEUMATICS
In engineering field may Machines make use of a fluid or compressed air to develop a force to move or hold an object

A system which is operated by compressed air is known as Pneumatic System. It is most widely used the work Piece turning drilling sawing etc.

By the use of Pneumatic System the risk of explosion on fire with compressed air is minimum high working speed and simple in construction.

PNEUMATIC COMPONENTS

In engineering field, many machines make use of fluid for developing a force to move or hold an object. A number of fluid can be used in devices and system. Two commonly used fluids are oil and compressed air. A system which is operated by compressed air. A system which is operated by compressed air is know as pneumatic system.

AIR COMPRESSOR Compressor is a device which gets air fro the atmosphere and compresses it for increasing the pressure of air. Thus the compressed air. Thus the compressed air used for many application.

The compression process requires work in put. Hence a compressor is driven by a prime mover. Generally an electric motor is used as prime mover. The compressed air from compressor is stored in vessel called

reservoir. Fro reservoir it be conveyed to the desired place through pipe lines.

2. FLTER In pneumatic system, an air filter is used to remove all foreign matter. An air filter dry clean air to flow without resistance various materials are used for the filter element. The air may be passed thorugh a piece metal, a pours stone felt resin impregnated paper. In some filters centrifugal action or cyclone action is used to remove foreign matters.

3. PRESSURE REGULATOR Constant pressure level is required for the trouble free operation of a pneumatic control., A pressure regulator is fitted downstream of the

compressed air filter. It provides a constant set pressure at the outlet of the outlet of the regulator. The pressure regulator is also called as pressure

reducing valve or pressure regulating valve.

4. LUBRICATOR The purpose of an air lubricator is to provide the pneumatic components with sufficient lubricant. These lubricants must reduce the wear of the moving parts reduce frictional forces and protect the equipment from corrosion.

Care should be taken to ensure that sufficient lubrication is provided. But excessive lubrication should be avoided.

. 5. FLR Package (or) FRL Package The air service unit is a combination of following units.

1. Compressed air filter 2. Compressed air regulator 3. Compressed air lubricator

Air Filter, regulator and lubricator are connected together with close nipples as one package. This unit is know as FLR (Filter, regulator, lubricator.)

6. PRESSURE CONTROL VALVE : Each hydraulic system is used to operate in a certain pressure range. Higher pressure causes damage of components. To avoid this pressure control valves are fitted in the circuits. 7. Direction control valve : Directional control valves are used to control the direction of flow. The design principle is a major factor with regard to service life actuating force switching times etc.

8. Piston and Cylinder single acting pneumatic cylinder;

PNEUMATIC CITCUIT SYMBOL FOR SINGLE ACTING PNEUMATIC

CYLINDER;

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which produce force, often in combination with movement, and are powered by
compressed gas (typically air).

To perform their function, pneumatic cylinders impart a force by converting the

potential energy of compressed gas into kinetic energy. This is achieved by the

compressed gas being able to expand, without external energy input, which itself occurs due to the pressure gradient established by the compressed gas being at a greater pressure than the atmospheric pressure. This air expansion forces a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved. When selecting a pneumatic cylinder, you must pay attention to:

how far the piston extends when activated, known as "stroke" surface area of the piston face, known as "bore size"
action type

pressure rating, such as "50 PSI" type of connection to each port, such as "1/4" NPT" must be rated for compressed air use mounting method

Types Although pneumatic cylinders will vary in appearance, size and function, they generally fall into one of the specific categories shown below. However there are also numerous other types of pneumatic cylinder available, many of which are designed to fulfill specific and specialised functions. Single acting cylinders Single acting cylinders (SAC) use the pressure imparted by compressed air to create a driving force in one direction (usually out), and a spring to return to the "home" position Double acting cylinders Double Acting Cylinders (DAC) use the force of air to move in both extend and retract strokes. They have two ports to allow air in, one for outstroke and one for instroke. Other types Although SACs and DACs are the most common types of pneumatic cylinder, the following types are not particularly rare:

Rotary air cylinders: actuators that use air to impart a rotary motion Rodless air cylinders: These have no piston rod. They are actuators that use a mechanical or magnetic coupling to impart force, typically to a table or other body that moves along the length of the cylinder body, but does not extend beyond it.

