PNEUMATIC QUICK RETURN MECHANISM

SYNOPSIS

The Pneumatic quick return mechanism is designed to quickly return the tool
in return stoke. The machine is exclusively intended for mass production and they
represent fasten and more efficient way to operate the engine.

NEED FOR AUTOMATION

Nowadays almost all the manufacturing process is being automised in order to
deliver the products at a faster rate. The manufacturing operation is being
automised for the following reasons.

 To achieve mass production

 To reduce man power
 To increase the efficiency of the plant
 To reduce the work load
 To reduce the production cost
 To reduce the production time
 To reduce the material handling
 To reduce the fatigue of workers
 To achieve good product quality
 Less Maintenance

1
 1. DESIGN METHODS OF NEW DESIGNS

Machinery Accidents

The ideal solution is to take a system-wide approach to preventing the

machine accident. The system includes not just the machine and the operator;
but rather, it includes everything from the initial design of the machine to the
training of everyone that is responsible for any aspect of it, to the documentation
of all changes, to regular safety audits and a finally a corporate culture of safety-
first.

Design is the part of a machine's life where the greatest impact can be made in
relation to avoiding accidents. The designer should ensure that the machine is
safe to set up and operate, safe to install, safe to maintain, safe to repair, and safe
to decommission. Although safe operation is usually at the forefront of a
designer's mind, safe maintenance and repair should also be a high priority.
Around 50% of fatal accidents involving industrial equipment are associated
with maintenance activities, and design is a contributory factor in some 32% of
these fatalities. The designer should make the machine as reliable as reasonably
possible to minimize the maintenance requirement and allow for long intervals
between routine maintenance tasks. It is also important to design the machine
and its control system so that maintenance can be carried out safely. For
example, hold-to-run controls can be installed that allow a machine to be run at a
reduced speed, or removable tool holders can be used so that sharp blades can be
replaced on a workbench instead of in an difficult position inside a machine. In
addition, operators and maintenance technicians must be discouraged from
bypassing safety equipment.

2
Safety components are often designed to interrupt processes in the event of a
fault and will have an impact on machine availability. In order to minimize this
effect - and the temptation to interfere with the safety circuits - high-reliability
safety components should be specified so as to keep the number of nuisance
faults at a minimum. Designing safety into a new machine is important, but it
has to be remembered that the vast majority of machines do not remain
unaltered, with unchanged operating procedures, for their entire lifetime.
Modifications are almost inevitable and working practices can evolve or be
deliberately revised by managers in an attempt to improve throughput. Any
changes made to the machine or the way it is operated also changes the original
risk assessment. Research has shown that a significant number of industrial
accidents result from uncontrolled changes. It is usually via a complex sequence
of events that a change leads to an accident.

Clearly it is necessary to ensure that machinery and operating procedures

are fully documented. Even if a machine and its associated safety systems are all
properly designed and documented, it is vital that the machine is monitored
during installation, commissioning and first-off production. Often it is necessary
to make small changes during any or all of these stages. It is imperative that any
proposed change is first subjected to a rigorous risk assessment, and any changes
that are implemented must be fully documented. After production has
commenced, a further review should take place to make certain that no further
changes have been made. Note also that "no further changes" also refers to the
raw materials or components that are being processed by the machine.

Audits should be undertaken on a regular basis to check that the machine

and operating procedures are still in the documented state. Furthermore,
functional audits should also be carried out on the machinery safety systems.
3
Often the components in a safety control system are only used in the event of an
emergency, which can make them very difficult to test. Nonetheless these
systems should be tested at regularly scheduled intervals. Safety fieldbuses such
as AS-i Safety At Work (AsiSafe) and Profisafe can support intelligent field
devices able to perform self-monitoring functions and transmit diagnostic data to
a central controller that can alert the machine operator prior to the failure
becoming an unacceptable risk.

Education and training is another aspect of the company-wide approach to

machinery safety. Increasingly complex modern machinery makes education and
training ever more important. There are new standards and regulations with
which companies must comply. On-the-job experience may have sufficed in the
past but this is unlikely to be acceptable in the future. Obviously training for
machine operators and maintenance technicians is a requirement, but there is
also an important need for more general education of the workforce and
management in order to generate a safety-first corporate culture.

Machine Safety :

The ideal solution is to take a system-wide approach to machine safety.

The system includes not just the machine and the operator; but rather, it includes
everything from the initial design of the machine to the training of everyone that
is responsible for any aspect of it, to the documentation of all changes, to regular
machine safety audits and a finally - and perhaps most importantly - a corporate
culture of safety-first.

Design is the part of a machine's life where the greatest impact can be
made in relation to safety. The designer should ensure that the machine is safe to

4
install, safe to set up, safe to operate, safe to maintain, safe to repair and safe to
decommission. Safe operation is usually at the forefront of a designer's mind, but
safe maintenance and repair should be of at least as high a priority. Around 50%
of fatal accidents involving industrial equipment are associated with
maintenance activities. Design is a contributory factor in some 32% of these
fatalities. The designer should make the machine as reliable as reasonably
possible to minimize the maintenance requirement and allow for long intervals
between routine maintenance tasks. The machine and its control system should
also be designed so that maintenance can be carried out safely. For example,
hold-to-run controls can be installed that allow a machine to be run at a reduced
speed, or removable tool holders can be used so that sharp blades can be
replaced on a workbench instead of in an difficult position inside a machine. In
addition, operators and maintenance technicians must be discouraged from
bypassing safety equipment.

Machine safety components are often designed to interrupt processes in

the event of a fault and will have an impact on machine availability. In order to
minimize this effect - and the temptation to interfere with the safety circuits -
high-reliability machine safety components should be specified so as to keep the
number of nuisance faults at a minimum. Designing safety into a new machine is
important, however most machines do not remain unaltered, with unchanged
operating procedures, for their entire lifetime. Modifications are almost
inevitable and working practices can evolve in an attempt to improve
throughput. Any changes made to the machine or the way it is operated should
first be subjected to a risk-assessment. Research has shown that a significant
number of industrial accidents result from uncontrolled changes. It is usually via
a complex sequence of events that a change leads to an accident.

