Pneumetic Punching Machine PPN

Automatic Pneumatic Punching machine
Module 1
ABSTRACT
Presses are used in industries for a wide variety of uses, including blanking,
piercing and pressing. There are many different types of presses. The most popular are
pneumatic presses and hydraulic presses. These two models of presses are very similar in
function. But pneumatic presses are more preferable than hydraulic presses.
The greatest advantage of Pneumatic presses is their speed. Pneumatic presses are 10
times faster than hydraulic presses and they can perform many jobs faster and more
efficiently. They can also be stopped at any time by opening the valves to release the air.
Pneumatic presses are extremely flexible, that they can be placed in a factory in any required
position, even upside down.
The objective of our project is to MANUFACTURE THE PNEUMATIC

PUNCHING MACHINE of 2 tonne capacity and to make a U-Bend of 1mm thickness sheet
made of Galvanized Iron.
Dept. Of Mechanical Engineering
1.1 SPECIFICATIONS OF PNEUMATIC

PRESS: The acting load is 2 tonne.
Cylinder Bore is 160mm. Stroke length is 170mm.
Diameter of Piston Rod is 63mm. Punch diameter is 24mm.
Die diameter is 24mm.
Volume of working plate is 540 x 465 x 50 mm3
By using this, the overall working time is reduced compared to other presses and hence,
the overall productivity increases.
Module 2
INTRODUCTION
A power press is a machine that supplies force to a die used to blank, form, or shape
metal or nonmetallic material. Thus, a press is a component of a manufacturing system that
combines the press, die, material, and feeding method to produce a part. Presses are
composed of frame, bed, or bolster plate and a reciprocating member called a ram or slide,
which exerts force upon work material through special tools mounted on the ram and bed.
Energy stored in the rotating flywheel of a mechanical press (or supplied by a hydraulic system
in a hydraulic press, or supplied by pneumatic cylinder in a pneumatic press) is transferred to
the ram to provide linear movement.
Power presses can be classified according to:
1. Energy Supply
-
Mechanical presses
Hydraulic presses
Pneumatic presses
Steam presses
Electromagnetic presses
2. Function
-
Energy-producing machines
Force-producing machines
Stroke-controlled machines
3. Construction
-
C-frame presses or gap-frame

Closed-frame presses or O-frame
2-Pillar type
4-Pillar type
4. Operation
-
Single-Action Press
Double-Action Press
Triple-Action Press
Multi-slide Press
2.1 Pneumatic Presses

These type employs pressurized air using compressor as actuator and several valves to
generate a high compressive force acting on the male element its look like the hydraulic presses
but it deal with lower pressure requirements i.e. it generate lower acting forces.
2.2 C-Frame Presses or Gap-Frame

C-frame construction is often used with smaller-capacity presses. Their main advantage
lies in the easily accessible work area, which accounts for shorter setup and adjustmenttimes.
This advantage is perhaps outweighed by their faults, mostly attributable to theshape of their
frame, whose construction is likely to suffer from deflection under load.However, in current
machine building, ribs, back plate and other reinforcements are used tosecure the machines
sturdiness and accuracy.
Module 3
PRINCIPLE OF PROJECT
Punching is a metal forming process that uses a punch press to force a tool, called a
punch, through the workpiece to create a hole via shearing. The punch often passes through the
work into a die. A scrap slug from the hole is deposited into the die in the process. Depending on
the material being punched this slug may be recycled and reused or discarded. Punching is often
the cheapest method for creating holes in sheet metal in medium to high production volumes.
When a specially shaped punch is used to create multiple usable parts from a sheet of material
the process is known as blanking. In forging applications the work is often punched while hot,
and this is called hot punching
Punch tooling (punch and die) is often made of hardened steel or tungsten carbide. A die
is located on the opposite side of the workpiece and supports the material around the perimeter of
the hole and helps to localize the shearing forces for a cleaner edge. There is a small amount of
clearance between the punch and the die to prevent the punch from sticking in the die and so less
force is needed to make the hole. The amount of clearance needed depends on the thickness, with
thicker materials requiring more clearance, but the clearance is always less than the thickness of
the workpiece. The clearance is also dependent on the hardness of the workpiece. The punch
press forces the punch through a workpiece, producing a hole that has a diameter equivalent to
the punch, or slightly smaller after the punch is removed. All ductile materials stretch to some
extent during punching which often causes the punch to stick in the workpiece. In this case, the
punch must be physically pulled back out of the hole while the work is supported from the punch
side, and this process is known as stripping. The hole walls will show burnished area, rollover,
and die break and must often be further processed. The slug from the hole falls through the die
into some sort of container to either dispose of the slug or recycle it
This Pneumatic hole Punching machine Have Pneumatic cylinder, 5/2 solenoid valve, Tool
Arrangements , bolts Nut Supporting pillar.
When The air from compressor, it will be taking a decision to move the tool down.
Also it will up and down movement when the obstacle crossing time that will also press sheet
with the help of pneumatic cylinder, and it will be given to the solenoid valve and then it will

