DESIGN AND FABRICATION OF AUTOMATIC PNEUMATIC SHEET CUTTING MACHINE WITH SENSOR Done By: J.Johnny Hudson (410713114060) E.Jude Livingstone (410713114062) Karan M.Valooran (410713114066) R.Marimuthu (410713114081) Co-ordinator : R. Sendil kumar Assistant professor Mechanical department Guide: C.Sivakandan Associate professor Mechanical department

ABSTRACT The sheet metal cutting process is a main part of the all industries. Normally the sheet metal cutting machine is manually operated in medium and small scale industries. In our work ,we have replaced human force by pneumatic force. Automation in the modern world is inevitable. Any automatic machine aimed at the economical use of man, machine, and material worth the most. In our work we have used solenoid valve and control timing unit for automation purpose. The sheet metal cutting machine works with the help of pneumatic double acting cylinder. The piston is connected to the moving cutting tool. It is used to cut the small size of sheet metal. The machine is portable in size, so easy transportable.

INTRODUCTION This is an area 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. Degrees of automation are of two types, viz. Full automation. Semi automation. In semi automation a combination of manual effort and mechanical power is required whereas in full automation human participation is very negligible.

WORKING PRINCIPLE The compressed air from the compressor is used as the force medium for this operation. There are pneumatic double acting cylinders, solenoid valve; flow control valve and timer unit used .The arm from the compressor enters to the flow control Valve. The controlled air from the flow control valve enters to the solenoid valve. The function of solenoid valve is to supply air of correct time interval. The 5/2 solenoid valve is used. In one position air enter to the cylinder and pushes the piston, so that the cutting stroke is obtained. The next position air enters to the other side of cylinder and pushes the piston return back, so that the releasing stroke is obtained. The speed of the cutting and releasing stroke is varied by the timer control unit circuit.

NEED FOR AUTOMATION 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. Reduction of labour and material cost Reduction of overall cost Increased production

LAYOUT OF PNEUMATIC SHEET CUTTING

COMPONENTS REQUIRED Pneumatic cylinder Cutting plate Solenoid valve Flow control valve Polyurethane tube Frame Infrared Sensor

CONTROL UNIT The term PIC, or Peripheral Interface Controller, is the name given by Microchip Technologies to its single – chip microcontrollers. These devices have been phenomenally successful in the market for many reasons, the most significant ones are mentioned below. PIC micros have grown in steadily in popularity over the last decade, ever since their inception into the market in the early 1990s. PIC micros have grown to become the most widely used microcontrollers in the 8- bit microcontroller segment.

SOLENOID ELECTRIC 5/2 Voltage : 230 v AC Supply Type : 5/2 Valve Material : Aluminium and plastic

TECHNICAL SPECIFICATIONS FOR PNEUMATIC CYLINDER DOUBLE ACTING PNEUMATIC CYLINDER Stroke length : Cylinder stoker length 160 mm = 0.16 m Quantity : 1 Seals : Nitride (Buna-N) Elastomer End cones : Cast iron Piston : EN – 8 Media : Air Temperature : 0-80 º C Pressure Range : 8 N/m²

FLOW CONTROL VALVE Port size : 0.635 x 10 ֿ² m Pressure : 0-8 x 10 ⁵ N/m² Media : Air Quantity : 1

HOSE AND CONNECTER A hose coupling is a connector on the end of a hose to connect (or couple) it with another hose or with a tap or a hose appliance, such as an irrigation sprinkler. It is usually made of steel, brass, stainlesteel, aluminium or plastic.

INFRARED SENSOR An infrared sensor is an electronic device that emits and/or detects infrared radiation in order to sense some aspect of its surroundings. Infrared sensors can measure the heat of an object, as well as detect motion. Applications : Can be used for measuring distance. Can be used to finding the rightness or color

CONNECTOR Max working pressure : 10 x 10 ⁵ N/m² Temperature : 0-100 º C air media : Air Material : Brass

HOSE SPECIFICATION Max pressure : 10 x 10 ⁵ N/m² Outer diameter : 6 mm = 6 x 10 ˉ ³m Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m

PNEUMATIC CYLINDER DESIGN Design of Piston rod: Load due to air Pressure. Diameter of the Piston (d) = 40 mm Pressure acting (p) = 6 kgf/cm² = 6 ×0.981 = 5.886 bar = 0.5886N/mm2 Material used for rod = C 45 (data book page no 1.12 ) Yield stress (σy ) = 36 kgf/mm² = 36×98.1 = 3531.6 bar = 353.16N/mm2 factor of safety = 2( data book page.no 8.19)

Force acting on the rod (F) = Pressure x Area = p x (Πd² / 4) = 0 Force acting on the rod (F) = Pressure x Area = p x (Πd² / 4) = 0.5886 x {( Π x 40² ) / 4 } F = 739.6 N Design Stress(σy) = σy / F0 S = 353.16 / 2 = 176.5N/mm2 ∴d = √4F/π [σy] = √ (4×739.6)/ π[176.5] ∴ Minimum diameter of rod required for the load = 2.3 mm We assume diameter of the rod = 15 mm

Length of piston rod: Approach stroke = 160 mm Length of threads = 2 x 20 = 40mm Extra length due to front cover = 12 mm Extra length of accommodate head = 20 mm Total length of the piston rod = 160 + 40 + 12 + 20 = 232 mm By standardizing, length of the piston rod = 230 mm

ADVANTAGES The pneumatic is more efficient in the technical field Quick response is achieved Simple in construction Easy to maintain and repair Cost of the unit is less when compared to other machine No fire hazard problem due to over loading Comparatively the operation cost is less The operation of cutting is faster because the medium used to operate is air Continuous operation is possible without stopping

DISADVANTAGES 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.(<50 N)

APPLICATIONS This machine is very useful for small scale industries This machine is used to cut the roller sheet metal All Industrial Application

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