CONTENTS

1. SYNOPSIS

2. INTRODUCTION

3. LITERATURE REVIEW

4. COMPONENTS DESCRIPTION

5. DESIGN AND DRAWINGS

6. WORKING PRINCIPLE

7. ADVANTAGES AND APPLICATIONS

8. COST ESTIMATION

9. FUTURE SCOPE

10. CONCLUSION

11. BIBLIOGRAPHY

12. PHOTOGRAPHY
 SYNOPSIS

Automatic plays vital role in all fields likes automobile, production

agriculture etc., Automation will give high accuracy, and good look and decrease
the production cost and labor cost. Keeping it in mind we invented and designed a
project “AUTOMATIC PAINT SPRAYING SYSTEM”.

This project used to paint the objects automatically, which are coming in
conveyors from mass production process. Here we have done a single chamber to
demonstrate the working principle of the car painting station since the
unavailability of conveyor sections.

The object has to stop in the chamber for a movement for painting.

This stopping is provided to endure the even surface painting and to avoid paint
wastage. Here we can use micro switch to control the paint. We can also use
sensors if we implement it in the continuous process conveyors.

The working principle and construction are described in the following

chapter.
 INTRODUCTION

Our project “Automatic Car Painting Station” is designed and fabricated

properly. Move care is taken in the fabrication of nozzle part and solenoid coils.
As per our design, the outcome of the project is good. The performance of the
equipment is more satisfactory and the working is very good.

The painted surface of the objects painted by the equipment is good in look
and the spray of paint is even through out the entire area in all products.

The object has to stop in the chamber for a movement for painting.

This stopping is provided to endure the even surface painting and to avoid paint
wastage. Here we can use micro switch to control the paint. We can also use
sensors if we implement it in the continuous process conveyors
 CONTENTS

 SYNOPSIS

 INTRODUCTION

 LITERATURE SURVEY

 FABRICATION OF PAINTING SYSTEM

 GENERAL DETAILS OF PNEUMATICS

 DESCRIPTIONS OF PARTS

 LIST OF MATERALS

 COST ESTIMATION

 ASSEMBLY DIAGRAM

 WORKING PRINCIPLE

 APPLICATIONS & ADVANTAGES

 CONCLUSION

 BIBLIOGRAPHY

 PHOTOGRAPHY
PNEUMATIC

SYSTEMS
PNEUMATIC SYSTEMS

A pneumatic system is a system that uses compressed air to transmit and

control energy. Pneumatic systems are used in controlling train doors, automatic
production lines, mechanical, clamps…
Main pneumatic components

Pneumatic components can be divided into two categories:

1. Components that produce and transport compressed air.
2. Components that consume compressed air.
All main pneumatic components can be represented by
simple pneumatic symbols. Each symbol shows only the function of
the component it represents, but not its structure. Pneumatic symbols
can be combined to form pneumatic diagrams. A pneumatic diagram
describes the relations between each pneumatic component, that is,
the design of the system.
 The production and transportation of compressed air
Examples of components that produce and transport compressed air
include compressors and pressure regulating components.

Compressor
A compressor can compress air to the required pressures.
It can convert the mechanical energy from motors and engines into
the potential energy in compressed air.
A single central compressor can supply various pneumatic
components with compressed air, which is transported through pipes
from the cylinder to the pneumatic components. Compressors can be
divided into two classes;

1. Resiprocatory
2. 2.rotary

Pneumatic symbol of a compressor

 Pressure regulating component

Pressure regulating components are formed by various components, each of

which has its own pneumatic symbol:
(i) Filter – can remove impurities from compressed air before it is fed to the
pneumatic components.

(ii) Pressure regulator – to stabilise the pressure and regulate the operation of
pneumatic components
(iii) Lubricator – To provide lubrication for pneumatic components
 Pneumatic symbols of the pneumatic pressure
components within a regulating component

Different types of air compressor

Though the reciprocating air compressor is the most commonly used one,

there are also many different types of air compressors which are used in various

industries. Get the insight about the reciprocating air compressor and rotary

compressors like screw, lobe, vane and scroll compressors.

Introduction:
The usage of compressed air is not limited only to industries, but they

are also used in manufacturing, welding, constructions, power plants, ships,

automobile plants, painting shops, and for filling breathing apparatus too. Thus

there are so many types of air compressors used specifically for the above

purposes. Let us discuss on various types of air compressors.

Types of Air Compressors:

Compressors are classified in many ways out of which the common
 one is the classification based on the principle of operation.

1. Positive Displacement and

2. Roto-Dynamic Compressors.

Positive displacement compressors cab be further divided into Reciprocating

and rotary compressors.

