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Guided by:
Submitted in partial fulfillment of the
requirement for the
Award of Diploma in
----------------------------------------By the State Board of Technical Education
Government of
Tamilnadu, Chennai.
Department:
College name:
Place:
COLLEGE NAME
COIMBATORE
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT REPORT-2012-2013
This Report is certified to be the Bonafide work done by
Selvan/Selvi ---------------- Reg.No. ------------ Of VI
Semester class of this college.
Guide
External Examiner
ACKNOWLEDGEMENT
ACKNOWLEDGEMENT
At
this
pleasing
moment
of
having
successfully
for
her/him
constructive
suggestions
CONTENTS
CONTENTS
CHAPTER NO
TITLE
SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1
Introduction
Literature review
Description of equipments
3.1
Pneumatic cylinder
3.2
Solenoid Valves
3.3
Air compressor
3.4
3.5
POT
3.6
Relay
3.7
Control unit
4.1
4.2
Block diagram
4.3
Overall diagram
Working principle
Applications
List of materials
Cost Estimation
10
Conclusion
Bibliography
Photography
LIST OF FIGURES
LIST OF FIGURES
Figure
Number
Title
Block diagram
Overall Diagram
NOMENCLATURE
NOMENCLATURE
A =Area of cylinder(m2 )
D=Diameter of Piston (m)
F =Force exerted on the piston (N)
H=Height (m)
L=Length(m)
P=Pressure (N/m2)
V=Volume (m3)
SYNOPSIS
SYNOPSIS
In this project we fabricate the solar operated reciprocating
water pump this is a new innovative concept. Reciprocating water
pump is most important in the agriculture field. In this project
electrical power is generated through the solar panel so this
equipment compensates the electrical power demand and very much
helpful to agricultural field. The main objective of this project is to
pump the water with very less electric power. The process is carried
out by the pneumatic cylinder and the compressed air. The model
consists of a tank, non return valve and a pneumatic cylinder. The
concept is pneumatic since it is easy to operate and also a quick
process. The concept can bring a drastic change in the field of
mechanical especially for lubrication purpose in the machining areas.
CHAPTER -1
INTRODUCTION
CHAPTER -1
INTRODUCTION
The main objective of our project is to perform various machine
operations using machine with the help of pneumatic sources. For a
developing industry the operation performed and the parts (or)
components produced should have it minimum possible production
cost, and then only industry runs profitability.
Less maintenance
CHAPTER -2
LITERATURE REVIEW
CHAPTER -2
LITRATURE SURVEY
PNEUMATICS:
The word pneuma comes from Greek and means wind. The
word pneumatics is the study of air movement and its phenomena is
derived from the word pneuma. Today pneumatics is mainly
understood to means the application of air as a working medium in
industry especially the driving and controlling of machines and
equipment.
Pneumatics has for some considerable time between used for
carrying out the simplest mechanical tasks in more recent times has
Played a more important role in the development of pneumatic
technology for automation.
Pneumatic systems operate on a supply of compressed air
which must be made available in sufficient quantity and at a pressure
to suit the capacity of the system. When the pneumatic system is
being adopted for the first time, however it wills indeed the necessary
to deal with the question of compressed air supply.
Any gas can be used in pneumatic system but air is the mostly used
system now a days.
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 control system (although equally pneumatic control
systems may be economic and can be advantageously applied to
other forms of power).
The main advantages of an all pneumatic system are usually
Economic and simplicity the latter reducing maintenance to a low
level. It can have out standing advantages in terms of safety.
PNEUMATIC POWER:
The key part of any facility for supply of compressed air is by means
using reciprocating compressor. A compressor is a machine that
takes in air, gas at a certain pressure and delivered the air at a high
pressure. Compressor capacity is the actual quantity of air
compressed and delivered and the volume expressed is that of the air
At intake conditions namely at atmosphere pressure and normal
ambient temperature.
Clean condition of the suction air is one of the factors, which
decides the life of a compressor. Warm and moist suction air will
result increased precipitation of condense from the compressed air.
2. Turbo compressor
Positive displacement compressors are most frequently employed for
Compressed air plant and have proved highly successful and supply
air for pneumatic control application.
The types of positive compressor
1. Reciprocating type compressor
2. Rotary type compressor
RECIPROCATING COMPRESSORS:
Built for either stationary (or) portable service the reciprocating
compressor is by far the most common type. Reciprocating
compressors lap be had is sizes from the smallest capacities to
deliver more than 500m3/min.In single stage compressor, the air
pressure may be of 6 bar machines discharge of pressure is up to
15bars.Discharge pressure in the range of 250bars can be obtained
CHAPTER-3
DESCRIPTION OF EQUAPMENTS
CHAPTER-3
DESCRIPTION OF EQUAPMENTS
3.2 VALVES
SOLENOID VALVE
The directional valve is one of the important parts of a pneumatic
system. Commonly known as DCV; this valve is used to control the
direction of air flow in the pneumatic system. The directional valve
does this by changing the position of its internal movable parts.