5
 The machine's operating procedures must be fully documented. Even if
the machine safety systems are all properly designed and documented; the
machine must be monitored during installation, commissioning and initial
production. Sometimes personnel will make small changes during any or all of
these stages. These changes must first be subjected to a rigorous risk assessment,
and any that are implemented must be documented. After going into production,
a further review should take place to make certain that no further changes have
been made. Note also that "no further changes" also refers to the raw materials
or components that are being processed by the machine.

Regularly scheduled audits should be performed to ensure that the

machine and operating procedures are still in the documented state. Functional
audits should also be carried out on the machinery safety systems. Often the
components in the machine safety control system are only used in the event of
an emergency, which can make them very difficult to test. Nonetheless these
systems should be tested at regularly scheduled intervals. Safety fieldbuses can
support intelligent machine devices able to perform self-monitoring functions
and transmit diagnostic data to a central controller. The central controller can be
programmed to alert the machine operator prior to the failure becoming an
unacceptable risk.

The company-wide approach to machine safety must also include

education and training. Increasingly complex modern machinery makes this
increasingly important. There are new standards and regulations with which
companies must comply. On-the-job experience may have sufficed in the past
but this is unlikely to be acceptable in the future. Training for machine operators
and maintenance technicians is a requirement. There is also an important need

6
for more general education of the workforce and management in order to
generate a safety-first corporate culture.

Industrial Accidents & Workplace Accident :

This is an extremely broad category covering everything from small spills

in the workplace to huge disasters such as the Bhopal tragedy that killed
thousands of people and forced the evacuation of hundreds of thousands. I will
categorize industrial accidents into two categories. One being external accidents
that affect the environment around the factory and the other being internal
accidents that affect the people within the factory or worksite.

External industrial accidents can take the form of fires, chemical spills,
discharges of toxic gases and radiation. These types of accidents can be huge
disasters with effects that cross international boundaries. Causes of these
industrial accidents include: organizational errors, human factors, component
failures, deviation from normal operational conditions, software defects, outside
interference and natural forces.

Internal industrial accidents can involve transmission machinery,

metalworking machines, woodworking machines, agricultural machines,
construction machinery and equipment, textile machines, tire-making machines,
food-making machines, printing machines, lifting equipment, pressure vessels,
furnaces, refrigerators, hand tools, ladders and scaffolding.

Worker's compensation laws generally protect the employer from lawsuits

brought by injured workers, though in some cases where the employer is aware
of unsafe conditions and fails to correct the problems there may be liability. The
worker's compensation laws do not protect the makers of the machinery so

7
product liability lawsuits may follow industrial accidents. Similarly, contracting
companies that provide maintenance or training services may find themselves
involved in lawsuits after an accident.

1.1 DESIGN METHOD FOR NEW MACHINES

The designer should make the machine as reliable as reasonably possible

to minimize the maintenance requirement and allow for long intervals between
routine maintenance tasks. It is also important to design the machine and its
control system so that maintenance can be carried out safely.

For example, hold-to-run controls can be installed that allow a machine to

be run at a reduced speed, or removable tool holders can be used so that sharp
blades can be replaced on a workbench instead of in an difficult position inside a
machine. In addition, operators and maintenance technicians must be
discouraged from bypassing safety equipment.

Safety components are often designed to interrupt processes in the event

of a fault and will have an impact on machine availability. In order to minimize
this effect - and the temptation to interfere with the safety circuits - high-
reliability safety components should be specified so as to keep the number of
nuisance faults at a minimum.

Designing safety into a new machine is important, but it has to be

remembered that the vast majority of machines do not remain unaltered, with
unchanged operating procedures, for their entire lifetime.

8
 2. NEED FOR SAFETY SYSTEM IN MACHINERY

Modifications are almost inevitable and working practices can evolve or

be deliberately revised by managers in an attempt to improve throughput. Any
changes made to the machine or the way it is operated also changes the original
risk assessment. Research has shown that a significant number of industrial
accidents result from uncontrolled changes. It is usually via a complex sequence
of events that a change leads to an accident.

Clearly it is necessary to ensure that machinery and operating procedures

are fully documented. Even if a machine and its associated safety systems are all
properly designed and documented, it is vital that the machine is monitored
during installation, commissioning and first-off production. Often it is necessary
to make small changes during any or all of these stages.

It is imperative that any proposed change is first subjected to a rigorous

risk assessment, and any changes that are implemented must be fully
documented. After production has commenced, a further review should take
place to make certain that no further changes have been made. Note also that "no
further changes" also refers to the raw materials or components that are being
processed by the machine. Audits should be undertaken on a regular basis to
check that the machine and operating procedures are still in the documented
state.

Furthermore, functional audits should also be carried out on the

machinery safety systems. Often the components in a safety control system are
only used in the event of an emergency, which can make them very difficult to
test. Nonetheless these systems should be tested at regularly scheduled intervals.

9
 Safety field buses such as AS-i Safety At Work (AsiSafe) and Profisafe
can support intelligent field devices able to perform self-monitoring functions
and transmit diagnostic data to a central controller that can alert the machine
operator prior to the failure becoming an unacceptable risk.

Education and training is another aspect of the company-wide approach to

machinery safety. Increasingly complex modern machinery makes education and
training ever more important. There are new standards and regulations with
which companies must comply. On-the-job experience may have sufficed in the
past but this is unlikely to be acceptable in the future.

Obviously training for machine operators and maintenance technicians is

a requirement, but there is also an important need for more general education of
the workforce and management in order to generate a safety-first corporate
culture.