Under the classification of reciprocating compressors, we have

 Reciprocating In-line Compressors:

These are most commonly used compressors with varying pressure ranges. These
are simple in design with almost very little automation. The cylinders of various
stages are found in a straight line when seen from top. These compressors are
commonly direct driven by electric motors or diesel engines. Refer the attached
diagram of the reciprocating in-line compressors.

 “V”-Shaped Compressors:
These are usually air cooled compressors with concentric valves mounted on each
cylinder head unit. The compressor has different units displaced usually by 90
degrees, may or may not be connected to same crank pin on the crank shaft. Higher
capacity compressors are water cooled. Better torque and balancing is achieved by
displacing the units by certain angle.

 Single-Acting Compressors:
These are usually reciprocating compressors, which has piston working on air only
in one direction. The other end of the piston is often free or open which does not
perform any work. The air is compressed only on the top part of the piston. The
bottom of the piston is open to crankcase and not utilized for the compression of
air.
 Double-Acting Compressors:
These compressors are having two sets of suction/intake and delivery valves on
both sides of the piston. As the piston moves up and down, both sides of the piston
is utilized in compressing the air. The intake and delivery valves operate
corresponding to the stroke of the compressor. The compressed air delivery is
comparatively continuous when compared to a single-acting air compressor. Thus
both sides of the pistons are effectively used in compressing the air.

 The rotary compressors are not of reciprocating nature, therefore does not have any
pistons and crankshaft. Instead, these compressors have screws, vanes, scrolls, and
other devices which rotate and thus compress air. The rotary compressors are
classified into screw type, vane type-lobe type, scroll type and other types.
 Rotary Compressors:
These compressors are not of reciprocating nature, therefore does not have any
pistons and crankshaft. Instead, these compressors have screws, vanes, scrolls, and
other devices which rotate and thus compress air. The rotary compressors are
classified into screw type, vane type-lobe type, scroll type and other types

The screw compressors are efficient in low air pressure requirements. Two
screws rotate intermeshing with each other, thus trapping air between the screws
and the compressor casing, forming pockets which progressively travel and gets
squeezed and delivering it at a higher pressure which opens the delivery valve. The
compressed air delivery is continuous and quiet in operation than a reciprocating
compressor

The Vane type Air Compressor is having a fixed casing and a rotary rotor
disc which has slots for holding the sliding plates as shown in the figure. As the
rotor rotates, the disc also rotates, thus allowing the sliding plates to slide as the
inner surface of the casing is eccentric. Thus the sliding plates moves away from
the center, huge quantities of air will be trapped in, thus as the plates converge, the
air gets compressed and thus results in compressed air.

The Scroll type compressors are having scrolls driven by the prime mover.
The scrolls outer edges trap air and then as they rotate, the air travel from outwards
to inwards thus getting compressed due to the reduction in the area. Thus the
compressed air is delivered through the central space of the scroll to the delivery
air line.

The Lobe type air compressor is very simpler type with no complicated moving
parts. There are single or twin lobes attached to the drive shaft driven by the prime
mover. The lobes are displaced by 90 degrees. Thus if one of the lobes is in
horizontal position, the other at that particular instant will be in vertical position.
Thus the air gets trapped in between these lobes and as they rotate they get
compressed and delivered to the delivery line.

LITERATURE

SURVEY
DUMP TRUK

A typical dump truck is equipped with an open-box bed, which is hinged at the rear
and equipped with hydraulic pistons to lift the front, allowing the material in the
bed to be deposited ("dumped") on the ground behind the truck at the site of
delivery.

Mercedes-Benz dump truck with eight-wheel drive

A dump truck (or, UK, dumper/tipper truck) is a truck used for transporting loose
material (such as sand, gravel, or dirt) for construction. In the UK and Australia the
term applies to off-road construction plant only, and the road vehicle is known as
a tipper, tipper lorry (UK) or tip truck (AU).
A 1927 Fruehauf Dump Trailer

History

A KenworthK-100 dump truck

The Graff &Hipple Wagon Dumper, ca. 1884, showing an early lever-based
dumping mechanism

The dump truck is thought to have been first conceived in the farms of late 19th
century Europe. developed a in 1896 with a tipper mechanism The first motorized
dump trucks in the United States were developed by small equipment companies
such as The Fruehauf Trailer Corporation|), Galion Buggy Co. and many others
around 1910. August Fruehauf had obtained military contracts for his semi-trailer,
invented in 1914 and later created the partner vehicle, the semi-truck for use in
World War I. After the war, Fruehauf introduced hydraulics in his trailers. They
offered hydraulic lift gates, hydraulic winches and a dump trailer for sales in the
early 1920s. Fruehauf became the premier supplier of dump trailers and their
famed "bathtub dump" was considered to be the best

The lifting device was a winch attached to a cable that fed over sheave (pulley)
mounted on a mast behind the cab. The cable was connected to the lower front end
of the wooden dump box which was attached by a pivot at the back of the truck
frame. The operator turned a crank to raise and lower the box. The first dump bed
apparatus on a wheeled vehicle patented in Canada

Types

Today, virtually all dump trucks operate by hydraulics and they come in a variety
of configurations each designed to accomplish a specific task in the construction
material supply chain.

