DESIGN AND

FABRICATION MINI WATER

SERVICE STATION

ABSTRACT

The aim of
DESIGN AND FABRICATION MINI WATER SERVICE STATION
There is a lot of energy going to waste every day that we could
possibly take advantage of to power land transport. In order to explore
this theory, project using the pneumatic power to run the water pump.
By means of this project we can clean our vehicles and bikes
autumatically in our homes in simple manner.Finally the main reason for
creation of this project is to clean without spending more money. This
project has high advantage of not using the more electric power.

Need of the project

For maintaining the automobiles in good manner
For cleaning of equipments

 Reducing the servicing time.

INTRODUCTION
PNEUMATICS
Pneumatics is a section of technology that deals with the study and
application of pressurized gas to produce mechanical motion.

Pneumatic systems, that are used extensively in industry, and factories,

are commonly plumbed with compressed air or compressed inert gases.
This is because a centrally located and electrically compressor, that
powers cylinders and other pneumatic devices through solenoid valves,
can often provide motive power in a cheaper, safer, more flexible, and
more reliable way than a large number of electric motors and actuators.
Pneumatics also has applications in dentistry, construction, mining, and
other areas.

Gases used in pneumatic systems

Pneumatic systems in fixed installations, such as factories, use

compressed air because a sustainable supply can be made by
compressing atmospheric air. The air usually has moisture removed, and
a small quantity of oil is added at the compressor to prevent corrosion
and lubricate mechanical components.

Factory-plumbed pneumatic-power users need not worry about poisonous

leakage, as the gas is usually just air. Smaller or stand-alone systems can
use other compressed gases that present an asphyxiation hazard, such as
nitrogenoften referred to as OFN (oxygen-free nitrogen) when
supplied in cylinders.

Any compressed gas other than air is an asphyxiation hazardincluding

nitrogen, which makes up 78% of air. Compressed oxygen (approx. 21%
of air) would not asphyxiate, but is not used in pneumatically- devices
because it is a fire hazard, more expensive, and offers no performance
advantage over air.

Portable pneumatic tools and small vehicles, such as Robot Wars

machines and other hobbyist applications are often

by compressed

carbon dioxide, because containers designed to hold it such as soda

stream canisters and fire extinguishers are readily available, and the
phase change between liquid and gas makes it possible to obtain a larger
volume of compressed gas from a lighter container than compressed air
requires. Carbon dioxide is an asphyxiant and can be a freezing hazard if
vented improperly.
Advantages of pneumatics
Simplicity of design and controlMachines are easily designed using
standard cylinders and other components, and operate via simple on-off
control.
ReliabilityPneumatic systems generally have long operating lives and
require little maintenance. Because gas is compressible, Equipment is
less subject to shock damage. Gas absorbs excessive force, whereas fluid
in hydraulics directly transfers force. Compressed gas can be stored, so
machines still run for a while if electrical power is lost.

SafetyThere is a very low chance of fire compared to hydraulic oil.

Machines are usually overload safe.

PUMP
A pump is a device that moves fluids (liquids or gases), or sometimes
slurries, by mechanical action. Pumps can be classified into three major
groups according to the method they use to move the fluid: direct lift,
displacement, and gravity pumps.
Pumps operate by some mechanism (typically reciprocating or rotary),
and consume energy to perform mechanical work by moving the fluid.
Pumps operate via many energy sources, including manual operation,
electricity, an engine of some type, or pedal powerpower.
Types
A positive displacement pump makes a fluid move by trapping a fixed
amount and forcing (displacing) that trapped volume into the discharge
pipe.
Some positive displacement pumps use an expanding cavity on the
suction side and a decreasing cavity on the discharge side. Liquid flows