Sizes

Air cylinders are available in a variety of sizes and can typically range from a small 2.5 mm air cylinder, which might be used for picking up a small transistor or other electronic component, to 400 mm diameter air cylinders which would impart enough force to lift a car. Some pneumatic cylinders reach 1000 mm in diameter, and are used in place of hydraulic cylinders for special circumstances where leaking hydraulic oil could impose an extreme hazard. Pressure, radius, area and force relationships Although the diameter of the piston and the force exerted by a cylinder are
related, they are not directly proportional to one another. Additionally, the typical

mathematical relationship between the two assumes that the air supply does not become saturated. Due to the effective cross sectional area reduced by the area of the piston rod, the instroke force is less than the outstroke force when both are powered pneumatically and by same supply of compressed gas. The relationship, between force on outstroke, pressure and radius, is as follows:

This is derived from the relationship, between force, pressure and effective cross-sectional area, which is: F = p A\,

With the same symbolic notation of variables as above, but also A represents the effective cross sectional area. On instroke, the same relationship between force exerted, pressure and effective cross sectional area applies as discussed above for outstroke. However, since the cross sectional area is less than the piston area the relationship between force, pressure and radius is different. The calculation isn't more complicated though, since the effective cross sectional area is merely that of the piston less that of the piston rod. For instroke, therefore, the relationship between force exerted, pressure, radius of the piston, and radius of the piston rod, is as follows: Where:

F represents the force exerted r1 represents the radius of the piston r2 represents the radius of the piston rod is pi, approximately equal to 3.14159.
VALVE CONNECTORS;

POLYURETHANE TUBE ; shortly say PUN tube;

Manual operations involving heavy lifting. Pushing or pulling motions can be firing for the operations and can induce a monotony which results in lowered production. Cylinders have been designed to carry out these

movements with a pre determined force and stroke and can be fitted to synchronize with operation cycles of many machines it is worth wile to

examine the existing plan and methods of movement and to consider the numberous mechanical applications which the range of pneumatic cylinders make possible. Quality is to keynote of air cylinder. Engineer them into you production setup to get the last ounce of power, speed and efficiency to save time, space and money.

Piston is cylinder part which moves in a cylinder have corresponding hole on it. To make the strokes effective there is no gap between them or with a very tiny gap, part of the micron. The cylinder and its piston have a glazing surface where there is a contact between them for easy motion of piston and avoiding wear and tear of both. The outer side of the cylinder have mountings consists

of plate and studs attached with it. But the of these mountings, the cylinder and piston assembly can fitted on any place of the piston have threads on it for fastening theother parts (or) accessories according the operating performed and the application required. We can fit holding devices, Clamping materials or other metal cutting and forming ports with which can be movable with the piston.

Pneumatics are used practically in every industry for a wide variety of manufacturing process, pneumatics equipments are used for multiple reasons.

The best reason is that it is air powered ordinary air turns out to be very excellent as a fluid power components.

Solenoid Valve : In order to automate the air flow in our system we have to provide an electrically controlled valves. Electrical devices can provide more effective control, less expensive interlocks having many additional safety features and simplified automatic sequencing when a machine must operate in a hazardous area, remote actuation is a desirable. The operator can provide satisfactory control though electrical devices from a remote point with in a safe area, uding a semi automatic system and these electrical flow control devices are also in use in full automation by providing proper action signals.

Push and pull actuation can be priced b solenoids. These movements are used to open and close the pop pet type valves. These actuations are done according to the signals given to the solenoid coil when the decided by the program. The outlet of solenoiud coil when the decided by the program,. The outlet of solenoid valve is connected to a spray gun, which is going to spray the paint.

SOLENOID OPERATED VALVES:

Solenoid valves are electromechanical devices like relays and contractors. A solenoid valve is used to obtain mechanical movement in machinery by utilizing fluid or air pressure. The fluid or air pressure is applied to the cylinder piston through a valve operated by a cylindrical electrical coil. The electrical coil along with its frame and plunger is known as the solenoid and the assembly of solenoid and mechanical valve is known as solenoid valve. The solenoid valve is thus another important electromechanical device used in control of machines. Solenoid valves are of two types, 1. Single solenoid spring return operating valve,(5/2) 2. Double solenoid operating valve.

In fig 1 is shown a single solenoid spring return valve in its de-energized condition. The symbol for the solenoid and the return are also shown. The solenoid valve is shown connected to the cylinder to help readers understand the solenoid valve action. In the de energized condition, the plunger and the valve spool position as shown in figure 1.