Standard dump truck

A modern 405/UGN dump truck

An Ashok Leyland Comet dump truck, an example of a very basic 4 x 2 dump

truck used for payloads of 10metric tons (11.0 short tons; 9.8 long tons) or less

Another kind of 8x4 dump truck: three rear axles

A standard dump truck is a truck chassis with a dump body mounted to the frame.
The bed is raised by a vertical hydraulic ram mounted under the front of the body,
or a horizontal hydraulic ram and lever arrangement between the frame rail and the
back of the bed is hinged at the back of the truck. The tailgate can be configured to
swing up on top hinges (and sometimes also to fold down on lower hinges) or it
can be configured in the "High Lift Tailgate" format wherein pneumatic rams lift
the gate open and up above the dump body.

In the United States, a standard dump truck has one front steering axle, and one or
two rear axles which typically have dual wheels on each side. Tandem rear axles
are virtually always powered in the U.S., far less often in Europe. Most unpowered
rear axles can be raised off the pavement, to minimize wear and tear when the
truck is empty or lightly loaded, and lowered to become load-bearing when the
truck needs the extra support. These are referred to as lift axles or drop axles. Lift
axles can be steerable or non-steerable; steerable lift axles are always configured
with single wheels on each side, instead of dual

The largest of the standard European dump trucks is commonly called a

"centipede" and has seven axles. The rear two axles are powered, the front axle is
the steering axle, and the remaining four are lift axles. The intermediate axles are
present to support the weigh over the length of the chassis and sometimes to
provide additional braking power.

The shorter wheelbase of a standard dump truck often makes it more

Transfer dump truck

Example of a transfer truck and trailer

The second aggregate container on the trailer ("B" box),[12] is powered by an

electric motor, a pneumatic motor or an hydraulic line. It rolls on small wheels,
riding on rails from the trailer's frame into the empty main dump container ("A"
box).

Another configuration is called a triple transfer train, consisting of a "B" and "C"
box. These are common on Nevada and Utah Highways, but not in California.
Depending on the axle arrangement, a triple transfer can haul up to 129,000
kilograms (284,000 pounds) with a special permit in certain American states. As of
2007, a triple transfer costs a contractor about $105 an hour, while a A/B
configuration costs about $85 per hour.

Truck and pup

Truck and pup dump truck

A truck and pup is very similar to a transfer dump. It consists of a standard dump
truck pulling a dump trailer. The pup trailer, unlike the transfer, has its own
hydraulic ram and is capable of self-unloading.

Fruehauf super dump with GMC tractor

Super dump truck

A Super dump is a straight dump truck equipped with a trailing axle, a load-bearing
axle rated as high as 13,000 pounds (5,897 kg). Trailing 11 to 13 feet (3.35 to
3.96 m) behind the rear tandem, the trailing axle stretches the outer "bridge"
measurement—the distance between the first and last axles—to the maximum
overall length allowed. This increases the gross weight allowed under the federal
bridge formula, which sets standards for truck size and weight.

Semi trailer end dump truck

Semi trailer end dump truck

A semi end dump is a tractor-trailer combination wherein the trailer itself contains
the hydraulic hoist. A typical semi end dump has a 3-axle tractor pulling a 2-
axle semi-trailer. The key advantage of a semi end dump is rapid unloading. A key
disadvantage is that they are very unstable when raised in the dumping position
limiting their use in many applications where the dumping location is uneven or off
level.

Semi trailer bottom dump truck

Bottom dump trailer.

A semi bottom dump (or "belly dump") is a 3-axle tractor pulling a 2-axle trailer
with a clam shell type dump gate in the belly of the trailer. The key advantage of a
semi bottom dump is its ability to lay material, unlike the double and triple trailer
configurations described below. These trailers may be found either of the windrow
type shown in the photo, or may be of the "cross spread" type, with the gates
opening front to rear instead of left and right. The cross spread gates will actually
spread gravel fairly evenly the width of the trailer. By comparison, the windrow
gates leave a pile in the middle. The cross spreads tend to jam and may not work
well with coarse materials.

