International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 7, Issue 9, September 2017)
Design and Fabrication of Pneumatic Four Axis Material
Handling Robot
B. Babu1, V. Muthu Kumar2, S. R. Mohan3
1,2,3
Assistant Professor, Rathinam Technical Campus, Coimbatore., India
Abstract— 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.
Keywords—cylinder-horizontal, vertical, rotary, arm
lifting, rack and pinion, gripper arm, D.C.valves, Hose collar
Hose connector
I. INTRODUCTION
Automation can be achieved through computers,
hydraulics, pneumatics, robotics, etc., of these sources,
pneumatics form an attractive medium for low cost
automation. The main advantages of all pneumatic systems
are economy and simplicity. Automation plays an
important role in mass production. Automation plays a vital
role in mass production .for mass production of a product,
the machining operations decides the sequence of
machining .the machines designed for producing a
particular product are called transfer machines.
II. PROBLEM IDENTIFICATION
Pneumatic system use 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.
III. 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.
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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.
IV. SELECTION OF COMPONENTS
The major parts ―Pneumatic Material Handling System‖
are
1. Air compressor
2. FLR unit
3. Direction Control Valve
4. Cylinder
5. Rack and pinion block
6. Connecting hose
V. WORKING PRINCIPLES
The experimental setup consists of four pneumatic
cylinders, all are of double acting type. The cylinder is used
to actuate rack and pinion assembly, piston rod of cylinder-
1 is connected to rack, which is mentioned with the pinion.
By operating the cylinder-1, rack and pinion turns the
whole assembly for 260 degrees. By varying the length of
the rack the turning angle can be altered. vertical cylinder
or cylinder-2 is used to increase the height of the setup. The
height is limited to piston rod length. Horizontal cylinder or
cylinder-3 is used to increase the arm length, the working
area of the arm is limited to the length of the piston length.
Gripper cylinder or cylinder-4 is used to actuate the
gripper.
VI. DESIGN OF EQUIPMENT
6.1 Design of cylinders:
Horizontal, vertical, rotary cylinders & arm lifting
cylinder are of same design and selected from the product
catalogue (Janatics pneumatic products).
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 7, Issue 9, September 2017)
Cylinders are of double acting type. According to the For working pressure of 0.4105 N/m2
applications the forward and return stroke of the piston has
to be controlled with some time interval. So double- acting Extending force = 50.3
cylinders are preferred. This time interval cannot be Retracting force = 42.2 N
achieved by single- acting cylinders.
Design of Arm Lifting Cylinder
6.2 Design of Horizontal, Vertical & Rotary Cylinders
Force to be exerted is 40N
Force to be exerted is 30 N
Force = pressurearea
Pressure in the cylinder = 0.4 x105 N/m2 Force = pressurearea
Area of the piston, (πd2)/4 = Force/pressure
= 40/ 40000 Pressure in the cylinder = 0.4105 N/m2
= 0.001m2 Area of the piston = (π d2)/4
Bore diameter = 0.0356m
= 35.6 mm = 30/0.410