10
 3. GENERAL DESCRIPTION

3.1 PRODUCTION OF COMPRESSED AIR:

Pneumatic systems operate on a supply of compressed air, which must be
made available in sufficient quantity end at a pressure to suit the capacity of the
system. When a pneumatic system is being adopted for the 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 the compressor. A
compressor is a machine that takes in air, gas or vapours at any certain pressure
and delivers 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.

A clean condition of the suction air is one of the factors, which decides the life
of the compressors. Warm and moist air will result in compressors may be
classified into two types, namely

1. positive displacement compressors

2. Turbo compressors.

Positive displacement compressors are most frequently employed for

compressed air plants and have proved highly successful to supply air for
pneumatic control application.

11
The types of positive compressors are,
a. Reciprocating type compressors
b. Rotary type compressors.

Turbo compressors are employed where large capacity of air is required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
applications unless built in multi stage designs are seldom encounted in
pneumatic service.

3.2RECIPROCATING COMPRESSOR:
Built for either stationary or portable service, the reciprocating
compressor is by for the most common type. Reciprocating compressor can be
had in sizes from the smallest capacities to deliver more than 500cu.m/min.in
single stage compressor; the air pressure may be of 6 bars and in exceptional
cases up to 10 bars, two stage 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 these and four stages.

Single stage and two stage models are particularly suitable for pneumatic
application with reference going to the two stage design as soon as the discharge
pressure exceeds 6 bars, because it is capable of matching the performance of a
single stage machine at lower costs per driving power in the range.

12
3.3 PRESS TOOLS
Die is the lower part of the press tools and the punch is upper part of the
press tool. These both together are called as press tools. Press tools are used to
do various operations.

3.4 PRINCIPLE OF OPERATION OF A PRESS

Every press has got certain basic units. They are frame, sliding ram, drive
for the ram and power source.
Base or bed is the lower part of the press frame. A thick plate called
bolster plate is placed on the top of the bed. A die is fitted on the top of the
bolster plate. The driving mechanism is mounted on the frame. The frame has
got guide ways for the sliding movement of the ram. The driving mechanism is
connected to the ram. The punch is fitted at the bottom of the ram. The die and
punch are correctly aligned. The work piece is in the form of sheet metal. It is
fed over at the die. When the ram comes down, the punch presses the sheet
metal. The required operation is carried out.
As said earlier the force from the press is used to do a particular operation.
This is done by two main parts die and punch.

DIE:
Die is the lower part of the press tool. It is clamed on to the bolster plate of the
press. It remains stationary during the operation. The die has a capacity suitable
or respective profile to receive the punch. The cavity may or without a clearance.

13
PUNCH:
Punch is the upper part of the press tool. It is attached to the lower end of the
ram of the press. It slides with the press ram during the operation and is forced
in the die cavity.

The die and punch must be in perfect alignment for proper operation. Materials
used for punch and die,
1. High speed steel
2. Starlit or cemented carbide.

PRESS ACCESSORIES:
The various accessories along with the punch and die are
1. Stop
2. Pilot
3. Stripper
4. Knock out
5. Pressure pad

SPECIFICATION AND CAPACITY OF PRESS:

1. Capacity
2. Maximum stroke length of the ram
3. Die space
4. Type of drive
5. Type of frame
6. Number of slides
7. Weight and floor area.

14
TYPES OF PRESSES:
1. According to the type of press
a) Hand press
b) Power press
2. According to the type of frame
a) OBI
b) Adjustable
c) Horn
d) Straight slide
e) Pillar
3. According to the driving mechanism
a) Crank and connecting rod
b) Eccentric
c) Knuckle joint
d) Toggle drive
e) Screw
f) Rack and Pinion
g) Hydraulic
4. According to the number of slides
a) Single acting
b) Double acting
c) Triple acting
Also the press tool consisting of die and punch are differentiated for the various
operations to be done on it.
a. Shearing dies – for blanking, cutting, punching, slitting
b. Drawing dies – for drawing purpose
c. Bending dies – for bending operations
15
 d. Squeezing die – for coining, embossing, and flattening operations
e. Punching die – for punch the work materials
But based on the construction of die they are classified further as,
1. Simple die:
Simple die can perform only one operation at each stroke of the ram. It
consists of one punch and one die.
2. Compound die:
A compound die can perform two or more operations in stroke of the
press at a single station.
3. Combination die:
These die can perform two dissimilar simulations operations at the same
workstation
4. Progressive die:
Progressive dies can perform two or more press operations one after
another every time the ram moves down.

MECHANICAL ADVANTAGE
Mechanical advantage can be defined as the ratio or the load lifted to the
power or effort applied in the system to overcome the load successfully.
This is applied by using lever,
Mechanical advantage = w/p = load/effort

CLEARANCE
It is the space between the mating members of a die set. Proper clearance
between cutting edge enable features to meet and the fractured position of the
shared edge has a clear appearance. For optimum finish of cut edge , proper

16
clearance is necessary and is a function of the kind thickness and temper of the
work material.

PUNCH CLEARANCE
For complete clearance of the metal is necessary that the punch
should enter in to the cavity of the die block.
The space between each face of the die block and the corresponding face of the
punch block and the corresponding face on the die is called punch clearance.
The amount of clearance depends upon the type of material and the thickness of
the blank being should share. The usual value of the punch clearance is 5% to
8% of the plate thickness. If the punch clearance, the fracture fails to meet at the
center. If the punch clearance is too great, then the punch and die will operate
like a drawing die.

DIE CLEARANCE
The operating of the die is slightly conical extending from the cutting
edge. The metal is backed off all around the cutting edge to provide relief. The
clearance is usually ¼ degree which may be more or less according to the type
of material being punched. The die clearance is also serves to provide relief to
punched metal to fall through without getting struck up in the die cavity.