move up or down depends upon the air speed. The tool movement and Up, down can be done
with the help of pneumatic cylinder.
This machine are mostly used in Industrial use to Mass Production It can punch hole rapidly and
Multi size Jobs.
It Have 10 bar maximum Pressure capacity . It can clamp 1 mm to 2mm thickness work pieces.
It cost also less, high efficiency, work loading time is less.
Module 4
PNEUMATICS
Pneumatics is that branch of technology, which deals with the study and application of use of
pressurized air to affect mechanical motion.
Pneumos means Air and Tics means Technology.
The compressed air is used as the working medium, normally at a pressure of 68bars(also can be extended up to 15bar) and a maximum force up to 50KN can be
obtained.Pneumatics is used extensively in industry as well as in many everyday applications. It
has many distinct advantages in terms of energy consumption, cost and safety.Pneumatic power
is used in industry, where factory machines are commonly plumbed for compressed air
(other compressed inert gases can also be used). Pneumatics also has applications in dentistry,
construction, mining, and other areas.
4.1 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 added at the compressor, to avoid corrosion of mechanical
components and to lubricate them.

4.2 ADVANTAGES OF PNEUMATICS
Simplicity of Design and Control
-
Machines are designed using standard cylinders and other components. Control is as
easy as ON-OFF type.
Reliability
-
Pneumatic systems tend to have long operating lives and require very little
maintenance.
-
Because gas is compressible, the equipment is less likely to be damaged by
Storage
lost.
Compressed Gas can be stored, allowing the use of machines when electrical power is
Safety
-
Very low chance of fire (compared to hydraulic oil).
Machines can be designed to be overload safe.
4.3 PNEUMATIC SYSTEMS

Pneumatics is something that we probably know very little about, yet come across every
day without even realising it. Some examples of everyday pneumatic systems are shown below.
.
Fig#1 Example of a pneumatic system
Pneumatics is also used a lot in industry and you would expect to see pneumatic systems in
factories, production lines and processing plants. It can be used to do lots of different jobs such
as moving, holding or shaping objects.
Fig # 2 Operations done by Pneumatic System

Every one of these pneumatic systems makes use of compressed air. Compressed air is quite
simply the air that we breathe forced or squashed into a smaller space. We can use the energy
stored in this compressed air to do things.
4.4 PREPARATION OF AIR

For a pneumatic system, we need the pressurized air which is free from dust,
moisture and smoke. To remove these pollutants, air is filtered. During the filtration,
the dust, moisture and smoke are eliminated about 90%. Then the pressurized air
passes through the air dryer to remove the moisture and make the air dry. Then it
passes through another filter, where a complete free air is available for the system.
This pressurized air goes to the FRL unit, then to the system.
Fig # 3 Basic Pneumatic System
To understand how compressed air is able to do things, lets think of a ball. If we blow up
the ball so that it is full, it will contain a lot of compressed air. If we bounce the ball, it will
bounce very high. However, if the ball is burst then the compressed air will escape and the ball
will not bounce as high. Quite simply, the ball bounces because it is using the energy stored in
the compressed air.
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Fig # 4 Example of Pneumatic Systems
4.5 ADVANTAGES OF PNEUMATICS

There are usually lots of different ways to carry out a task, so it is important to understand
some of the reasons for choosing pneumatic systems.
1
Clean:
Pneumatic systems are clean because they use compressed air. We know already that this
is just the air we breathe forced into small spaces. If a pneumatic system develops a leak, it will
be air that escapes and not oil. This air will not drip or cause a mess and this makes pneumatics
suitable for food production lines.
Safe:
Pneumatic systems are very safe compared to other systems. We cannot, for example, use
electronics for paint spraying because many electronic components produce sparks and this could
cause the paint to catch fire.
It is important, however, that we look after and maintain the different components. It is also
important that we follow the correct safety rules.
Reliable:
Pneumatic systems are very reliable and can keep working for a long time. Many
companies invest in pneumatics because they know they will not have a lot of breakdowns and
that the equipment will last for a long time.
Economical:
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If we compare pneumatic systems to other systems, we find that they are cheaper to run.
This is because the components last for a long time and because we are using compressed air.
Many factories already have compressed air for other reasons.
Flexible:
Pneumatic systems are easy to install and they do not need to be insulated or
protected like electronic systems.
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4.6 SUPPLYING COMPRESSED AIR

We know already that pneumatic systems need compressed air to make them work. A
bicycle pump can produce compressed air. This is all right for inflating the tyres of the bicycle,
but can you imagine trying to blow up all the tyres on a lorry using this? You would soon become
tired, exhausted even.
In order to supply pneumatic systems with compressed air we use a machine called a
compressor. Compressors come in lots of different shapes and sizes but they all work in the same
way.
Fig # 5 Compressor
A pump that is driven by a motor, sucks-in air from the room and stores it in a tank called
the receiver. We will be able to hear the compressor when it is running. Sometimes though, it will
stop because the receiver is full.
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Fig # 6 ON/OFF positions for air flow
4.7 SAFETY RULES