Double and triple trailer bottom dump truck

Double and triple bottom dumps consist of a 2-axle tractor pulling one single-axle
semi-trailer and an additional full trailer (or two full trailers in the case of triples).
These dump trucks allow the driver to lay material in without leaving the cab or
stopping the truck. The main disadvantage is the difficulty in backing double and
triple units.

The specific type of dump truck used in any specific country is likely to be closely
keyed to the weight and axle limitations of that jurisdiction. Rock, dirt and other
types of materials commonly hauled in trucks of this type are quite heavy, and
almost any style of truck can be easily overloaded. Because of that, this type of
truck is frequently configured to take advantage of local weight limitations to
maximize the cargo. For example, within the United States, the maximum weight
limit of 40 throughout the country, except for specific bridges with lower limits.
Individual states, in some instances, are allowed to authorize trucks up to 52.5
short tons (47.6 t; 46.9 long tons). Most states that do so require that the trucks be
very long, to spread the weight over more distance. It is in this context that double
and triple bottoms are found within the United States.
Side dump truck

Side Dump Industries Train Set.

A side dump truck (SDT) consists of a 3-axle tractor pulling a 2-axle semi-trailer.
It has hydraulic rams which tilt the dump body onto its side, spilling the material to
either the left or right side of the trailer. The key advantages of the side dump are
that it allows rapid unloading and can carry more weight in the western United
States. In addition, it is almost immune to upset (tipping over) while dumping,
unlike the semi end dumps which are very prone to tipping over. It is, however,
highly likely that a side dump trailer will tip over if dumping is stopped
prematurely. Also, when dumping loose materials stone, the side dump can
become stuck if the pile becomes wide enough to cover too much of the trailer's
wheels. Trailers that dump at the appropriate angle (50° for example) avoid the
problem of the dumped load fouling the path of the trailer wheels by dumping their
loads further to the side of the truck, in some cases leaving sufficient clearance to
walk between the dumped load and the trailer.

Winter service vehicles

Off-highway dump trucks equipment and share little to highway dump trucks.
Bigger off-highway dump trucks are used strictly off-road for mining and heavy
dirt hauling jobs. There are two primary forms: rigid frame and articulating frame.

The term ‘dump’ truck is not generally used by the mining industry, or by the
manufacturers that build these machines. The more appropriate U.S. term for this
strictly off road vehicle is "haultruck" and the equivalent European term is
'dumper'.

Haul truck

Haul trucks are used in large surface mines and quarries. They have a rigid frame
and conventional steering with drive at the rear wheel. As of late 2013, the largest
ever production haul truck is the 450 metricton 75710, followed by the T 282B,
the MT6300AC and the Caterpillar797F, which each have payload capacities of up
to 400 shorttons (363 t; 357longtons). Most large size haul trucks employ Diesel-
electric power trains, using the Diesel engine to drive an AC alternator or DC
generator that sends electric power to electric motors at each rear wheel

Articulated hauler

Articulated dump truck or dumper

An articulated dumper is an all-wheel drive, off-road dump truck. It has a hinge
between the cab and the dump box, but is distinct from a semi-trailer truck in that
the power unit is a permanent fixture, not a separable vehicle. Steering is
accomplished via hydraulic cylinders that pivot the entire tractor in relation to the
trailer, rather than rackandpinion steering on the front axle as in a conventional
dump truck. By this way of steering, the trailers wheels follow the same path as the
front wheels. Together with all-wheel drive and low center of gravity, it is highly
adaptable to rough terrain. Major manufacturers include Volvo CE, Terex, John
Deere and Caterpillar.

Dangers

Collisions

Dump trucks are normally built for some amount of off-road or construction site
driving; as the driver is protected by the chassis and height of the driver's
seat, bumpers are either placed high or omitted for added ground clearance. The
disadvantage is that in a collision with a standard car, the entire motor section or
luggage compartment goes under the truck. Thus, the passengers in the car could
be more severely injured than would be common in a collision with another car.
Several countries have made rules that new trucks should have bumpers
approximately 40 cm (16 in) above ground in order to protect other drivers better.

Tipping

Another safety consideration is the level of the truck before unloading. If the truck
is not parked on relatively horizontal ground, the sudden change of weight and
balance due to lifting of the skip and dumping of the material can cause the truck
to slide, or even to tip over.
Back-up accidents

Because of their size and the difficulty of maintaining visual contact with on-foot
workers, dump trucks can be a threat, especially when backing up. Mirrors
and back-upalarmsprovide some level of protection, and having a spotter working
with the driver also decreases back-up injuries and fatalities.
PNEUMATIC CYLINDERS

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. Engineers sometimes 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

GENERAL 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.