5/2 WAY VALVE

In this position of spool, port P is connected to port A and port B is connected to tank or exhaust (i.e. atmosphere) if air is used. Spring pressure (S) keeps the spool in this condition as long as the coil is de energized. Fluid pressure from port P through port A is applied to the left side of the cylinder piston. Thus the cylinder piston moves in the right direction. Now

when the solenoid coil is energized, plunger is attracted and it pushes the spool against spring pressure. The new position of plunger and spool are shown in fig 2.

In this position of spool, port A gets connected to tank and port P gets connected to port B. Thus pressure is applied to the cylinder piston from right and moves the piston rod to the left. At the same time fluid in the other side is drained out to the tank. When the solenoid coil is again de energized, the spring (S) will move the spool to its original position as shown in figure 1. Thus, normally when the solenoid coil is de energized the piston rod remains extended.

PNEUMATIC CIRCUIT DIAGRAM

PNEUMATIC FITTING

PNEUMATIC FITTINGS: There are no nuts to tighten the tube to the fittings as in the conventional type of metallic fittings. The tube is connected to the fitting by a simple push ensuring leak proof connection and can be released by pressing the cap and does not require any special tooling like spanner to connect (or) disconnect the tube from the fitting.

SPECIFICATION OF THE FITTING:

Body Material Collect/Thread Nipple Seal Fluid Used Max. Operating Pressure

- Plastic - Brass - Nitrate Rubber - Air - 7 Bar

Tolerance on OD of the tubes - 1 mm Min. Wall thickness of tubes - 1 mm.

FLEXIBLE HOSES: The Pneumatic hoses, which is used when pneumatic components such as actuators are subjected to movement. Hose is fabricated in layer of

Elastomer or synthetic rubber, which permits operation at high pressure. The standard outside diameter of tubing is 1/16 inch. If the hose is subjected to rubbing, it should be encased in a protective sleeve.

ADVANTAGES AND LIMITATIONS

ADVANTAGES: The Pneumatic arm is more efficient in the technical field Quick response is achieved Simple in constructions 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 media to operate is air
Continuous operation is possible without stopping.

LIMITATIONS: High torque cannot be obtained. Load Carrying capacity of this unit is not very high (3 5 kg/s) Silencer may be used, to reduce the noise of compressed air

APPLICATION

1) DISCHARGE OF WORKPIECE: The arm fed has wide application in low cost automation. It can be used in automated assembly lines to pick-up the finished product from workstation and place them in the bins. It can also be used to pick-up the raw material and place them on the conveyor belts and vice versa.

2) JOB CLAMPING: This unit can also be used in clamping operations in certain areas of mass productions where clamping and unclamping have to be done at high speeds. The application of this unit is limited to operations, which involves moderate clamping forces.

3) TRANSFER OF JOBS BETWEEN WORK STATIONS: The gripping method used in a low cost automation to move the work piece from one workstation to another. The combination of an angular rotary motion is the principle behind this method. The gripper holds the work rigidly. The to and fro motion is achieved by means of the actuating cylinder.

4) TOOL CHANGING APPLICATION: When the pneumatic arms are made smaller in size they can be used in automatic tool changer in CNC turning and drilling machines, by attaching suitable tool holding device to the rotary cylinder.

CHAPTER 5

ELECTRICAL CIRCUIT DETAILS

CIRCUIT DETAILS
1. Micro controller system

2. Interface Circuit for Solenoid valves 3. Power supply (230V A.C. to 24vdc V and 5V DC) 4. Key Board Circuit

MICRO CONTROLLER SYSTEM: This system monitors the engine condition by using PIC 16F870 (28 pin IC Package) micro controller. The pin details of micro controller are shown in figure.

The circuit diagram for this micro controller board is shown below,

MOTHER BOARD CIRCUIT DETAILS

in no 2&5.The pin no 1 is RESET switch..The INPUTS are connected to port B .The OUTPUTS are connected to PORT C.6 MHZ crystal is connected to pin no 9,10.

Keypad interface; Here seven soft microswitches are soldered in the main board and their connections are shown below.