into the pump as the cavity on the suction side expands and the liquid
flows out of the discharge as the cavity collapses. The volume is constant
through each cycle of operation.Positive displacement pumps, unlike
centrifugal or roto-dynamic pumps, theoretically can produce the same
flow at a given speed (RPM) no matter what the discharge pressure.
Thus, positive displacement pumps are constant flow machines.
However, a slight increase in internal leakage as the pressure increases
prevents a truly constant flow rate.
A positive displacement pump must not operate against a closed valve on
the discharge side of the pump, because it has no shutoff head like
centrifugal pumps. A positive displacement pump operating against a
closed discharge valve continues to produce flow and the pressure in the
discharge line increases until the line bursts, the pump is severely
damaged, or both.
A relief or safety valve on the discharge side of the positive displacement
pump is therefore necessary. The relief valve can be internal or external.
The pump manufacturer normally has the option to supply internal relief
or safety valves. The internal valve is usually only used as a safety

precaution. An external relief valve in the discharge line, with a return

line back to the suction line or supply tank provides increased safety.
Positive displacement types
Screw pump
A positive displacement pump can be further classified according to the
mechanism used to move the fluid:
Rotary-type positive displacement: internal gear, screw, shuttle block,
flexible vane or sliding vane, circumferential piston, flexible impeller,
helical twisted roots (e.g. the Wendelkolben pump) or liquid ring vacuum
pumps.

Rotary vane pump

Positive displacement rotary pumps move fluid using a rotating
mechanism that creates a vacuum that captures and draws in the
liquid.Rotary pumps are very efficient because they naturally remove air
from the lines, eliminating the need to bleed the air from the lines
manually.

Rotary positive displacement pumps fall into three main types:

Gear pumps - a simple type of rotary pump where the liquid is pushed
between two gears
Screw pumps - the shape of the internals of this pump usually two screws
turning against each other pump the liquid
Rotary vane pumps - similar to scroll compressors, these have a
cylindrical rotor encased in a similarly shaped housing. As the rotor
orbits, the vanes trap fluid between the rotor and the casing, drawing the
fluid through the pump.

Reciprocating positive displacement pumps

Reciprocating pumps move the fluid using one or more oscillating

pistons, plungers, or membranes (diaphragms), while valves restrict fluid
motion to the desired direction.
Pumps in this category range from simplex, with one cylinder, to in some
cases quad (four) cylinders, or more. Many reciprocating-type pumps are
duplex (two) or triplex (three) cylinder. They can be either single-acting
with suction during one direction of piston motion and discharge on the
other, or double-acting with suction and discharge in both directions. The
pumps can be powered manually, by air or steam, or by a belt driven by
an engine. Now reciprocating pumps typically pump highly viscous
fluids like concrete and heavy oils, and serve in special applications that
demand low flow rates against high resistance. Reciprocating hand
pumps were widely used to pump water from wells. Common bicycle
pumps and foot pumps for inflation use reciprocating action.
These positive displacement pumps have an expanding cavity on the
suction side and a decreasing cavity on the discharge side. Liquid flows
into the pumps as the cavity on the suction side expands and the liquid
flows out of the discharge as the cavity collapses. The volume is constant
given each cycle of operation.

Typical reciprocating pumps are:

Plunger pumps - a reciprocating plunger pushes the fluid through one or
two open valves, closed by suction on the way back.
Diaphragm pumps - similar to plunger pumps, where the plunger
pressurizes hydraulic oil which is used to flex a diaphragm in the
pumping cylinder. Diaphragm valves are used to pump hazardous and
toxic fluids.
Piston displacement pumps - usually simple devices for pumping small
amounts of liquid or gel manually.
Gear pump
This is the simplest of rotary positive displacement pumps. It consists of
two meshed gears that rotate in a closely fitted casing. The tooth spaces
trap fluid and force it around the outer periphery. The fluid does not
travel back on the meshed part, because the teeth mesh closely in the
centre. Gear pumps see wide use in pump engine oil pumps and in
various hydraulic power packs.
Screw pump