ANGULAR CLEARANCE
This is defined as the clearance below the straight portion of die surface
introduced for the purpose of enabling the blank or the slug (piercing operation)
to clear the die. Angular clearance is usually ground from ¼ degree to 4 degree
per side depending mainly on stock thickness and the frequency of sharpening.

17
LEVERS
A lever is a rigid rod or bar capable of turning about a fixed point called
fulcrum. Lever is used as a machine to apply r lift a load with less effort. The
force applied by the lever may be parallel or inclined to one another.

PRINCIPLE OF LEVERS
The points A and B through which the load and effort is applied are
known as load and effort point respectively. F is the fulcrum about which the
lever is capable of turning. The perpendicular distance between the load point
and the fulcrum is known as the load arm. The perpendicular distance between
the effort point and the fulcrum is called as effort arm.

L2 L1

W
P

Taking moments about the fulcrum points,

18
W * L1 = P * L2

The ratio of effort arm to parallel arm L2/L1 is called leverage.

The displacement of effort to the displacement of load is called as the

displacement ratio. To obtain great leverage compound levers may be used. In a
compound lever, the leverage is the product of leverages of various levers.

TYPES OF LEVERS
a) First type lever
The fulcrum is in between the load and the effort arm. Effort arm is greater than
the load arm. Mechanical advantage is more than one.
b) Second type lever
The load is in between the fulcrum and the effort. The effort arm is more than
the load arm. So mechanical advantage is more than one.
c) Third type lever
The effort arm is in between the fulcrum and the effort arm. The effort is less
than load arm. Mechanical advantages are less than one.

MECHANICAL SYSTEM
In this mechanical system, the mechanical operations are used for the
movement of the punch or die. The drive for the movements of the punch is
obtained by various mechanical systems. The various types of mechanical
systems used for driving the punch are,
1. Crank and connecting rod drive
2. Eccentric drive
19
 3. Knuckle joint drive
4. Cam drive
5. Toggle lever drive
6. Screw drive
7. Rack and pinion drive

1.Crank and connecting rod drive

This is the simplest and most common method of drive. Here the crank shaft
is driven by the motor. The ram is connected to the crank by a connecting rod.
So when the crank shaft rotates the ram reciprocates. This type of drive used to
get long stroke lengths of the ram.

2. Eccentric Drive
An eccentric is made integral with the driving shaft. One end of the
connecting rod has housing. This fits on eccentric. The other end of the
connecting rod is connected to the ram. The driving shaft rotates with the
eccentric. So the ram reciprocates. This type drive is used for shorter stroke
lengths or ram.

3. Knuckle joint drive

The knuckle joint drive has two knuckle levers and one connecting lever. One
end of the upper knuckle lever is pivoted to the crown of the machine. One end
of the lower lever is connected to the ram. A pin joints the other end of the
knuckle levers and one end of the connecting lever. The other end of the
connecting lever is connected to the crank of the crank shafts. When the crank
shaft rotates, the ram reciprocates. Heavy loads can be applied in the press.

20
4. Cam drive
In this press the driving shaft has a cam. The upper part of the connecting rod
has housing. The housing fits over the cam. The other end of the connecting rod
is connected to the ram. When the driving shaft rotates, the cam actuates the ram
to reciprocate. This gives shorter stroke length of the ram.

5.Toggle lever drive

In this drive the two toggle levers. These levers are pivoted at their center to
the machine frame. The bottom of the toggle levers are connected to the ram
through small links. The upper part of the toggle lever and one end of the
connecting lever are joined together by pin. The other end of the connecting
lever is fitted to the crank. The crank is rotated by the driving shaft. When the
crank rotates due to the toggle levers the ram actuated to move up and down.
This drive gives a shorter length of the ram.

6.Screw drive
Here the ram is loosely connected to the screw. The screw passes through the
stationary nut. The top end of the screw is connected to a flywheel. The
periphery of the flywheel is in contact with a friction disc. When the friction disc
rotates the screw also rotates. The screw moves down and so the ram also
moves down. The ram does not rotate. The ram reaches the bottom of the stroke,
the friction disc reverses and the ram moves up. This screw drive is used for the
longer stroke length. The movement of the ram is uniform in this drive.

7.Rack and pinion drive

In this drive, the ram is connected to a long rack. The rack is in mesh with
a pinion. The pinion rotates about a fixed axis. When the pinion is rotated, the
21
rack moves down the ram. At the end of the stroke, the pinion reverses. So, the
ram moves up. Rack and pinion drive is used when a long stroke length is
required.
HYDRAULIC DRIVE:
This type of drive is a power operated drive. In this system the drive is
obtained with the use of personalized oil. This system consists of a hydraulic
cylinder, piston, piston rod, direction control valve, pressure control valves,
motor, pipelines and accessories.

The hydraulic cylinder may be a single acting cylinder or double acting

cylinder. The piston rod is connected to the piston. The piston along with the
piston rod moves inside the cylinder to the rod. The suitable valve and other
accessories are connected with the cylinder with the use of pipes. When the high
pressure oil is pumped through the top side of the cylinder the ram moves down
thereby moving the ram down thereby moving the ram downwards. At the end of
the stroke, the oil is pumped through the bottom side of the piston.

The hydraulic drive is used when a high pressure is required on the ram.
Hydraulic drive gives a noiseless and smooth operation. The pressure is applied
uniformly and can be varied. It moves at uniform speed. It is used where more
force is required on the ram.

PNEUMATIC SYSTEM
The pneumatic system has a number of units for its operations. It has
those parts for the smooth operation and for better efficiency. The units that
contribute this smooth operation are a filter, lubricator, regulator and valves etc.