Compressibility of gasses

One major issue engineers come across working with pneumatic cylinders has to
do with the compressibility of a gas. Many studies have been completed on how
the precision of a pneumatic cylinder can be affected as the load acting on the
cylinder tries to further compress the gas used. Under a vertical load, a case where
the cylinder takes on the full load, the precision of the cylinder is affected the most.
A study at the National Cheng Kung University in concluded that the accuracy is
about ± 30 nm, which is still within a satisfactory range but shows that the
compressibility of air has an effect on the system.

Fail safe mechanism

Pneumatic systems are often found in settings where even rare and brief system
failure is unacceptable. In such situations locks can sometimes serve as a safety
mechanism in case of loss of air supply (or its pressure falling) and, thus remedy or
abate any damage arising in such a situation. Leakage of air from the input or
output reduces the pressure and so the desired output.

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 cylinders

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
Stroke length for this design is not limit. 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.

CONSTRUCTION DETAILS

COMPRESSOR

A compressor is a machine which provides high pressure air. An air

compressor takes in atmospheric air and compresses it to a high pressure. This
pressurized air is then delivered to storage vessel from which it can be conveyed to
the desired place through pipe lines. During the process of compression of a gas
work should be done upon it. Hence a compressor is drawn by prime mover
(motor). Some of the energy received by the compressor from the prime mover is
absorbed in work done against friction. Some portion of energy lost due to
radiation and coolant. The rest is maintained with in high pressure at delivered.

CYLINDER
 In small compressor, the cylinder is formed by precision boring the main
body which is constructed of closed grained cast iron. In large sized compressor,
the cylinder is made separately and fits into the main body. Such a cylinder is
called a cylinder sleeve or liner with a removable cylinder sleeve, it is a easier and
cheaper to replace a sleeve than the complete compressor body, when the
cylinder bore has worm out.

PISTON

A piston is a cylindrical metal plug that moves up and down in the cylinder.
Piston is made of cast iron or aluminum. The piston must be just loose to allow
leak back of the discharge gas from the top of the crank case. The clearance
between the cylinder and piston (The difference is the diameter of the cylinder
bore outside diameter of the piston) is filled with an oil film to provide lubrication
and also to obvious that the clearance should be quit low to retain this oil flim.

PISTON RINGS
 The piston rings are circular rings, fitted in the circumferent5isl grooves of
piston. There are two sets of rings. Upper rings are known as compression rings
which provide air tight seal. This present the leak of air into casing. The lower
rings are called oil scraper rings. The piston rings are made up of special steel.

PISTON PIN

The piston end of the connecting rod is attached to the piston by the
‘Piston Pin’ the piston pin usually titled in their piston and it is lock by use of circle
pin.

CONNECTING ROD

The is the connecting line between the piston and the crank shaft. The
converts the rotary motion of crank shaft in to the reciprocating motion of the
piston. The upper and of connecting rod is called small end which carries piston
by means of gudgeon pin. The lower end of connecting rod which connects the
crank through a crank pin. The connection rod is made up of nickel chromium
steel..
CRANK SHAFT

This is a main housing at the bottom of the cylinder. Providing support for
the cylinder and shaft bearing. The crank cases provide protection to the parts
described above from dust and also acts as lubrication sump. The crank case is
made up of cast iron.
 CLASSIFICATION OF COMPRESSOR

1. According to design and principle of operation

a. RECIPROCATING COMPRESSOR

It uses a cylinder in which the piston slides.

Reciprocating compressor may be further classified as:

 Single acting compressor:

In this type of compressor suction, compression and delivery air or gas takes
place on one side of piston.

 Double acting compressor:

In this type of compressor, suction, compression and delivery air or

gas takes place on both side of piston.

b. Rotary compressor:
 Rotary compressor may be classified as:

 Steady flow compressor:

(e.g. Centrifugal and axial flow)

 Displacement compressor:

(e.g. Root and vane blower)

In this type of compressor, compression of air from initial pressure to final

pressure takes place in one cylinder only.
Multi stage compressor:

In this type, air compressor from initial pressure to final pressure is carried
out in more than one cylinder.

1. According to pressure limit:

 Low pressure compressor:

Final delivery pressure of this of compressor is less than 1.0MN/m2.

 Medium pressure compressor:

Final delivery pressure of the type of compressor is 1.0MN/m2 to 8.

0MN/m2.

 High pressure compressor:

Final delivery pressure of this type of compressor is ;8.0 to 10 MN/m2.

2. According to capacity:

 Low capacity compressor:

It delivers 0.15m3/s of compressed air.

 Medium capacity compressor:

It delivers up to 5m3/s of compressed air.