This valve was selected for speedy operation and to reduce the
manual effort and also for the modification of the machine into
automatic machine by means of using a solenoid valve.
A solenoid is an electrical device that converts electrical energy
into straight line motion and force. These are also used to operate a
mechanical operation which in turn operates the valve mechanism.
Solenoid is one is which the plunger is pulled when the solenoid is
energized.
The name of the parts of the solenoid should be learned so that
they can be recognized when called upon to make repairs,to do
service work or to install them.
3. Solenoid plunger
The solenoid plunger is the mover mechanism of the solenoid. The
plunger is made of steel laminations which are riveted together
under high pressure, so that there will be no movement of the
lamination with respect to one another. At the top of the plunger a
to
spool
position:
the
ports
get
connected
and
disconnected.
The working principle is as follows.
Position-1
When the spool is actuated towards outer direction port P gets
Hoses:
Hoses used in this pneumatic system are made up of
polyurethane. These hose can with stand at a maximum pressure
level of 10 x105N/m2.
Connectors:
In our system there are two type of connectors used. One is the
Hose connector and the other is the reducer. Hose connectors
normally comprise an adopt hose nipple and cap nut. These types of
stage compression since the pressure ratio over the first stage will be
decreased.
check valves generally are very small, simple, and/or cheap. Check
valves work automatically and most are not controlled by a person or
any external control; accordingly, most do not have any valve handle
or stem. The bodies (external shells) of most check valves are made
of plastic or metal.
An important concept in check valves is the cracking pressure
which is the minimum upstream pressure at which the valve will
operate. Typically the check valve is designed for and can therefore
be specified for a specific cracking pressure.
AUDIO CONTROL
One of the most common uses for modern low-power
potentiometers is as audio control devices. Both linear pots (also
known as "faders") and rotary potentiometers (commonly called
knobs) are regularly used to adjust loudness, frequency attenuation
and other characteristics of audio signals.
The 'log pot' is used as the volume control in audio amplifiers,
where it is also called an "audio taper pot", because the amplitude
response of the human ear is also logarithmic. It ensures that, on a
volume control marked 0 to 10, for example, a setting of 5 sounds
half as loud as a setting of 10. There is also an anti-log pot or reverse
audio taper which is simply the reverse of a log pot. It is almost
always used in a ganged configuration with a log pot, for instance, in
an audio balance control.Potentiometers used in combination with
filter networks act as tone controls or equalizers.
TELEVISION
Potentiometers
were
formerly
used
to
control
picture
3.6 RELAY
3.8 BATTERY
MICROCONTROLLER:
INTRODUCTION:
Microcontrollers are destined to play an increasingly important
role in revolutionizing various industries and influencing our day to
day life more strongly than one can imagine. Since its emergence in
the early 1980's the microcontroller has been recognized as a
general purpose building block for intelligent digital systems. It is
finding using diverse area, starting from simple children's toys to
highly complex spacecraft. Because of its versatility and many
advantages, the application domain has spread in all conceivable
directions, making it ubiquitous. As a consequence, it has generate a
great deal of interest and enthusiasm among students, teachers and
practicing engineers, creating an acute education need for imparting
the knowledge of microcontroller based system design and
development. It identifies the vital features responsible for their
MICROCONTROLLER:
A microcontroller is a complete microprocessor system built on
a single IC. Microcontrollers were developed to meet a need for
microprocessors to be put into low cost products. Building a complete
microprocessor system on a single chip substantially reduces the
cost of building simple products, which use the microprocessor's
power to implement their function, because the microprocessor is a
natural way to implement many products. This means the idea of
using a microprocessor for low cost products comes up often. But the
typical 8-bit microprocessor based system, such as one using a Z80
and 8085 is expensive. Both 8085 and Z80 system need some
additional circuits to make a microprocessor system. Each part
carries costs of money. Even though a product design may requires
only very simple system, the parts needed to make this system as a
low cost product.
single
chip
microcontroller.
This
could
be
called
microcomputer, as all the major parts are in the IC. Most frequently
they are called microcontroller because they are used they are used
to perform control functions.