22
AIR FILTERS
In pneumatic system filters are to remove all foreign and moisture from the
compressed air. Filters allow clean and dry air to flow to the system. The degree
of filtration depends upon the size of the particles that are to be removed. The
size of the particles varies from 5 min in the circuit point immediately after
tapping from the main tank.

Air filters are classified based on,

1. Degree filtration
2. filter element
3. construction

REGULATORS
Pressure regulators are reducing valves assigned the duty of maintaining a
largely constant operating pressure regardless of fluctuations in air main
pressure and air composition rate. The main function of pressure regulator is to
maintain a constant pressure irrespective of the fluctuations in supply the
compressed air. It is provided in the supply base from the tank of the system.

The most common type pressure regulators are diaphragm type. Regulators
type and piston type regulator. Outlet pressure is controlled in the regulator. The
gauge connected to the downstream indicates outlet pressure, namely the
operating pressure available. There are two different types pressure regulator
being used.
1. vented
2. Non Vented

23
LUBRICATOR
A lubricator is required to ensure an adequate supply of lubricant to the
pneumatic system. The oil injected to the stream should be dispersed sufficient
fine vapor to make sure that it will not be precipitated at the first lubricant points
are reduction to flow area is an extensive pneumatic system. Air passing through
the lubricator produces a pressure difference due to the different areas, thus
causing air to be entrained out of the reservoir in the unit and to be atomized as
it enters the stream of the air. The lubricator only starts working when the air
flow reaches a certain rate, below which the velocity across the nozzle is too low
to draw oil into the stream.

24
 4. INTRODUCTION OF HYDRAULICS AND PNEUMATICS

Pneumatic cylinders are the devices for converting the air pressure into
linear mechanical force and motion. They are basically used for single purpose
applications such as clamping, tilting, bending, turning and many other
applications.

The Pneumatic power is converted to straight line reciprocating motion

by pneumatic cylinders. The various industrial applications for which air
cylinders are used can be divided duty wise into the groups. They are light duty,
medium duty and heavy duty but according to the operating principle air
cylinders can be sub divided as 1.single-acting, 2.Double- acting cylinders.
Since our project is based on single acting cylinder we shall see deep about it.

In a single-acting cylinder, compressed air is fed only in one side hence, this
cylinder can produce work only in one direction the return movement of the
piston is affected by a built–in spring or by application of an external force the
spring is designed to return the piston to its initial position with a sufficiently
high speed.

 Most industrial processes require substances to be transformed from one

place to another. Also the final products should be shaped (or) compressed
(or) held by applying a great force. Such activities are performed by using
prime movers.
 The prime movers are operated by (i) electrical system (ii) Hydraulic
system (iii) Pneumatic system.

25
 In electrical system, the rotary motion is provided by simple motors. The
linear motions can be obtained by converting rotary motions with the aid
of screw jack (or) Rack and pinion.
 In ‘Hydraulic system, enclosed water (or) oil can be used to convey
energy from one location to another. In Greek, hydra means water.
 In Pneumatic system, enclosed gas (normally compressed air) is used to
transfer energy from one location to another). In Greek, Pneumatic means
wind.

26
 5. PNEUMATIC POWER SYSTEM

5.1INTRODUCTION

This chapter explains the different components of pneumatic and their

function.
Most parts of the machine can be controlled by hydraulic, pneumatic and electric
system for actuation and power transmission screen in the user.
For heavier loads, hydraulic or electric power transmission components are
required and pneumatic for lighter loads.
As in our project, the load is lighter and prefers pneumatic system and its
components

Pneumatic
Pneumatic system employs gas (most commonly compressed air) as the
fluid medium for transmitting power

Pneumatic power transmission

Pneumatic power is transmitted by the pressure and flow of compressed
gases. The most commonly used gas is air.
Suitability: They are suitable for power transmission over intermediate
distance
Advantage: Pneumatic systems use simple equipment, have small
transmission lines, and do not present a fire hazard

Advantages of pneumatic power over hydraulic power

1. Since the density of air is much lower than liquid (oil), the compressed air

27
 can be easily transported/ accelerated.
2. Simple construction of pneumatic elements and easier handling
3. High degree of controllability
4. As the viscosity of air is much lesser than liquid, this results in lesser
frictional pressure and power losses
5. Weights of the pneumatic systems are lesser when compared to hydraulic
systems.
6. Pneumatic system will not affect the operation of the system seriously
because the pneumatic systems receive the compressed air continuously.

Purpose of pneumatic

Pneumatic motion is selected for gear shifting owing to its large load
acceptance and ease of adaptability in the car. Also the gear shift should be
quick. The basic components of this circuit is listed are below.

5.2 Specifications of pneumatic components

COMPONENTS TYPE
AIR COMPRESSOR SCREW COMPRESSOR
RESERVOIR STORAGE TANK
PNEUMATIC CYLINDER SINGLE AND DOUBLE ACTING
CYLINDER
PNEUMATIC VALVE 3/2 AND 5/2 D.C VALVE
HOSE PVC

28
5.3 DESCRIPTION OF PNEUMATIC COMPONENTS
(a)AIR COMPRESSOR
Reason for selection of rotary screw due to the following advantages
Because of the simple design and few wearing parts, rotary screw air
compressors are easy to maintain, operate and provide great installation
flexibility. Rotary screw air compressors can be integrated into modular
packages for transportation air braking applications.

Major advantage

 No downstream oil contamination.

 Full flow capacity independent of engine RPM

Other advantages include -

 Designed to provide pulsation-free air

 100% continuous duty
 Quiet operation
 Energy efficient at full load
 Extended service intervals
 Reliable long life
 Improved air quality
 Low discharge temperatures

And so we prefer, rotary screw compressor for compressing atmospheric air.

Normally, the air can be filled in a master cylinder or separate storage tank
similar to hydraulic brake system.