Safety rules help to keep us safe. They highlight dangers and this helps to prevent accidents.
When we are using pneumatics we must follow these rules.
1. Never blow compressed air at anyone, not even yourself.
2. Never let compressed air come into contact with your skin, as this can be very dangerous.
3. Always wear safety goggles when you are connecting and operating circuits.
4. Check that all airlines are connected before turning on the main air supply.
5. Always turn off the main air supply before changing a circuit.
6. Keep your hands away from moving parts.
7. Avoid having airlines trailing across the floor or where someone could trip or become
entangled.
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Module 5
PARTS OF PNEUMATIC SYSTEM
5.1 PNEUMATIC CYLINDERS:
Pneumatic equipment can be split up into two basic categories of cylinders and valves.
Cylinders are the muscles of pneumatic systems as they are used to move, hold and lift objects.
They can even be used to operate other pneumatic components. Cylinders are operated by
compressed air and they covert the stored energy in the compressed air into linear motion.
Fig # 7 Pneumatic Cylinders
Linear motion is motion in a straight line: an apple falling from a tree or a sliding door closing is
an example of linear motion. We can represent linear motion by arrows like the ones below.
There are two types of cylinder that we will be using:

1
Single-Acting Cylinders
Double-Acting Cylinders
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5.2 Single-Acting Cylinder:

The symbol for a single-acting cylinder is shown below.
Fig # 8 Single Acting Cylinder
A single-acting cylinder requires only one air supply. If we supply compressed air to a
single-acting cylinder, the air pushes against the piston inside the cylinder and causes it to
outstroke. When the piston has fully outstroked it is said to be positive.
Fig # 9 Outstroke of the Piston
If we stop the supply of air then the spring inside the cylinder causes the piston to
instroke to its starting position and the piston is said to be negative. As this happens, the air
inside the cylinder is pushed back out.
Fig # 10 Instroke of the Piston
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Single-acting cylinders are easy to use and control but they do not produce very big
forces. This means that we need to be careful of what we use them for.
5.3 Double-Acting Cylinder

A double-acting cylinder has no spring inside to return it to its original position. It needs two
air supplies, one to outstroke the piston and the other to instroke the piston.
The symbol for a double-acting cylinder is shown below.
Fig # 11 Double Acting Cylinder
To outstroke a double-acting cylinder we need compressed air to push against the piston
inside the cylinder. As this happens, any air on the other side of the piston is forced out. This
causes the double-acting cylinder to outstroke. When the piston has fully outstroked it is said to
be positive.
Fig # 12 Outstroke of the Piston
To instroke a double-acting cylinder we need to reverse this action. We supply the

compressed air to the other side of the piston. As the air pushes the piston back to its original
position, any air on the other side is again forced out. This causes the piston to instroke and it is
said to be negative.
Fig # 13 Instroke of the Piston

Double-acting cylinders are used more often in pneumatic systems than
single-acting cylinders. They are able to produce bigger forces and we can make
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use of the outstroke and instroke for pushing and pulling.
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.
Materials:
The
pneumatic
cylinders
designed
for
educational
use
typically
have
transparent outer sleeves (often plexi glass), so students can see the piston moving
inside.
The pneumatic cylinders designed for cleanroom applications often use lubricant-free Pyrex
Glass pistons sliding inside graphite sleeves.
In general, the material used for a pneumatic cylinder is ST-52 (Steamless Tube).
5.4 VALVES:
Valves control the flow of compressed air to a cylinder. They can be used to turn the air
on or off, change the direction in which the air is flowing or even slow down the airflow. The
most common type of valve is the 3/2 valve.
3/2 valve:
A 3/2 valve gets its name because it has three ports and two states. A port is where we can
connect a pipe and a state is simply a position that the valve can be in. The ports are numbered to
help us make the right connections. The numbers will be stamped onto the casing of the valve.
Port 1 Main Air
This port is connected to main air. Remember that our main air is supplied through a
manifold. Main air is identified by this symbol:
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Port 2 Output Connection

This port lets us make connections to other components. Remember, the purpose of valves is
to control the flow of air to other components, usually cylinders.
Port 3 Exhaust
This port allows air trapped in the circuit to escape or exhaust. Remember, for our cylinders
to instroke and outstroke, they need the air on the other side of the piston to escape.
The 3/2 valve has two states of operation. One state prevents air from being supplied to other
components and the other allows the air to flow freely.
State 1 Off/Unactuated State:

In this state, the main air supply through the valve is blocked and so air is unable to reach
other components, such as cylinders. However, any air within the cylinder is able to exhaust
through the valve and this will allow the cylinder to return to its original position.
The symbol below represents the air flow through the valve in OFF state.
State 2 On/Actuated State:

In this state, the main air supply is able to flow freely through the valve and supply
components, such as cylinders, with air.
The symbol below represents the air flow through the valve in OFF state.
The complete symbol for a 3/2 valve combines both states and is usually drawn in the
OFF/Unactuated state. The complete symbol is shown below.
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5.5 T-PIECE
A T-piece or T-connector is a very simple component that lets us split or divide airflow. It
can be very useful if you want two cylinders to operate at the same time.
Fig # 14 T-Connector
On circuit diagrams, the T-piece is identified by a dot.
5.6 COMPRESSORS
An air compressor is a machine which takes in air at a certain pressure and delivers the air at
a higher pressure. Everything on earth is subjected to the absolute atmospheric pressure(pa), this
pressure cannot be felt. The prevailing atmospheric pressure is therefore regarded as the base and
any deviation is termed "gauge pressure".
Absolute pressure = Atmospheric pressure + gauge pressure
Absolute pressure is approximately one bar greater than the gauge pressure. Characteristics of
interest on a compressor are, Delivery volume or capacity of the compressor, Compression ratio.
Compressor capacity is usually expressed as air volume at ambient conditions at the compressor
intake, namely in units of meter cube per minute or litres per minute.
Compression ratio is expressed by the discharge pressure measured in the generally accepted
unit of bars. Compressors should be installed in a separate room. Special care is required to
ensure that the compressors will be able to take in air that is preferably cool but above all dry and
substantially dust-free. At locations where clean suction air is not available, the installation of a
separate intake filter can answer this requirement. Piping leading from the filter to the
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compressor intake should be amply dimensioned. In this way it is also possible for clean suction
air to be supplied to a multiple number of compressors via a common intake duct.
5.7 FRL Unit

It is a device that conditions air for use in pneumatic systems. An FRL is a
combination filter-regulator-lubricator.frl units have semi-auto-drain function and the
body is made of die casting aluminum alloy, thus making them sturdy to operate in
industrial environments.
Fig # 15 FRL Unit
The FRL units are used in various industries such as food processing, paper and packaging,
pharmaceutical and textile. Offered at economical prices, FRL units are robust in design,
construction and are ideal to be used in tough working conditions.
Specifications:
Medium: Compressed air
Mounting position: Vertical 5

Pressure range max.: 10 Bar
Temperature nominal: -10 to + 60
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5.8 COMPONENTS USED
Double acting cylinder

Pneumatic hand operated valve
High speed steel blade
SPECIFICATIONS
PNEUMATIC CYLINDER
Stroke length = 150mm
Diameter = 50mm
Pressure = 10bar
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5.9 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, pneumatic cylinders use the stored potential energy of a fluid, in
this case compressed air, and convert it into kinetic energy as the air expands in an attempt to
reach 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. Engineers prefer to use pneumatics sometime because they are quieter, cleaner, and do
not require large amounts or 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 DisneyTiki Room, pneumatics are
used to prevent fluid from dripping onto people below the puppet.
Figure (i)
DOUBLE-ACTING CYLINDER
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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 out-stroke and one
for in-stroke. Stroke length for this design is not limited, however, the piston rod is
more vulnerable to buckling and bending. Addition calculations should be
performed as well by using design data hand book using some relations between
cylinder and pressure we can accurately find out bending and buckling of tie rod.
2D VIEW:
Figure (ii)
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5.10 TWO WAY DIRECTIONAL VALVE

A two-way directional valve consists of two ports connected to each other withpassages,
which are connected and disconnected. In one extreme spool position, portA is open to port B;
the flow path through the valve is open. In the other extreme,the large diameter of the spool
closes the path between A and B; the flow path isblocked. A two-way directional valve gives an
on-off function.
(Flow path open and Flow path closed).
Figure (iii)
5.11 HIGH SPEED STEEL BLADE:

A blade is used to cut the sheet metal in a desired dimension. Here we are using high speed steel
blades to cut the sheet metal.
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5.12 PNEUMATIC TRANSMISSION OF ENERGY:

The reason for using pneumatics, or any other type of energy transmission on amachine,
is to perform work. The accomplishment of work requires the applicationof kinetic energy to a
resisting object resulting in the object moving through adistance. In a pneumatic system, energy
is stored in a potential state under the formof compressed air. Working energy (kinetic energy
and pressure) results in apneumatic system when the compressed air is allowed to expand. For
example, atank is charged to 100 PSIA with compressed air. When the valve at the tank outletis
opened, the air inside the tank expands until the pressure inside the tank equals theatmospheric
pressure. Air expansion takes the form of airflow.
To perform any applicable amount of work then, a device is needed which cansupply an
air tank with a sufficient amount of air at a desired pressure. This deviceis positive displacement
compressor.
What a Positive Displacement Compressor Consists of
A positive displacement compressor basically consists of a movable member insidea
housing. The compressor has a piston for a movable member. The piston isconnected to a
crankshaft, which is in turn connected to a prime mover (electricmotor, internal combustion
engine). At inlet and outlet ports, valves allow air toenter and exit the chamber.
How a Positive Displacement Compressor Works:
As the crankshaft pulls the piston down, an increasing volume is formed within
thehousing. This action causes the trapped air in the piston bore to expand, reducing itspressure.
When pressure differential becomes high enough, the inlet valve opens,allowing atmospheric air
to flow in. With the piston at the bottom of its stroke, inletvalve closes. The piston starts its
upward movement to reduce the air volume whichconsequently increases its pressure and
temperature. When pressure differentialbetween the compressor chamber and discharge line is
high enough, the dischargevalve opens, allowing air to pass into an air receiver tank for storage.
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5.13 Control of Pneumatic Energy:

Working energy transmitted pneumatically must be directed and under completecontrol at
all times. If not under control, useful work will not be done and machineryor machine operators
might be harmed. One of the advantages of transmittingenergy pneumatically is that energy can
be controlled relatively easily by usingvalves.
Control of Pressure:
Pressure in a pneumatic system must be controlled at two points - after thecompressor
and after the air receiver tank. Control of pressure is required after thecompressor as a safety for
the system. Control of pressure after an air receiver tankis necessary so that an actuator receives
a steady pressure source without wastingenergy.
Control of Pressure after a Compressor:

In a pneumatic system, energy delivered by a compressor is not generally
usedimmediately, but is stored as potential energy in air receiver tank in the form ofcompressed
air.
In most instances, a compressor is designed into a system so that it operates intermittently. A
compressor usually delivers compressed air to a receiver tank untilhigh pressure is reached, then
it is shut down. When air pressure in the tankdecreases, the compressor cuts in and recharges the
tank. Intermittent compressoroperation in this manner is a power saving benefit for the system.
A common way of sensing tank pressure and controlling actuation and de-actuationof relatively
small (2-15 HP) compressors, is with a pressure switch.
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Module 6
MECHATRONICS
Mechatronics is a multidisciplinary field of engineering that includes a combination of

mechanical engineering, electrical engineering, telecommunications engineering, control
engineering and computer engineering. As technology advances the subfields of engineering
multiply and adapt. Mechatronics' aim is a design process that unifies these subfields. Originally,
mechatronics just included the combination of mechanics and electronics, hence the word is a
combination of mechanics and electronics; however, as technical systems have become more
and more complex the word has been broadened to include more technical areas.
The word "mechatronics" originated in Japanese-English and was created by Tetsuro

Mori, an engineer of Yaskawa Electric Corporation. The word "mechatronics" was registered as
trademark by the company in Japan with the registration number of "46-32714" in 1971.
However, afterward the company released the right of using the word to public, and the word
"mechatronics" spread to the rest of the world. Nowadays, the word is translated in each
language and the word is considered as an essential term for industry.
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French standard NF E 01-010 gives the following definition: approach aiming at the
synergistic integration of mechanics, electronics, control theory, and computer science within
product design and manufacturing, in order to improve and/or optimize its functionality".
Many people treat "mechatronics" as a modern buzzword synonymous with "electromechanical
engineering". However, other people draw a distinction between an "electromechanical
component"does not include a computer; an electro-mechanical computer (such as the Z4)
does not include an electronic computer; vs. a "mechatronic system"a computer-controlled
mechanical system, including both an electronic computer and electromechanical components.
29
Module 7
ELECTRONIC CONTROL
7.1 POWER SUPPLY
Power supply is the first and most important part of our project. In the proposed project the
power supply circuit is used to provide the regulated supply to the IC`s used in the project.
Power supply circuit consists of step down transformer, rectifier circuit, filter circuit and
regulator IC.
BLOCK DIAGRAM OF POWER SUPPLY
INPUT
AC
SUPPLY
STEP DOWN
TRANSFORMER
RECTIFIER
CIRCUIT
FILTER
CIRCUIT
REGULATED
IC
CIRCUIT DIAGRAM OF THE POWER SUPPLY
Step Down Transformer

30

Transformers are static device which convert the electrical energy from one
circuit to another circuit without any change in frequency and power. Step down transformer
means the transformer which reduces the supply voltage to the desired value. In our project we
need 12 volt DC supply, therefore in this project 12-0-12, 500mA transformer is used.
Rectifier Circuit
Rectifier is a circuit which converts the AC electrical energy into Dc electrical
energy. For operating of semiconductor devices used in this project we need regulated DC
supply. In this project we use centre tap full wave rectifier. Full wave rectifier circuit is capable
of converting sinusoidal input into a unidirectional output. The circuit diagram is as shown in the
figure.
Filter Circuit
It is seen that the output of the rectifier is not pure DC, because it contain
some amount of AC component which is called as ripple factor which gives the fluctuation and
hence to minimize the ripple in the output the filter circuit is used. This circuit is connected after
the rectifier circuit. In our project capacitor input filter is used. The circuit is as shown in the
figure. The capacitor is connected in parallel to minimize the ripple factor.
Regulator Circuit
In our project for the operation of IC we need +5 volt regulated supply is
necessary therefore a voltage regulator circuit is used. A voltage regulator is a circuit that
supplies constant voltages regardless of change in the load current. IC voltage regulators are
versatile and generally used. The 78xx series consist of three terminal positive voltage regulators.
These ICs are designed as fixed voltage regulator and adequate heat sink. It can be deliver output
current in access of 1A. These devices do not required external component.
These ICs has internal terminal overload protection and internal short circuit
and current limiting protection.
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7.2 VALVE CONTROLLER CIRCUIT
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7.3 WORKING OF ELECTONICS CONTROLLER