 High capacity compressor:

It delivers more than 5m3/s of compressed air.

3. According to method of cooling:

 Air cooled compressor:

It uses air for cooling purposes.

 Water cooled compressor:

It uses water for cooling purposes.

4. According to method of installation:

 Portable compressor
 Semi fixed compressor
 Fixed compressor

5. According to application:

 Rock drill compressor

 Quarrying compressor
 Sand blasting compressor
 Spray painting compressor
 The word ‘pneuma’ comes from Greek and means breather wind. The
word pneumatics is the study of air movement and its phenomena. It is derived
from the word pneuma. Today pneumatics is mainly understood to mean the
application of air as a working medium in industry, especially the driving and
controlling of machines and equipments.
Pneumatic systems operate on a supply of compressed air, which
must be made available in sufficient quantity and at a pressure to suit the
capacity of the system. When the pneumatic system is being adopted for the first
time, however it will indeed the necessary to deal with the question of
compressed air supply. The key part of any facility for supply of compressed air is
by means using reciprocating compressor. A compressor is a machine that takes
in air/gas at a certain pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered

and the volume expressed is that of the air at intake conditions namely at
atmosphere pressure and normal ambient temperature. The compressibility of
the air was first investigated by Robert Boyle in 1962 and that found that the
product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C (or) Pı Vı = P2V2

In this equation the pressure is the absolute pressure which for free air is
about 14.7 Psi and is capable of maintaining a column of mercury, nearly 30
inches high in an ordinary barometer. Any gas can be used in pneumatic system
but air is the mostly used system now a days.
SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort

by mechanical power. Pneumatic is an attractive medium for low cost
mechanization particularly for sequential (or) repetitive operations. Many
factories and plants already have a compressed air system, which is capable of
providing the power (or) energy requirements and 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 out
standing advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be

made available. In sufficient quantity and at a pressure to suit the capacity of the
system. When pneumatic system is being adopted for the first time, however it
wills indeed the necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air/ gas at a
certain pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered

and the volume expressed is that of the air at intake conditions namely at
atmosphere pressure and normal ambient temperature. Clean condition of the
suction air is one of the factors, which decides the life of a compressor. Warm and
moist suction air will result in increased precipitation of condense from the
compressed air. Compressor may be classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor
Positive displacement compressors are most frequently employed for
compressed air plant and have proved highly successful and supply air for
pneumatic control application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor
Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic
control application unless built in multistage designs and are seldom
encountered in pneumatic service.

RECIPROCATING COMPRESSORS
Built for either stationary (or) portable service the reciprocating
compressor is by far the most common type. Reciprocating compressors lap
be had in sizes from the smallest capacities to deliver more than 500 m³/min.
In single stage compressor, the air pressure may be of 6 bar machines
discharge of pressure is up to 15 bars. Discharge pressure in the range of 250
bars can be obtained with high pressure reciprocating compressors that of
three & four stages.
 Single stage and multi stage models are particularly suitable for pneumatic
applications, with preference going to the two-stage design as soon as the
discharge pressure exceeds 6 bars, because it is capable of matching the
performance of single stage machine at lower costs per driving powers in the
range.
SPRINGS

Springs are the elastic bodies which absorb energy due to resilience.
The absorbed energy is released as and when required.

Springs placed a major role in this project. The design of spring

depends only on the axial load in the speed breaker. When the load applied
increases (or) decreases, the design of the spring is changed i.e., the load is
directly related with design spring.

Types of springs and material selection and spring design will as

follows.

5.1 TYPES OF SPRING

5.1.1 Helical Springs

The helical springs are made up of a wire coiled in the form of a helix
and is primarily intended for compressive (or) tensile loads.

It further divided into

(i) Open coil helical spring
(ii) Closed coil helical spring
 The helical springs are said to be closely coiled. When the spring wire is coiled
so close that the plane containing each turn is nearly at night angles to the axis
of the helix and wire is subjected to torsion. In this bending and tangential force
is negligible.

In the open coiled helical spring the helix angle is greater than 100

and the gap between the two consecutive turns are large.

5.1.2 Conical and volute springs

The conical springs are the springs where the spring rate that
increases with the Load is desired and the pitch is uniform.

The volute springs are the springs similar to that of conical spring but the wound is
in the form of paraboloid.

5.1.3 Torsion springs

There are the springs which are mainly applied where the load wind
up the spring. Torsion spring of spiral type is used in watches and clocks
where the coils are in flat strip.
5.1.4 Laminated spring

The laminated spring consist of a number of flat plates(leaves) of

varying lengths held together by means of clamps and bolts. These springs
are mainly used in automobiles.