Working of rotary compressor

29
 Rotary air compressors are positive displacement compressors. The most
common rotary air compressor is the single stage helical or spiral lobe oil
flooded screw air compressor. These compressors consist of two rotors within a
casing where the rotors compress the air internally. There are no valves.
Air enters a sealed chamber where it is trapped between two rotating
rotors and the housing. As the rotors intermesh, they reduce the volume of
trapped air and deliver it compressed to the proper pressure level. This simple
compression concept, with oil injected compression, allows the rotary screw air
compressor to operate with temperatures approximately one half that generated
by a reciprocating compressor. This lower temperature enables the rotary screw
air compressor to operate in a "fully loaded" continuous duty cycle 24 hours per
day, 365 days per year, if necessary.

(c) FRL UNIT

A pneumatic filter is a device which removes contaminants from a

compressed air stream. This can be done using a number of different techniques,
from using a "media" type that traps particulates, but allows air to pass through
to a venturi, to a membrane that only allows air to pass through.

Primary filters

Typical commercial pneumatic filters will remove particles as small as 5

micrometers from the air. The filters protect pneumatic devices from damage
that would be caused by these contaminants. These contaminants include
lubricant particles ejected by the compressor, dirt particles, small water droplets
or aerosols, and even oil vapor and dust particles

30
Secondary filters & Membrane Air Dryers

Secondary filters are used for a variety of applications and can remove
particles as small as 50 nanometers in size. These secondary filters can remove
fumes, odors, vapor, mist, moisture, oil, and tiny particles from the air stream.

In addition, special "point-of-use" air drying devices (called membrane air

dryers) may be used to depress the pressure dew point by selectively passing
water vapor out of the compressed air stream as it passes through the inside
hollows of a bundle of narrow, thinly-coated, membrane fibers. A small amount
of "sweep air" must then be purged around the outside of the bundle of hollow
fibers carrying the compressed air. Purge or "sweep" air is thus expanded (to
atmospheric pressure) and subsequently vented to the atmosphere. The "dryer"
purge air which is carried or swept along the outside of the hollow bundle of
fibers creates a vapor pressure gradient between the "wet" compressed air on the
inside the fibers and the "dryer" sweep air on the outside the bundle. This results
in delivery of cleaner, dryer air before the compressed air is sent into any
"moisture-sensitive" equipment(s).

Membrane air dryers, however, may be easily damaged through any contact
with liquid droplets (water or oil) so they should be protected with a high-
efficiency coalescing (nano) air filter, positioned either immediately upstream
(or integrated within) the membrane air dryer housing. Membrane dryers are
primarily used with equipments that are especially sensitive to water vapor such
as paint booths, two-part mixing equipment (polyurethane sealants), polyurea
dispensers, PUR-applicators (edge-banding equipment), laser-cutting machinery,
CMM's, industrial ink-jet printers, or even for laboratory use.

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(d) Draining valve

Normally the reservoir in four wheelers are provided with pressure relief
valve and draining valve. Compressed air usually has some water and some
compressor oil in it which is bad for the air brake system. For example, the
water can freeze in cold weather and cause brake failure. The water and oil tend
to collect in the bottom of the air tank; therefore, each air tank is equipped with a
drain valve in the bottom.

The two types of drain valves areas follow

1. The manual valve shown in figure 3-45 is operated by turning it a
quarter turn or by pulling a cable. Part of your post-operational procedures is to
drain all air tanks at the end of each day.
2. The automatic valve automatically expels the water and oil. This system
may also be equipped with a manual drain

Fig 5

(a) PNEUMATIC CYLINDER

32
 Pneumatic cylinders (sometimes known as air cylinders) are
mechanical devices which produce force, often in combination with movement,
and are powered by compressed gas (typically air).

Types of pneumatic cylinder

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.

33
Double acting cylinders

Fig 7

Double Acting Cylinders (DAC) uses the force of air to move in both
extends and retracts strokes. They have two ports to allow air in, one for
outstroke and one for in stroke.

In our project, we used 2 double acting cylinders A and B for selector rod
assigned for (1-2), (3-4) and one single acting cylinder C for reverse gear
engagement.

Stroke length
FOR DOUBLE ACTING CYLINDER A AND B = 60 mm
FOR SINGLE ACTING CYLINDER C = 70 mm

(b)PNEUMATIC HOSE

Hose capable of conducting gasses at greater than atmospheric pressure.

In mechanics, pneumatics is the application of pressurized gasses to perform
work. Many power tools, such as nail guns, air wrenches, and drills, utilize

34
pneumatic pressure. Some hydraulic systems also work upon the principle of
pneumatics, such as air brakes on certain aircraft and trains.

Hoses designed for pneumatic applications, as well as pneumatic valves

and accessories, are often made out of plastics, such as nylon, rubber, or
polyvinyl chloride (PVC). High-pressure pneumatic hose may also be made out
of plastics, yet reinforced with sheathing of fiber or metal weave to strengthen
the design. So we have selected PVC hose for conducting compressed air

Properties of PVC
 Due to its non-metallic nature, the material used is totally resistant to
all forms of metallic corrosion.
 Being made of a tasteless and odorless material, PVC pipes remain
neutral to all transported fluids.
 Because of their mirror-smooth inside surface, uPVC pipes have
minimum flow head loss.
 The physical properties of PVC pipes are not affected by either direct
sunshine, nor wind or rain.
 Rigid PVC is not conductive to combustion. In the event of a fire,
flames are unable to travel on uPVC pipes.
 Relatively light weight and their specific weight 1.43 is one-fifth (1/5)
that of steel pipes.
 Installation is quick and easy with a complete line of fittings either
with the solvent glue weld sockets or the rubber seal socket joints.