In this project automatic pnumetic valve controlled by the Micrcontroller.
Micrcontroller works on +5 Volt DC power supply. Program is dumped in the controller which is
written ic embedded c language and compiled in Keil Software.
When we powering the coontroller, mircontroller generate High pulse for 1 sec and low pulse for
1 sec as condition is written in the program.
We get this pulses at Pin 21 port2.0. this pin is connected to the BC547 NPN switching transister.
When high pulse is reaches at the base of transister then current flow from emmiter to collector
means transister is in on state cause current reaches to the coil of the relay it tend to actuate the
relay so current flow in pnumetic electonic valve.
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7.4 MICROCONTROLLER
AT89C52
AT89C52 is an 8-bit microcontroller and belongs to Atmel's 8051 family. AT89C52 has 8KB of
Flash programmable and erasable read only memory (PEROM) and 256 bytes of RAM.
AT89C52 has an endurance of 1000 Write/Erase cycles which means that it can be erased and
programmed to a maximum of 1000 times.
Though very slight difference between the features of AT89C51 and AT89C52, they are very
similar in their pin configurations* and operations. The differences between AT89C51 and
AT89C52 have been tabulated below.
RAM
Flash
Number of Timers/Counters
Number of Interrupt Sources
AT89C52
256 Bytes
8 KB
3 (16-bit each)
8
AT89C51
128 Bytes
4 KB
2 (16-bit each)
6
*The pin configuration of AT89C52 is exactly similar to that of AT89C51 except that the first
two pins, P1.0 and P1.1 are multiplexed to correspond to Timer2 operations as given in the
following table.
Existing
P1.0
P1.1
Alternate
T2
T2 EX
Function
Timer/counter 2 External Count input
Timer/counter 2 Trigger input
While AT89C51 has two timers (Timer0 & Timer1), AT89C52 also has Timer2. Corresponding to
Timer2, there are extra SFRs (Special Function Registers) T2CON & T2MOD. Also there are
registers RCAP2H & RCAP2L to configure 16 bit Capture & Auto-reload modes of Timer2.
7805 Voltage Regulator
7805 is a voltage regulator integrated circuit. It is a member of 78xx series of fixed linear
voltage regulator ICs. The voltage source in a circuit may have fluctuations and would not give
the fixed voltage output. The voltage regulator IC maintains the output voltage at a constant
34

value. The xx in 78xx indicates the fixed output voltage it is designed to provide. 7805 provides
+5V regulated power supply. Capacitors of suitable values can be connected at input and output
pins depending upon the respective voltage levels.
Pin Description:
Pin No
Function
Name
Input voltage (5V-18V)
Input
Ground (0V)
Ground
Regulated output; 5V (4.8V-5.2V)
Output
35

7.5 TRANSFORMER
A transformer is an apparatus for converting electrical power in an ac system at one voltage or
current into electrical power at some other voltage or current without the use of rotating parts.
Transformers have been an essential component in electrical as well as electronic circuits. Apart
from stepping up or stepping down the voltages, they are used for providing isolation, for
impedance mismatch and so on. Development of new technologies has reduced the usage of
transformers, but still they are quite vital in many applications.
Transformers are of many types and are used as per specific requirements. In addition to the
transformers used in power systems, in power transmission and distribution, a large number of
special transformers are in use in applications like electronic supplies, furnaces, traction, audio
applications, RF and microwave circuits, etc. Subsequent sections will present details about the
transformers.
What is a TRANSFORMER ?
A transformer is an electrical device that transfers electrical energy at one voltage from one
circuit to other at a different voltage merely by magnetic coupling; the transfer of energy doesnt
involve any kind of motion.
Transformers are analogous to gear box (used to convert torque and hence speed). Transformers
step up or step down the voltage and therefore vary the current. As the product of speed and
torque remains constant, product of voltage and current also remains constant.
Transformers utilises the principle of electromagnetism given by Faradays law. A conductor
carrying changing current carrying sets up a changing magnetic field around it. When a second
conductor is placed in this varying magnetic field, voltage will be induced into it. Get a clearer
picture about transformers through exclusive images detailing about its internal structure and
windings at the transformer insight page.
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When an AC voltage is applied to one (primary) coil, the varying magnetic field is set up around
the coil. By virtue of mutual induction, it creates an AC voltage in the other (secondary) coil. A
transformer can also be used with pulsating dc, but a pure dc voltage cannot be used, since only a
varying voltage creates the varying magnetic field which is the basis of the mutual induction
process.
An ideal transformer has infinite winding reactance, zero winding resistance, zero leakage
inductance and zero winding capacitances. Voltage ratio is equal to the turns ratio under all
loading conditions.
37
7.6 Relay
A relay is an electrical switch that opens and closes under the control of another electrical
circuit. In the original form, the switch is operated by an electromagnet to open or close one or
many sets of contacts. It was invented by Joseph Henry in 1835. Because a relay is able to
control an output circuit of higher power than the input circuit, it can be considered to be, in a
broad sense, a form of an electrical amplifier.
Latching relay
A latching relay has two relaxed states (bistable). These are also called "impulse",
"keep" or "stay" relays. When the current is switched off, the relay remains in its last state. This
is achieved with a solenoid operating a ratchet and cam mechanism, or by having two opposing
coils with an over-center spring or permanent magnet to hold the armature and contacts in
position while the coil is relaxed, or with a remanent core. In the ratchet and cam example, the
first pulse to the coil turns the relay on and the second pulse turns it off. In the two coil example,
a pulse to one coil turns the relay on and a pulse to the opposite coil turns the relay off. This type
of relay has the advantage that it consumes power only for an instant, while it is being switched,
and it retains its last setting across a power outage. A remanent core latching relay requires a
current pulse of opposite polarity to make it change state.
Relays are amazingly simple devices. There are four parts in every relay:
Electromagnet
Armature that can be attracted by the electromagnet
Spring
38
Set of electrical contacts
The following figure shows these four parts in action:
In this figure, you can see that a relay consists of two separate and completely independent
circuits. The first is at the bottom and drives the electromagnet. In this circuit, a switch is
controlling power to the electromagnet. When the switch is on, the electromagnet is on, and it
attracts the armature (blue). The armature is acting as a switch in the second circuit. When the
electromagnet is energized, the armature completes the second circuit and the light is on. When
the electromagnet is not energized, the spring pulls the armature away and the circuit is not
complete. In that case, the light is dark.
When you purchase relays, you generally have control over several variables:
The voltage and current that is needed to activate the armature
The maximum voltage and current that can run through the armature and the armature
contacts
The number of armatures (generally one or two)
The number of contacts for the armature (generally one or two -- the relay shown here
has two, one of which is unused)
Whether the contact (if only one contact is provided) is normally open (NO) or normally
closed (NC)
Relay Applications
39