From Janatics pneumatic products catalogue we have = 0.7510-3m2

selected 40mm bore diameter cylinder = 750mm
For forward stroke: Bore diameter = 27.38 mm
For 40mm bore diameter
From Janatics pneumatic product catalogue we have
Corresponding rod diameter =16mm
selected 32mm as bore diameter of arm lifting cylinder.
Area of the piston = (πd2)/4
2
= (πx40 )/4
=1256.8mm2 For forward stroke
For 32 mm bore diameter
Force (modified) to be exerted = pressure area
Corresponding Rod Diameter = 12mm
= 0.4 x105 x1256.8 Area of the Piston = (π d2)/4
= 50N
= (π 122)/4
= 804mm
Force to be Exerted = pressurearea
For return stroke:
= 0.4×105  804
On the return stroke, when the pressure is applied to the
= 32.2 N
reverse direction, the force on the piston due to the pressure
is = P (A-a) For return stroke
Where,
P = Pressure in the cylinder (N/m2) On the return stroke, when the pressure is applied to the
A = Area of the piston (m2) reverse direction
a = Cross sectional area of the piston rod (m2) The force o Therefore
The force on the piston due to pressure is =P(A-a)
Therefore 2 2
Actual area of the piston (A-a ) = {(πd )/4}-{(π d1 )/4}
2 2
Area of the piston (A-a) = {(π d2)/4}-{(π d12)/4} = {(π40 )/4}-{π (12 )/4}
= {(π 402)/4}-{π (162)/4} = 804-114
=1256.6-201 = 690 mm2
=1055mm2 Force to be exerted in the reverse direction =Pressure
Force to be converted area
=0.4 105 690
On the reverse direction = pressurearea =27.6 N
= 0.4 1051055
For working pressure of 0.4105 N/m2,
= 42.2 N
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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 7, Issue 9, September 2017)
Extending Force =32.2 N R = 1m
Retracting force =27.6 N Substituting the values of m, ω, r in equation [4]
fc = 7.56 N.
Downward force, fd = mxg
6.3 Design of pinion = 7 x 9.81
= 68.6N.
From PSG design data book (page no.7.18) Centrifugal force, f = fc + fd
= 68.6 + 7.56
dmin > (0.59/ σcmax) х [[Mt]/((1/E1)+(1/E2)) 2](1/______ (1)
= 76.17N
Where, Torque =fxr
σcmax =maximum contact compressive stress N/m2 = 76.17 x 1
E1, E2 = Young’s modulus N/m2 = 76.2Nm.
Mt = Torque N-m Power = Torque x angular velocity.
E1 = E2 = 1.1х106 N/m2 = 76.2 x 1.05
= 79.7w
Calculation of σcmaσcmax =HB х CB х Kcl _______________ (2)
Where, Substituting the value of kw and n in equation in [3],
HB = Brinell hardness number Mt = 776.7
CB = coefficient depends on hardness [Mt] = 1.4 x Mt
Kcl = life factor = 1.4 x 776.7
Kcl = {[1 x 107]/N} 1/6 _______________ (3) = 1087.1 N-m
N = 60 x n x T
Where Substituting the values of σcmax, [Mt], E1,E2 in equation
n = rpm [1],
N = life in no. Of cycle The minimum diameter of the pinion is calculated to be
T = life in hours 78.7mm.
= 8000 hours. We have taken the standard diameter of pinion as 75mm
6. 4 Specification of Pinion
From P.S.G design data book (page no.2.4),
CB = 20 Material : cast-iron
HB = 200 Outside diameter : 75mm
Circular pitch : 4.7mm
Substituting the values of N, n, T in the equation [3], Tooth depth : 3.375mm
The value of kcl is obtained as 1.139. Module : 1.5mm
Kcl = 1.139. Pressure angle : 21
Substituting the values in equation [2] Pitch circle diameter : 72mm
σcmax = 20 x 200 x 1.1309 Addendum : 1.5mm
= 4520 x105 N/m2 Dedendum : 1.875mm
Circular tooth Thickness : 2.355mm
Calculation of Mt Fillet radius : 0.45mm
____________ ( Clearance : 0.375mm
Mt = 97420 x (Kw/n). 4)
6.5 Design of rack
For power calculation
Pitch circle diameter of the gear is = 72mm
2 _________ Circumference of the gear is=   pitch circle diameter
Centrifugal force, fc= m ω r (5)
M = 7kg =  72
W= m x g = 226mm
The dimension is for 360 rotation
 = 2Πn/60
For 180 rotation the rack length is 113 mm

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 7, Issue 9, September 2017)
6.6 Specification Of Rack
Material : cast iron
Module : 1.5mm
Cross-section : 7525mm
Teeth on the rack is adjusted for 113mm

VII. FABRICATION AND TESTING

7.1 Equipment Functioning
The experimental setup consist of four cylinders, all are
of double acting type. The cylinder1 is used to actuate rack
and pinion assembly, piston rod of cylinder 1is connected
to rack, which is meshed with the pinion. By operating the
cylinder1, rack and pinion turns the whole assembly for VIII. CONCLUSION
260 . Thus we have developed a ―PNEUMATIC
MATERIAL HANDLING SYSTEM” which helps to
know how to achieve low cost automation.
The capacity of our material handling system is 35 N.
The application of pneumatics produces smooth operation.
The work volume is produced within the angle of 120o.
This would boom the mass reduction industries having
conveyors, MIG and TIG 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.

By varying the length of the rack the turning angle can

be altered. Vertical cylinder or cylinder2 is used to increase
the height of the setup. The height is limited to piston rod
length. Horizontal cylinder or cylinder3 is used to increase
the arm length, the working area of the arm is limited to
length of the piston rod length. Gripper cylinder or
cylinder4 is used to actuate the gripper.
7. 2 Description of Assembly
The assembly unit consists of a base block, cylinders,
rack and pinion, base plate, tie rods, solenoid valves and
gripper. Cylinder 1 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.
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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 7, Issue 9, September 2017)
REFERENCES Design data book –compiled by faculty of mechanical engineering
[1] Antonio Esposito - Fluid power with application. Prentice hall of [1] P.S.G. college of technology,Coimbatore
India private limited, 1980. [2] Festo Didactic KG – Fundamentals of control technology, Esslingen-
[2] Bolton,W.,Pneumatic and hydraulic systems,Butterworth- 1998. Festo Pneumatic Catlogue - Festo Pvt Ltd. – Bangalore.
Heinemann,Jordan Hill, Oxford,1997. [3] Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics,Vogel
[3] Catalogue of Janatics pneumatic product, Janatics Private Limited Buchverlag Wurzburg,1998
Coimbatore.

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