5.1.5 Disc spring

These springs consist of a number of conical discs held together

against slipping by a central bolts.

The springs classified according to services as

1. Severe service
2. Average service
3. Light service

SEVERE SERVICE

Severe service means rapid continuous loading where the ratio of

minimum to maximum load is one-half (or) less.
 AVERAGE SERVICE
Average service have the same stress range as in severe service but
with only intermittent operation.

LIGHT SERVICE
Light service includes springs subjected to loads that are static (or) very
frequently varying as in safety valve spring.
SPRING MATERIAL SELECTION

5.2.1 MATERIAL FOR HELICAL SPRINGS

1. High fatigue strength

2. High ductility
3. High resilience
4. Creep resistant
The springs are mostly made from oil- tempered carbon steel wires
containing 0.60 to 0.70 percent carbon and 0.60 to 1.0 present manganese
Music wire is used for small springs.

For the special purposes, to increase fatigue resistance, temp

resistance, and corrosion resistance we use non-ferrous materials like
phosphor bronze beryllium copper, Monel metal, brass etc.,

AIR COMPRESSOR

COMPRESSORS

The main function of the air compressor is to compress the air up to the
required pressure. The maximum capacity of the compressor is 10105 to 12 105
N/m2. It is a two stages or two-cylinder reciprocating air compressor. The two
cylinders are for low and high compression. The air pressure is measured at
various places by the use of pressure gauges. V-belt and pulley are used to drive
the compressor. Compressors can be broadly classifieds into two groups. They
are:

Positive Displacement Compressor

 Dynamic Compressors
 Non-positive Displacement Compressors

Positive Displacement Compressor

Successive volumes of air isolated and then compressed to a higher
pressure. There are essential two forms of positive displacement compressor,
reciprocating and rotary.

Dynamic compressors

These are rotary continuous machines in which a high speed-rotating

element accelerates the air and converts the resulting velocity head into pressure.

Positive displacement compressors, work on the principle of increasing the

pressure of a definite volume in an enclosed chamber. Dynamic (turbo)
compressor employs rotating vanes or impellers to impart velocity and pressure
to the flow of the air being handled. The pressure comes from the dynamic
effects such as centrifugal force.

SELECTION CRITERIA FOR COMPRESSORS

 A number of factors are involved in the selection criteria of a suitable air
compressor. These are dealt here briefly
1. Pressure
First of all, the pressure needed must be determined. Most air operated
system and tools are designed to operate at a pressure from 6 105 to 7105N/m2. A
compressor of normal make and type would normally be suitable if this can assure
a pressure 6 105 N/m2 in the distribution line laid down for a pneumatic tools and
system.
2. Capacity
Another important factor in compressor selection is the capacity or
volume of air required. This factor is sometimes extremely difficult to evaluate.
Obviously, the unit selected should be large enough to supply all the air devices,
which will be operating at any given time. If all the air operation is continuous, the
capacity required is simply the sum of air compression of each individual tool.

Pressure Gauge
Pressure gauge is used for measuring the outlet pressure of air from the
compressor. The gauge used is Bourdon type pressure gauge. The maximum
capacity of this gauge is 10 105 to 12 105 N/m2. The gauge is fitted at the outlet
of the air compressor.

PHYSICAL PRINCIPLES

AIR
The earth is surrounded by air up to a height of 1600 kilometers above the
top surface of the earth. We known that air nearer to the earth is denser while as
we go up, the density of air stats decreasing. This gaseous layer of air around the
earth is known as atmosphere. Air is invisible, odorless, colorless and tasteless.
 The main constituents of air by volume are 78% nitrogen, 21% oxygen. 1%
carbon dioxide, other gases including some amount of amount of water vapors.
Though all these components of air are found to retain their individual properties,
for all practical purposes, air, which is a mixture of various chemical elements,
follows the gas laws, just like any perfect or ideal gases.

BASIC SYSTEM
In modern industries, pneumatic system is used, as a means of workplace
mechanization and automation where a major part of manual and tedious work
may be supplemented by pneumatic controls is quick and economic production.

SELECTION OF PIPELINE FOR PNEUMATICS SYSTEM

In most plants, the air compressor is positioned at a distance away from the
main shop and installation area that is from the actual, point of consumption due to
the reasons of air borne noise problem or due to the reasons related to the machine
safety and other operational problems like transmission of vibration to other
equipment. The compressed air is stored in air receiver from which the air is drawn
into the consumer point by means of pipeline.
 The following factors are taken into account while selecting pneumatic
pipes and other air line installations.

 Pressure of compressed air in the line.