35
Dimensions of PVC hose
Dia of PVC hose = 6 mm.
Length of PVC = 5 m.

(c) PNEUMATIC VALVE

Pneumatic valve are the devices used to control pressure, flow direction or
flow rate in pneumatic circuits

Types of pneumatic valves

The pneumatic valves can be classified into many ways.
Classification based on their main function
1. Directional control valves
(i) Check valves
(ii) Shuttle valves
(iii) Two-way D.C. valves
(iv) Three-way D.C. valves
(v) Four-way D.C. valves
2. Pressure control valves
3. Flow control valves

Classification based on their construction

1. Poppet type valves
2. Sliding spool type valves, and
3. Rotary spool type valves

As we here are using only single and double acting cylinder, therefore to
get actuate, directional control valve of 3-way and 5-way valve are used.

36
3/2 DC valve

Next is the 3/2 air valve. As noted earlier, the first number is the number
of working ports that the valve has, and the second number indicates the number
of positions that the valve has. 3/2 air valve will have an in, an out and an
exhaust port for a total of three ports. At rest, the valve will either be open, with
compressed air flowing through, and out the power or working port to the
application, or it will be closed. When it is closed, compressed air will be
stopped from flowing from the source through the valve, and the working port
that let the air flow to the application when this valve was open, will now allow
flow to the exhaust port allowing any air that might be in the application
downstream of the valve to escape back down the air line, through the valve, to
atmosphere.

Fig 8

5/2 DC valve

Fig 9
The 5/2 compressed air valve functions similarly to the 4/2. It will have
one compressed air supply port, two working or application ports to supply air to

37
the application, and two exhaust ports through which air will flow to atmosphere
alternately from each of the application ports, in turn

Exception
Think of replacing manual lever by pneumatic in normal four wheelers
leads to mileage loss as we have to include compressor unit. What one have to
done is make slight alteration i.e. changing the pneumatic cylinders and hose as
in most of four wheelers there may be hydraulic sytem So our model serves a
common spare parts and modern gear set for old, current and new model car.

38
 CIRCUIT FOR PNEUMATIC SYSTEM
PISTON ROD WITH SPRING

PISTON
ROD
1 3

4
2

A B C
SINGLE ACTING CYLINDERS

AIR DISTRIBUTION PORT FOR A

AND B SIDE CYLINDERS

OUT
LET
OUTLET PORT
PORT OF “B” OF
“A”

SOLENOID
COILS
SOLENOID
VALVE

INPUT PORT FOR

COMPRESSED
AIR

39
 6. COMPONENTS AND DESCRIPTION

The major components of these systems are,

 Compressor
 Pneumatic Cylinder
 Solenoid Valve
 Hose and fitting
 Control Timer Circuit
 Flow control valve
 IR sensor

COMPRESSOR:

The air under high pressure is given by a compressor. It is driven by an

electric motor. The compressor delivers air to inlet of the cylinder. An air
compressor as the same indicates is a machine to compress the air and to raise its
pressure. The air compressor sucks air from the atmosphere, compresses it and
then delivers the same under a high pressure to a storage vessel from the storage
vessel it may be conveyed by a pipeline to a place where the supply of
compressed air is required.

Double Acting Cylinder

In this the force exerted by the compressed air moves the piston in two
directions. They are used partially when the piston is required to perform work
not only on the advance movement but also on the return stroke. This principle,
the stroke length is unlimited, although bucking and bending must be considered
40
before selecting the particular size of piston diameter, rod length and stroke
length.

The different parts of double acting cylinder are:

1. Barrel
2. Piston rod
3. Top Cover
4. Bottom Cover
5. Wiper Cover
6. Retaining ring
7. Piston
8. Piston guide
9. Bearing Cap
10.‘O’ ring for piston guide
11.Hexagonal socket head screw
12.Check nut

The double acting cylinder is made up of cast aluminium. The inner and
outer surface of the cylinder should be machined accurately. The internal
diameter of the cylinder should be accurate in order to provide a smooth surface
for the packing. The appearance of the outer diameter should be good.

The outer most part of the bottom and top cover contains internal threads
for inserting bolts to clamp the cylinder.

41
 In case of double acting cylinder a force is developed in both the
directions. The moving member inside the cylinder is nothing but a piston
which is found to be moving forward and backward due to high-pressure air.
The cylinder top and lower plate are flanged together by means of bolts and
nuts. The bottom of the cylinder is also flanged with end covers for the
movement of the piston in reciprocating manner.
Solenoid Valve
The directional valve is one of the important parts of a pneumatic system.
Commonly known as DCV, this valve is used to control the direction of air flow
in the pneumatic system. The directional valve does this by changing the
position of its internal movable parts.
This valve was selected for speedy operation and to reduce the manual
effort and also for the modification of the machine into automatic machine by
means of using a solenoid valve. A solenoid is an electrical device that converts
electrical energy into straight line motion and force. These are also used to
operate a mechanical operation which in turn operates the valve mechanism.
Solenoids may be push type or pull type. The push type solenoid is one in
which the plunger is pushed when the solenoid is energized electrically. The
pull type solenoid is one is which the plunger is pulled when the solenoid is
energized.
The name of the parts of the solenoid should be learned so that they can
be recognized when called upon to make repairs, to do service work or to install
them.

42
Working of Solenoid Valve

The solenoid valve has 5 openings. This ensure easy exhausting of 5/2
valve. The spool of the 5/2 valve slide inside the main bore according to spool
position; the ports get connected and disconnected. The working principle is as
follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets
connected to ‘B’ and ‘S’ remains closed while ‘A’ gets connected to ‘R’

43
Poisition-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets
connected to each other and ‘B’ to ‘S’ while port ‘R’ remains closed.

HOUSE AND FITINGS:

It is provided for the passage of compressed air from the compressor

outlet to the operating valve.

Two separate pipes also connect the operating valve with the working
cylinder pressure drop through and air line depends on the flow rate, pipe
diameter, pipe length and pipe geometry. It can be determined directly for
straight pipes of any given length. A small chaining bore size can have marked
effect on pressure drop, where as even doubling the pipe length, will only result
in doubling the pressure drop.