The microcontroller contains full implementation of a standard
MICROPROCESSOR, ROM, RAM, I/0, CLOCK, TIMERS, and also
SERIAL PORTS. Microcontroller also called "system on a chip" or
"single chip microprocessor system" or "computer on a chip".
A microcontroller is a Computer-On-A-Chip, or, if you prefer, a
single-chip computer. Micro suggests that the device is small, and
controller tells you that the device' might be used to control objects,
processes, or events. Another term to describe a microcontroller is
embedded controller, because the microcontroller and its support
circuits are often built into, or embedded in, the devices they control.
Today microcontrollers are very commonly used in wide variety
of intelligent products. For example most personal computers
keyboards and implemented with a microcontroller. It replaces
Scanning, Debounce, Matrix Decoding, and Serial transmission
CHAPTER-4
CHAPTER-IV
DESIGN OF EQUIPMENT AND DRAWING
4.1 PNEUMATIC COMPONENTS AND ITS SPECIFICATION
The design and fabrication of pneumatic reciprocating water
pumping system is consists of the following components to full fill the
requirements of complete operation of the machine.
DRAWING
CHAPTER -5
WORKING PRINCIPLE
CHAPTER-V
WORKING PRINCIPLE
This project is designed with control unit, pneumatic cylinder,
solenoid valve and a water tank. The unit is timing operated
according to our necessity the pneumatic cylinder can be operated.
The pneumatic cylinder is connected to the empty cylinder for
pumping the water from the tank. The relay output is directly
connected to the solenoid valve. Now the pump is operated and
lubricant is provided on the machines in order to reduce the heat.
Once the solenoid valve is actuated through the control circuit, the
pneumatic cylinder connected with it will be extended and retracted
respectively. This results in the pumping cylinder to extend and
retract, as the piston rods of both the cylinders are coupled with each
other. Once the pumping cylinder is retracted the water in the tank will
be sucked and it will be delivered as the cylinder is extended. The
continuous operation will deliver the water as per the requirement.
The process is controlled by the control unit.
In this concept we are using is the solar panel. A solar cell or
photovoltaic cell is a device that converts solar energy into electricity
by the photovoltaic effect. This plays the major role to convert the
CHAPTER -6
CHAPTER -VI
MERITS AND DEMERITS
MERITS:
Requirement of man power is not necessary
Electric power required is minimum
Quick process
Easy to handle
Free of energy
DEMERITS:
It is costlier than the other types of pumps
Leakage of air affects the working unit.
Needs separate air compressor
Solar power is only available at day time.
CHAPTER-7
APPLICATIONS
CHAPTER-VII
APPLICATIONS
It is applicable in all small scale and large scale industries for
lubrication.
Higher efficiency.
It does not require any prime mover like electric motor.
As the air is freely available.
CHAPTER-8
LIST OF MATERIALS
CHAPTER-VIII
LIST OF MATERIALS
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material are
discussed below.
1. Properties:
The material selected must posses the necessary properties for
the proposed application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand
environmental attack from chemicals, service life, reliability etc.
2. Manufacturing case:
Sometimes the demand for lowest possible manufacturing cost or
surface qualities obtainable by the application of suitable coating
substances may demand the use of special materials.
3. Quality Required:
This generally affects the manufacturing process and ultimately
the material. For example, it would never be desirable to go casting of
a less number of components which can be fabricated much more
economically by welding or hand forging the steel.
4. Availability of Material:
Some materials may be scarce or in short supply. It then
becomes obligatory for the designer to use some other material which
though may not be a perfect substitute for the material designed. the
delivery of materials and the delivery date of product should also be
kept in mind.
5. Space consideration:
Sometimes high strength materials have to be selected because the
forces involved are high and space limitations are there.
6. Cost:
As in any other problem, in selection of material the cost of
material plays an important part and should not be ignored.
Some times factors like scrap utilization, appearance, and nonmaintenance of the designed part are involved in the selection of
proper materials.
CHAPTER-9
COST ESTIMATION
CHAPTER-IX
COST ESTIMATION
1. LABOUR COST:
Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost
2. OVERGHEAD CHARGES:
The overhead charges are arrived bymanufacturing cost
Manufacturing Cost
Overhead Charges
3. TOTAL COST:
Total cost = Material Cost +Labour Cost +Overhead Charges
=
=
Total cost for this project =
CHAPTER-10
CONCLUSION
CHAPTER-X
CONCLUSION
BIBLIOGRAPHY
BIBLIOGRAPHY
-P.S.G.Tech.
2. Pneumatic handbook
-R.H.warrning
Institute, Bangalore.
4. Strength of Materials
-R.S.Kurmi
5. Manufacturing Technology
-M.Haslehurst.
PHOTOGRAPHY