A Screw pumps is a more complicated type of rotary pump that uses two
or three screws with opposing threade.g., one screw turns clockwise
and the other counterclockwise. The screws are mounted on parallel
shafts that have gears that mesh so the shafts turn together and everything
stays in place. The screws turn on the shafts and drive fluid through the
pump. As with other forms of rotary pumps, the clearance between
moving parts and the pump's casing is minimal.
Progressing cavity pump
Widely used for pumping difficult materials, such as sewage sludge
contaminated with large particles, this pump consists of a helical rotor,
about ten times as long as its width. This can be visualized as a central
core of diameter x with, typically, a curved spiral wound around of
thickness half x, though in reality it is manufactured in s single casting.
This shaft fits inside a heavy duty rubber sleeve, of wall thickness also
typically x. As the shaft rotates, the rotor gradually forces fluid up the
rubber sleeve. Such pumps can develop very high pressure at low
volumes.
Roots-type pumps

Named after the Roots brothers who invented it, this lobe pump displaces
the liquid trapped between two long helical rotors, each fitted into the
other when perpendicular at 90, rotating inside a triangular shaped
sealing line configuration, both at the point of suction and at the point of
discharge. This design produces a continuous flow with equal volume
and no vortex. It can work at low pulsation rates, and offers gentle
performance that some applications require.
Plunger pumps
These consist of a cylinder with a reciprocating plunger. The suction and
discharge valves are mounted in the head of the cylinder. In the suction
stroke the plunger retracts and the suction valves open causing suction of
fluid into the cylinder. In the forward stroke the plunger pushes the liquid
out of the discharge valve.
Efficiency and common problems: With only one cylinder in plunger
pumps, the fluid flow varies between maximum flow when the plunger
moves through the middle positions, and zero flow when the plunger is at
the end positions. A lot of energy is wasted when the fluid is accelerated
in the piping system. Vibration and water hammer may be a serious

problem. In general the problems are compensated for by using two or

more cylinders not working in phase with each other.
Velocity pumps
Rotodynamic pumps (or dynamic pumps) are a type of velocity pump in
which kinetic energy is added to the fluid by increasing the flow velocity.
This increase in energy is converted to a gain in potential energy
(pressure) when the velocity is reduced prior to or as the flow exits the
pump into the discharge pipe. This conversion of kinetic energy to
pressure is explained by the First law of thermodynamics, or more
specifically by Bernoulli's principle.
A centrifugal pump is a rotodynamic pump that uses a rotating impeller
to increase the pressure and flow rate of a fluid. Centrifugal pumps are
the most common type of pump used to move liquids through a piping
system. The fluid enters the pump impeller along or near to the rotating
axis and is accelerated by the impeller, flowing radially outward or
axially into a diffuser or volute chamber, from where it exits into the
downstream piping system. Centrifugal pumps are typically used for
large discharge through smaller heads.

Centrifugal pumps are most often associated with the radial-flow type.
However, the term "centrifugal pump" can be used to describe all
impeller type rotodynamic pumps including the radial, axial and mixedflow variations.

Radial-flow pumps
Often simply referred to as centrifugal pumps. The fluid enters along the
axial plane, is accelerated by the impeller and exits at right angles to the

shaft(radially). Radial-flow pumps operate at higher pressures and lower

flow rates than axial and mixed-flow pumps.
Axial-flow pumps
Axial-flow pumps differ from radial-flow in that the fluid enters and exits
along the same direction parallel to the rotating shaft. The fluid is not
accelerated but instead "lifted" by the action of the impeller. They may be
likened to a propeller spinning in a length of tube. Axial-flow pumps
operate at much lower pressures and higher flow rates than radial-flow
pumps.
Mixed-flow pumps
Mixed-flow pumps, as the name suggests, function as a compromise
between radial and axial-flow pumps, the fluid experiences both radial
acceleration and lift and exits the impeller somewhere between 090
degrees from the axial direction. As a consequence mixed-flow pumps
operate at higher pressures than axial-flow pumps while delivering higher
discharges than radial-flow pumps. The exit angle of the flow dictates the
pressure head-discharge characteristic in relation to radial and mixedflow.