In general, the point of a relay is to use a small amount of power in the electromagnet -- coming,
say, from a small dashboard switch or a low-power electronic circuit -- to move an armature that
is able to switch a much larger amount of power. For example, you might want the electromagnet
to energize using 5 volts and 50 milliamps (250 milliwatts), while the armature can support 120V
AC at 2 amps (240 watts).
Relays are quite common in home appliances where there is an electronic control turning on
something like a motor or a light. They are also common in cars, where the 12V supply voltage
means that just about everything needs a large amount of current. In later model cars,
manufacturers have started combining relay panels into the fuse box to make maintenance easier.
For example, the six gray boxes in this photo of a Ford Windstar fuse box are all relays:
In places where a large amount of power needs to be switched, relays are often cascaded. In this
case, a small relay switches the power needed to drive a much larger relay, and that second relay
switches the power to drive the load.
40
7.7 PUNCHING
Punching is a metal forming process that uses a punch press to force a tool, called a
punch, through the workpiece to create a hole via shearing. The punch often passes through the
work into a die.
Fig # 16 Punching
A scrap slug from the hole is deposited into the die in the process. Depending on the material
being punched this slug may be recycled and reused or discarded. Punching is often the cheapest
method for creating holes in sheet metal in medium to high production. When a specially shaped
punch is used to create multiple usable parts from a sheet of material the process is known as
blanking. In forging applications the work is often punched while hot, and this is called hot
punching.
41

Pneumatic hole punching helps to make the hole in sheet metal by using Compressed Air.
Pneumatic actuators controlled energy to the punch , so the Operator needs to provide only
modest effort regardless of conditions. Pneumatic Punching machine helps to make hole in
Various size by changing tool. As well, pneumatic Punch provides some feedback of forces
acting on the Sheet and Hole can Made in Sheet metal.
Pneumatic Hole punching machine is reduce Effort To Operator. Operator Need Very Less
amount of effort.
Pneumatic hole punching machine operated by compressed Air. Pneumatic clamp have
pneumatic Cylinder, 5/2 Flow control Hand Lever valve
Design Construction Depending on the job specification, there are multiple forms of body
constructions available :
Tie rod cylinders: The most common cylinder constructions that can be used in many
types of loads. Has been proven to be the safest form.
Flanged-type cylinders: Fixed flanges are added to the ends of cylinder, however, this
form of construction is more common in hydraulic cylinder construction.
One-piece welded cylinders: Ends are welded or crimped to the tube, this form is
inexpensive but makes the cylinder non-serviceable.
Threaded end cylinders: Ends are screwed onto the tube body. The reduction of material
can weaken the tube and may introduce thread concentricity problems to the system
42
7.8 TOOL AND TOOL DESIGN