P O R T B (K E Y P A D )IN P U T & O U T P U T C IR C U IT

POWER SUPPLY 5V DC AND 24V DC;

A 12 0 -12v step down transformer is used to stepdown 230V AC to 24V AC .This 24V AC supply is converted to 12V DC using four rectifier diodes. The voltage from the rectifier section is regulated to 12V DC using 7812 IC . From 12V DC the 7805 IC is used for regulating 5V DC for the power supply of microcontroller. the power supply circuit is shown in fig.

INTRODUCTION:

All the electronic components starting from diode to Intel ICs only work with a DC supply ranging from +5V to +12V. We are utilizing for the same, the cheapest and commonly available energy source of 230V-50Hz and stepping down, rectifying, filtering and regulating the voltage. STEP DOWN TRANSFORMER: When AC is applied to the primary winding of the power transformer, it can either be stepped down or stepped up depending on the value of DC needed. In our circuit the transformer of 230V/15-0-15V is used to perform the step down operation where a 230V AC appears as 15V AC across the secondary winding. Apart from stepping down voltages, it gives isolation between the power source and power supply circuitries. RECTIFIER UNIT: In the power supply unit, rectification is normally achieved using a solid state diode. Diode has the property that will let the electron flow easily in one direction at proper biasing condition. As AC is applied to the diode, electrons only flow when the anode and cathode is negative. Reversing the polarity of voltage will not permit electron flow. A commonly used circuit for supplying large amounts of DCpower is the bridge rectifier. A bridge rectifier of four diodes (4 x IN4007) are used to achieve full wave rectification. Two diodes will conduct during the negative cycle and the other two will conduct during the positive half cycle, and only one diode conducts. At the same time one of the other two diodes conducts for the negative voltage that is applied from the

bottom winding due to the forward bias for that diode. In this circuit due to positive half cycle D1 & D2 will conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of 100Hz. Since each alteration produces a resulting output pulse, frequency = 2 x 50 Hz. The output obtained is not a pure DC and therefore filtration has to be done. The DC voltage appearing across the output terminals of the bridge rectifier will be somewhat less than 90% of the applied rms value. Normally one alteration of the input voltage will reverse the polarities. Opposite ends of the transformer will therefore always be 180 degree out of phase with each other. For a positive cycle, two diodes are connected to the positive voltage at the top winding.

FILTERING CIRCUIT: Filter circuits which is usually capacitor acting as a surge arrester always follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a bypassing capacitor, is used not only to short the ripple with frequency of 120Hz to ground but also to leave the frequency of the DC to appear at the output. A load resistor R1 is connected so that a reference to the ground is maintained. C1, R1 is for bypassing ripples. C2, R2 is used as a low pass filter, i.e. it passes only low frequency signals and bypasses high frequency signals. The load resistor should be 1% to 2.5% of the load. 1000f/25V : for the reduction of ripples from the pulsating

10f/25V 0.1f

: for maintaining the stability of the voltage at the load side. : for bypassing the high frequency disturbances

BLOCK DIAGRAM FOR POWER SUPPLY

STEP DOWN

BRIDGE

POSITIVE

TRANSFORMER

RECTIFIER

CHARGE CAPACITOR

5V REGULATOR

12V REGULATOR

MOTHER

DISPLAY

BOARD

BOARD

RELAY

VOLTAGE REGULATOR: The voltage regulators play an important role in any power supply unit. The primary purpose of a regulator is to aid the rectifier and filter circuit in providing a constant DC voltage to the device. Power supplies without

regulators have an inherent problem of changing DC voltage values due to

variations in the load or due to fluctuations in the AC linear voltage. With a regulator connected to the DC output, the voltage can be maintained within a close tolerant region of the desired output. IC7812 and 7912 is used in this project for providing +12V and 12V DC supply.

5 TO 24 V DC DRIVE CARD

Here we have to drive the 24V DC load. The 5V signal from the PIC 16F870 micro-controller is fed into the input of interface circuit. SL100

transistor is used here for high speed switching purpose and IRF 540N MOSFET is connected to the motor to handle the larger current drawn by the valves.