FLOW CONTROL VALVE:

Flow Control Valves are fitted to all the distribution tubes. This valve is
made of brass. Both the ends have stepped surface to insert hoses. A handle is
provided to control the flow of oil in every valve.

(a) Technical Data:

44
 Size : ¼”
Pressure : 0 to 10 kg / cm2
Media : Air

SPECIFICATIONS OF PNEUMATIC ELEMENTS:

The various pneumatic elements are specified according to different

standards. The standard varies depending upon the manufacturers.

1. Double acting Cylinder:

Stroke length
= 170 mm
Piston Diameter
= 55 mm
Maximum Operating Pressure
= 10 bar
Temperature range
= 120C to +80C
Material
= Aluminium alloy
Seals
= Polyurethane
O’ ring
= Nitrile
45
 2. Solenoid Directional Control valve
We have used 5/2 solenoid valve as the directional control valve.
Voltage
= 230 volts
Frequency
= 50 Hz
Maximum Operation Pressure
= 10 bar
Port size
7 mm

3. Flow control Valve

Technical Data
Port size.635 x 10 ² m

Pressure-8 x 10 ⁵ N/m²

Media-Air
Quantity-1

4. Connectors Technical data

Max working pressure-10 x 10 ⁵ N/m²

Temperature0-100 º C
Fluid media-Air
Material-Brass

5. Hoses Technical date

Max pressure-10 x 10 ⁵ N/m²

46
Outer diameter- mm = 6 x 10 ˉ ³m
Inner diameter-3.5 mm = 3.5 x 10 ˉ ³m

6. WORKING PRINCIPLE
The compressed air from the compressor reaches the solenoid
valve. The solenoid valve changes the direction of flow according to the signals
from the timing device. The compressed air pass through the solenoid valve and it is
admitted into the front end of the cylinder block. The air pushes the piston for the
forward stroke. At the end of the forward stroke air from the solenoid valve
reaches the rear end of the cylinder block. The pressure remains the same but the
area is less due to the presence of piston rod. This exerts greater pressure on the
piston, pushing it at a faster rate thus enabling faster return stroke. The stroke length
of the piston can be changed by making suitable adjustment in the timer.

47
7. CIRCUIT DIAGRAM OF THE PROJECT

CONTROL UNIT RELA

POWER SUPPLY

MACHINE

48
 LIST OF MATERIALS

SI.NO PART NAME MATERIAL QUANTITY

01. Pneumatic Aluminium 1

Double Acting Cylinder
02. Solenoid Value Aluminium 1

03. Flow Control Aluminium 1

04. Punch (Model) M.S 1

05. Bottom base M.S 1

49
 06. Electronic timing Electronic 1
control unit
08. Frame Stand M.S 1

09. Hose Collar and Brass 6

Connector
10. PU tube Polyurethane 3 meter

9. ADVANTAGES AND APPLICATIONS

ADVANTAGES

1. The outstanding advantage of pneumatic system is the control valve

which consistently applies a specified load with minimum effort.

2. To prevent the accident by using sensor unit.

3. From thin foils to metal sheets can be pierced according to desirable

shapes.

4. It can be modified to any extend bring out the required effort.

5. It outcome can be utilized properly in the extensive mechanical field.

50
6. Multiple cylinder systems can be put into action according to the need
of pressing effort.

7. In modern payer plants this pneumatic system can be used for loading
press roll.

8. Simple construction that the mechanical and hydraulic presses.

9. Compared to hydraulic and mechanical presses pneumatic press is

economical.

10.It does not require current carrying cables.

11.No extra skill is required for operating this system.

12.Operation is very smooth and in this system we can get more output by
applying less effort.

13.The system can be effectively used for punch mark in industrial materials
such as industries name, address or number of product.

APPLICATIONS
All Heavy Punching machine
All Ramming Machine
In all Foundries
In all Machine Shop
51
All the industries
DISADVANTAGES
The addition cost is required (sensor, Control Unit cost)

52
10. LINE DIAGRAM OF PNEUMATIC QUICK RETURN
MECHANISM

53
 11. COST ANALYSIS

Sl. Description Qty.

No.
01. Double acting cylinder 1 No. 1200
02. Solenoid Valve 1 No. 1100
03. Timer 1 No. 950
04. Flow Control Valves 1 No. 900
05. Hoses 2M 150
06. Wire 2M 75
07. Stand 1 No. 900
08. Base Board 1 No. 250
9 Hose Collar 6 NO. 120
10. Reducer 1 NO. 140
11. Male Punching Die 1 NO. 200
12. Work Piece 1 NO. 50

Total=6000

Material cost =6000+Fabrication cost=4000

Total cost of the project=10000

54
CONCLUSION:

This report deals with the PNEUMATIC QUICK RETURN

MECHANISM and it’s principle is attached with the line diagram.. The pneumatic

system can be found in almost all industries /fields. However some of the industrial
application is punching, clamping, materials handling, hammering throughout the
project period we gained knowledge on all type of machining Process and safety
system is studied. We have done to our ability and skill making maximum use of
available facilities.

55
BIBLOGRAPHY

 GUPTA J.K and KHURUMI R.S (1981) “Text book of Machine Design”,
S.Chand & comp and.

 Parr. ANDREW (2003) ‘Hydraulic & Pneumatics’ Butterworth Heimann Ltd

 Dr.D.K.AGGARVAL & Dr.P.C SHARMA(2004) “machine design”,

S.K.Kataria and sons

 MAJUMDAR.S.R “Pneumatic systems”, Tata mcgraw-hills company ltd.

 SRINIVASAN.R(2004) “Hydraulic & pneumatic controls”, vijay Nicole

imprints private ltd.

56