PUNCH:
Punch is used to press the sheet metal, to the shape of DIE. The load from the cylinder is
impacted on to the punch, which bends the sheet metal.
Fig # 30 Punch Design
Punch tooling (punch and die) is often made of hardened steel or tungsten carbide. A die
is located on the opposite side of the workpiece and supports the material around the perimeter of
the hole and helps to localize the shearing forces for a cleaner edge. There is a small amount of
clearance between the punch and the die to prevent the punch from sticking in the die and so less
force is needed to make the hole. The amount of clearance needed depends on the thickness, with
thicker materials requiring more clearance, but the clearance is always less than the thickness of
the workpiece. The clearance is also dependent on the hardness of the workpiece. The punch
press forces the punch through a workpiece, producing a hole that has a diameter equivalent to
the punch, or slightly smaller after the punch is removed. All ductile materials stretch to some
extent during punching which often causes the punch to stick in the workpiece. In this case, the
punch must be physically pulled back out of the hole while the work is supported from the punch
side, and this process is known as stripping. The hole walls will show burnished area, rollover,
and die break and must often be further processed. The slug from the hole falls through the die
into some sort of container to either dispose of the slug or recycle it.
43
Module 8
WORKING OF PNEUMATIC PRESS
The pneumatic press is provided with a 2 tonne capacity cylinder.
Compressor is a pump which stores up air at working pressure say 6 psi (pounds per
square inch) and compresses air, raising it to a higher pressure. The compressed air from the
compressor (in this case 6 psi) is delivered to the cylinder (160mm Bore) of the pneumatic press
(sometimes, can also be used to generate a vacuum).
When the lever is operated, the high pressure air in the cylinder is released, pushing the
piston and the rod attached to it, downwards.
The released air is free and non- toxic. Often the air is slightly modified by taking out
some of the water vapor and adding a small amount of atomized oil to make the gas more
machines friendly by using FRL unit.
A 160mm (6.299 inches) diameter cylinder has an area of r2. So if we have 6 psi air
pressure pushing on 3.14 square inches of surface. That cylinder has 6psi x 31.14 inch2 = 186.88
lbs of pressure.
This pressure pushes down the rod. Ram connected to the rod is forced downwards
which in turn pushes down the punch which is fixed to the ram. This punch, hits the metal
sheet placed on the die having a U-Groove. The pressure is applied until the part has been
formed to the proper angle.
44
Module 9
APPLICATIONS
Sheet metals are used in
Car bodies
Airplane wings
Medical tables
Roofs for buildings (Architectural) and many other things
Sheet metal of iron and other materials with high magnetic permeability, also
known as laminated steel cores, has applications in transformers and electric
machines.
Historically, an important use of sheet metal was in plate armor worn by cavalry,
and sheet metal continues to have many decorative uses, including in horse tack.
45
Module 10
ADVANTAGES
Low cost
Less consumption of time
Easy to handle
Skilled labor is not required
Less maintainance
High accuracy
Good surface finish
Less floor space
46
Module 11
FUTURE EXTENSION
We contemplate the following future features which can be incorporated into this project:
A die to produce a washer of less than 1mm thickness.
Automation of pneumatic press.
Improvements in pneumatic press by adding components like timers, silencers etc.
47
Module 12
REFERENCES
http://www.ciri.org.nz/bendworks/bending.pdf
We made this project with our own idea with the help of
HYDRAULIC AND PNEUMATIC SYSTEM written by Srinivasan,
TOTAL AUTOMATIVE TECHNOLOGY written by Anthony E Schwaller,
INDUSTRIAL ENGINEERING AND THE ENGINEERING DIGEST written by

Robert Thurston Kent, Charles MaccaugheySomes
WEBSITES:
www.pumpwork.in
www.wikipedia.com
www.howstuffworks,com
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Automatic Pneumatic Punching machine

The objective of our project is to MANUFACTURE THE PNEUMATIC

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Automatic Pneumatic Punching machine

1.1 SPECIFICATIONS OF PNEUMATIC

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C-frame presses or gap-frame

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Automatic Pneumatic Punching machine

2.1 Pneumatic Presses

2.2 C-Frame Presses or Gap-Frame

Dept. Of Mechanical Engineering

Automatic Pneumatic Punching machine

Dept. Of Mechanical Engineering

Automatic Pneumatic Punching machine

Dept. Of Mechanical Engineering

Automatic Pneumatic Punching machine

Pneumos means Air and Tics means Technology.

4.1 GASES USED IN PNEUMATIC SYSTEMS

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Automatic Pneumatic Punching machine

easy as ON-OFF type.

Because gas is compressible, the equipment is less likely to be damaged by

Very low chance of fire (compared to hydraulic oil).

Machines can be designed to be overload safe.

Dept. Of Mechanical Engineering

Automatic Pneumatic Punching machine

4.3 PNEUMATIC SYSTEMS

Fig#1 Example of a pneumatic system

Fig # 2 Operations done by Pneumatic System

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Automatic Pneumatic Punching machine

4.4 PREPARATION OF AIR

Fig # 3 Basic Pneumatic System

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Automatic Pneumatic Punching machine

Fig # 4 Example of Pneumatic Systems

4.5 ADVANTAGES OF PNEUMATICS

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Automatic Pneumatic Punching machine

Dept. Of Mechanical Engineering

Automatic Pneumatic Punching machine

4.6 SUPPLYING COMPRESSED AIR

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Automatic Pneumatic Punching machine

Fig # 6 ON/OFF positions for air flow

4.7 SAFETY RULES

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Fig # 7 Pneumatic Cylinders

There are two types of cylinder that we will be using:

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Automatic Pneumatic Punching machine

5.2 Single-Acting Cylinder:

Fig # 8 Single Acting Cylinder

Fig # 9 Outstroke of the Piston

Fig # 10 Instroke of the Piston

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Automatic Pneumatic Punching machine

5.3 Double-Acting Cylinder

Fig # 11 Double Acting Cylinder

Fig # 12 Outstroke of the Piston

To instroke a double-acting cylinder we need to reverse this action. We supply the