CHAPTER 6 POWER HACKSAW MACHINE

CHAPTER 6

POWER HACKSAW MACHINE

6.1 POWER HACKSAW MACHINE : Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting diameters of more than 10/15mm is very hard work with a normal hand held hacksaw. Therefore power hacksaws have been developed to carry out the difficult and time consuming work. The heavy arm moves backwards and forwards, cutting on the forward stroke. The metal to be cut is held in a machine vice which is an integral part of the base. Turning the handle tightens or loosens the vice. The vice is very powerful and locks the metal in position. When cutting is taking place, the metal and especially the blade heats up quickly. Coolant should be fed onto the blade, cooling it down and lubricating it as it cuts through the metal. Without the use of coolant the blade will over heat and break /snap. This can be dangerous as the blade can break with powerful force, shattering. When the metal is placed and fixed in the vice, the blade is lowered onto its top surface. The diagram below shows the arm being lowered with the adjusting handle. Blades of power hacksaws are graded according to the material they are made from and the number of teeth per inch. Top quality blades are

manufactured from High Speed Steel. Although there are cheaper alternatives such as carbon steel blades. In general the number of teeth per inch (TPI) range from 14 to 24 the more teeth per inch the smoother the cut. Every power hacksaw should have a foot switch / emergency switch. This allows the operator to turn the machine off quickly by using his/her foot to step on the switch. The foot switch is normally positioned at the front or side of the machine. Power hacksaws have electric motors that power the blade through a pulley system. Some have ratchet systems. The pulley system showed below shows how rotary power is transferred from the motor and changed to reciprocating motion allow the blade to cut through the material. Most power hacksaws have two pulley wheels. If the belt is placed on the smaller pulley wheel the speed of cut will be fast. Changing the belt so that it runs round the larger pulley wheel will reduce the speed. 6.1.1. TYPES OF POWER HACKSAW MACHINE Hydraulic type Pneumatic type Hydro Pneumatic type

6.1.2. SPECIFICATION OF MACHINE

Speed of the motor Stroke length Speed of crank Max height of job that could be machined.

1400 rpm 110 185mm 105 rpm 4 inches.

Table 6.1. Machine Specification 6.1.3. SPECIFICATION OF MOTOR Phase Voltage Speed Power Rating Frequency Horse power Current 3 Phase 1095 volt 1400 rpm 0.75 watts Constant 50 Hz 1 HP 415 Amps Table 6.2. Motor Specification

CHAPTER 7 TEAM SPLIT

CHAPTER 7 TEAM SPLIT

We decided to split our work to join two members for our work. We split our work as follows, M. VINOD KUMAR & M. SHANMUGAM G..B. SURESH & G. DAVID RAJA R. SUNDAR R. SELVARAJ

CHAPTER 8 COST ESTIMATION

CHAPTER 8 COST ESTIMATION

S.NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

PARTICULARS BASE PLATE R.H.V. BLOCK MOVING V BLOCK L.H.V. BLOCK MTG. CYLINDER BRACKET GUIDE ROD GUIDE BUSH STOPPER SCREW NUT STOPPER SCREW V- CLAMP PNEUMATIC CYLINDER HAND OPERATING VALVE SCREW 1/8TH HAND OPERATING CONNECTOR 1/4TH HAND OPERATING CONNECTOR T-CONNECTOR PIPE (P6) 4M ALUMINIUM ROD

NO.OFF 1 1 1 1 2 2 2 1 8 1 2 3 1 8 5 6 2 1 1

AMOUNT 550 500 450 500 700 500 400 100 50 50 150 2000 500 100 250 250 50 50 150

TABLE 8.1 COST ESTIMATION TOTAL COST OF THIS PROJECT : RS. 6000/-

CHAPTER 9 CONCLUSION

CHAPTER 9 CONCLUSION
The machine was erected in the fitting shop it is a pneumatically operated machine. It can be adjusted for required cutting length of bar automatically by using power hacksaw machine.

The machine is very much useful for cutting work pieces for actively classes in fitting shop and near by welding shop.

REFERENCE

REFERENCE

 Bansal, R.K., Fluid Mechanics and Hydraulics Machines (5th edition), Laxmi

publications (P) ltd, New Delhi, 1995. Ramamirtham,S., Fluid Mechanics and Hydraulics and Fluid Machines, Dhanpat Rai and Sons, Delhi, 1998. P.C. Sharma, A Text Book of Production Engineering, S. Chand and Co.ltd, IV edition, 1993. Hajra Choudry, Elements of work shop Technology Vol. II Media Promoters. 2002. Majundar s.r., Pneumatic systems Principles and Maintenance, tata McGraw hill, 1995.