 Total flow rate per unit time through the line.
 Permissible pressure drops in the line.
 Type of tube material and type of line fittings.
 Length and diameter of tubes or other pipelines.
 Working environment etc.,

PIPE MATERIALS

If the system pressure is quite high material of pipes and metallurgical

properties became an important parameter for their correct selection. But as the
pneumatic system usually works at a much lower pressure in comparison to
hydraulic system, one may not need super high strength material for pneumatic
pipeline and fittings.

Materials, which are mostly used, for pneumatic pipes and tubes are listed
below:

 Galvanized iron pipes (GI pipes)

 Cast iron pipes
 Copper tube
 Aluminum pipes
 Rubber hose
  Plastic & nylon hose
 High strength pipes
 Brass tubes
 Reinforced rubber or plastic hose

Though all the above materials are widely used for pneumatic lines, flexible
material are more suitable for absorption of shocks, and hence find extensive use
in pneumatic system.

For air means, standard wrought iron pipes or galvanized iron pipes are
quite satisfactory. The supply to the pneumatic circuit is generally branched off in
copper, brass or synthetic tubes in most cases.

PRESSURE RATING FOR PIPE MATERIALS

Due to low-pressure application of pneumatics this may not be important
criterion for selection of tubes for compressed air system. But the maintenance
mechanic should have an idea of the pressure range for all these pipe materials.
Table given below gives the tolerable pressure range for some common types of
piping:
S.No Pipe Material Max. pressure(bar)

1. Copper 250

2. Aluminum 125

3. Brass 200

4. Stainless steel 2500-4500

5. Polthene 12-15
80deg

6. Nylon 100deg 7-10

7. Vinyl 25deg 8-10

8. Rubber 80 deg 3-7

APPLICATION OF PNEUMATICS

The technology of pneumatics deals with the study off the behavior and
application of compressed air. Though the science of air was known to man for
centuries, it was not much used in industry before the beginning of Second World
War. The applications of pneumatics in industries are more advantages and
exceptionally suitable in handling. The following features are suitable.

 Wide availability of air

 Compressibility of air
 Easy transportability of compressed air in pressure vessels, containers and
large pipes
 Fire proof characteristic of the medium
  Simple construction of pneumatics and easy handling
 High degree of controllability of pressure, speed and force
 Possibility of easy but reasonably reliable remote controlling
 Easier maintenance
 Explosion proof characteristic of the medium
 Comparatively cheaper in cost than other systems
ADVANTAGES AND CHARACTERISTICS OF COMPRESSED AIR

Availability
Air is available practically everywhere in unlimited quantities.

Transport
Air can be easily transported in pipelines, even over large distances

Storage
A compressor need not be in continuous operation. Compressed air can be
stored in a reservoir and removed as required. In addition, the reservoir can be
transportable.

Temperature
Compressed is relatively insensitive to temperature fluctuations. This
ensures reliable operations, even under extreme conditions.
Cleanliness
Un lubricated exhaust air is clean. Any un lubricated air which escapes
through leaking pipes or components does not cause this is an contamination.
Important point, when considering the food wood and textile industries.

Components
The operating components are of simple construction and are therefore
relatively inexpensive.

Speed
Compressed air is a very fast working medium. This enables high working
speeds to be attained.

Adjustable
With compressed air components, speeds and forces are infinity variable.

Overload safe
Pneumatic tools and operating components to the point of stopping and
are therefore overload safe. In order to accurately define the areas of
applications of pneumatics, it is also necessary to be acquainted with the negative
characteristics.

Preparation
Compressed air requires good preparation. Dirt and condensate should not
be present.
Force requirement

Compressed air is economical only up to a certain force requirements.

Under the normal working pressure of 6 to 7 bar and dependent on the travel and
speed, the output limit is between 20000 and 30000 newton.

Noise Level
The exhaust air is loud. This problem is now however, been largely solved
due to the development of sound absorption materials and silencers.

Costs
Compressed air is a relatively expensive means of conveying power. The
high energy cost is partially compresated by inexpensive components and high
performance.

A comparison with other forms of energy is an essential part of the

selection process, when considering pneumatics as a control of working medium.
This evaluation embraces the total system form the input signal through the
output devices. All factors must be considered such as

 Work or output requirements

 Systems currently installed which are to be integrated with the new project
 APPLICATIONS

o All highways
o All road ways Speed brake

DISADVANTAGES

 Pushing Arrangement is required in the speed brake

 Mechanical moving parts is high
 CONCLUSION

First of all we thank every one contributing for the grand success of our project.

“KNOWLEDGE IS POWER”

The knowledge were we gained has been spent for the same. In addition, we are

glad about our optimistic and creative thinking which leads society from front.

The project developed for the sake of human lives has been

dedicated to themselves as a TRIBUTE.