Gravity pumps
Gravity pumps include the syphon and Heron's fountainand there also
important qanat or foggara systems that simply use downhill flow to take
water from far-underground aquifers in high areas to consumers at lower
elevations. The hydraulic ram is also sometimes called a gravity pump.
Steam pumps
Steam pumps have been for a long time mainly of historical interest.
They include any type of pump powered by a steam engine and also
pistonless pumps such as Thomas Savery's, the Pulsometer steam pump
or the Steam injection pump.
Recently there has been a resurgence of interest in low power solar steam
pumps for use in smallholder irrigation in developing countries.
Previously small steam engines have not been viable because of
escalating inefficiencies as vapour engines decrease in size. However the
use of modern engineering materials coupled with alternative engine
configurations has meant that these types of system are now a cost
effective opportunity.
Types of centrifugal pumps

Centrifugal pumps can be classified into three general categorized

according to the way the impeller imparts energy to the fluid. Each of
these categories has a range of specific speeds and appropriate
applications.
The three main categories of centrifugal pumps:
1) Radial flow Impeller
2) Mixed Flow Impeller
3) Axial flow Impeller

Radial flow impeller

Most centrifugal pumps are of radial flow. Radial flow impellers impart
energy primarily by centrifugal force. Water enters the hub and flows
radically to the periphery. Flow leaves the impeller at 90 degree angle
from the direction it enters the pump.
Mixed flow impeller
Mixed flow impellers impart energy partially by centrifugal force and
partially as an axial compressor. This type of pump has a single inlet
impeller with flow entering axially and discharging in an axial and radial
direction. Mixed flow impellers are suitable for pumping untreated waste
water. They operate at high speeds than the radial flow impeller pumps;
are usually of lighter construction; and where applicable, cost less than
other pumps. Impeller may be either open or enclosed, but enclosed is
preferred.
Axial flow impeller
Axial flow impeller imparts energy to the water by acting as axial flow
compressors. The axial flow pump has a single inlet impeller with flow
entering and exiting along the axis of rotation (along the pump drive

shaft). These pumps are used in low head, large capacity applications
such as water supplies, irrigation, drainage etc.

CHARACTERISTICS
The water pump is characterized by parameters such as:

Construction

Mechanism of delivering power

Size of working area

Single or multiple stations

Force rating

The type of grinding tool and its capacity

Speed or productivity

Maximum weight of work piece

Safety features

Power consumption

scope FOR PROJECT

To achieve mass production

To reduce manpower

To increase the efficiency of the plant

To reduce the work load

To reduce the production cost

To reduce the production time

To reduce the material handling

To reduce the fatigue of workers

To achieve good product quality

Less Maintenance

COMPONENTS
The pneumatic cutting machine consists of
1. Suction & delivery pipes
2. Pneumatic cylinder
3. nozzle
4. water tank

5. Metal frame

Pneumatic cylinder
Pneumatic cylinders (sometimes known as air cylinders) are
mechanical devices which use the power of compressed gas to produce a
force in a reciprocating linear motion.

Like hydraulic cylinders, something 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. prefer to use
pneumatics because they are quieter, cleaner, and do not require large
amounts of space for fluid storage.

Because the operating fluid is a gas, leakage from a pneumatic

cylinder will not drip out and contaminate the surroundings, making
pneumatics more desirable where cleanliness is a requirement. For
example, in the mechanical puppets of the Disney Tiki Room,

pneumatics are used to prevent fluid from dripping onto people below the
puppets.

Operation
Once actuated, compressed air enters into the tube at one end of
the piston and, hence, imparts force on the piston. Consequently, the
piston becomes displaced (moved) by the compressed air expanding in an
attempt to reach atmospheric pressure.
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
specialized functions.

Single-acting cylinder
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. More often than not, this
type of cylinder has limited extension due to the space the compressed
spring takes up. Another downside to SACs is that part of the force
produced by the cylinder is lost as it tries to push against the spring.

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. Stroke length for this design is not

limited, however, the piston rod is more vulnerable to buckling and

bending. Additional calculations should be performed as well.

Multi-stage, telescoping cylinders

Telescoping cylinders, also known as telescopic cylinders can be
either single or double-acting. The telescoping cylinder incorporates a
piston rod nested within a series of hollow stages of increasing diameter.
Upon actuation, the piston rod and each succeeding stage "telescopes"
out as a segmented piston. The main benefit of this design is the
allowance for a notably longer stroke than would be achieved with a
single-stage cylinder of the same collapsed (retracted) length. One cited
drawback to telescoping cylinders is the increased potential for piston
flexion due to the segmented piston design. Consequently, telescoping
cylinders are primarily utilized in applications where the piston bears
minimal side loading

Other types

Although SACs and DACs are the most common types of

pneumatic cylinder, the following types are not particularly rare

Through rod air cylinders: piston rod extends through both sides of
the cylinder, allowing for equal forces and speeds on either side.
Cushion end air cylinders: cylinders with regulated air exhaust to
avoid impacts between the piston rod and the cylinder end cover.
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.
Tandem air cylinder: two cylinders are assembled in series in order
to double the force output.
Impact air cylinder: high velocity cylinders with specially designed
end covers that withstand the impact of extending or retracting piston
rods.

Pneumatic cylinder force

Due to the forces acting on the cylinder, the piston rod is the most
stressed component and has to be designed to withstand high amounts of
bending, tensile and compressive forces. Depending on how long the
piston rod is, stresses can be calculated differently. If the rods length is
less than 10 times the diameter, then it may be treated as a rigid body
which has compressive or tensile forces acting on it. In which case the
relationship is:

Where:
is the compressive or tensile force
is the cross-sectional area of the piston rod
is the stress
However, if the length of the rod exceeds the 10 times the
value of the diameter, than the rod needs to be treated as a
column and buckling needs to be calculated as well
Instroke and Outstroke

Although the diameter of the piston and the force exerted

by

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

pneumatically and by same supply of

compressed gas.
The relationship between the force, radius, and pressure can
derived from simple distributed load equation:[7]

Where:
is the resultant force
is the pressure or distributed load on the surface
is the effective cross sectional area the load is acting on

Outstroke
Using the distributed load equation provided
the

can be replaced with area of the piston

surface where the pressure is acting on.

Where:
represents the resultant force
represents the radius of the piston
is pi, approximately equal to 3.14159.
Instroke
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 surface minus the cross
sectional area 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:
represents the resultant force
represents the radius of the piston
represents the radius of the piston rod
is pi, approximately equal to 3.14159.

CONSTRUCTIONAL DETAILS

S.No

Components

Quantity

1.

Pump

2.

Compressed air

5 bar

3.

nozzle

4.

pipes

5.

Water tank

BLOCK DIAGRAM

Compressed air

Pneumatic
cylinder

Reciprocating
motion

Water
pumping

Discharge

Working Principle

This project pneumatic reciprocating water pump consists of a pneumatic

cylinder and a tank. When the compressed air is supplied to the

pneumatic cylinder, the extension rod extends and gives reciprocating

action. The reciprocating action is transmitted to the water pumping
action. Due to this movement water is pumped out from the tank. By
means of this project we can pump the water very accurately. It is often
used where a relatively small quantity of liquid is to be handled and
where delivery pressure is quite large. In reciprocating pumps, the
chamber in which the liquid is trapped, is a stationary cylinder that
contains the piston or plunger.

ADVANTAGES

Higher productivity

Less machining time

Less man power

Simple in construction

No electric power

APPLICATIONS

Used in all machine shop and industrial applications

CONCLUSION

With the idea on view, we have completed the project titled

DESIGN AND FABRICATION OF mini water service station
This is one of the most reliable and simple machine in the machine
shop in which many number of operations can be done.
By means of this project, we can clean the automobiles.

REFERENCES
1.

Production technology by P.C. Sharma

2.

Todd, Robert H.; Allen, Dell K. Manufacturing

Processes Reference Guide

3.

Industrial Press Inc., ISBN 0-8311-3049-0,

4.

Colvin, Fred H. (1947), Sixty Years with Men and

Machines, McGraw-Hill,
5.

Floud, Roderick C. (2006) [1976], The British

Machine Tool Industry,

6.

Hounshell,

David

A. :

The

Development

of

Manufacturing Technology in the United States,

7.

Noble, David F. (1984), Forces of Production: A

Social History of Industrial Automation