See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/274387327

Automation of Drilling Machine using Pneumatic Devices

Conference Paper · January 2015

CITATIONS READS

0 9,655

1 author:

Maughal Ahmed Ali Baig

CMR Technical Campus
75 PUBLICATIONS   279 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

International Conference on Advanced Light-weight Materials and Structures View project

All content following this page was uploaded by Maughal Ahmed Ali Baig on 30 January 2016.

The user has requested enhancement of the downloaded file.

 Automation of a Drilling Machine using Pneumatic Devices
Arvind Kumar1, Maughal Ahmed Ali Baig2 and Ravindra Lathe3
1
Assistant professor, Mechanical Engineering, Bearys Institute of Technology, Mangalore, Karnataka,
India, n.arvind.taskantker@gmail.com
2
Associate Professor, Mechanical Engineering, Bearys Institute of Technology, Mangalore, Karnataka,
India, mabaig13@gmail.com
3
Assistant professor, Mechanical Engineering, PDA college of Engineering, Gulbarga, Karnataka, India.
Abstract
This paper presents an automation methodology involving Pneumatic systems to convert the
existing conventional drilling machines into automated drilling machines. The automation process
involves various pneumatic devices, pneumatic systems and also some electrical and electronic
devices. The automation strategy, when implanted is believed to result in reduced cycle time, costs,
improved product quality and increase in productivity. By considering a particular task of drilling
holes, it is found from the present investigation that by the process of conversion the output rate
increases four times as compared to that of conventional type of machines.

Key words: Automation, Pneumatic devices, Solenoid control valves, Actuators.

1.INTRODUCTION
Automation can be defined as a technology concerned with performing a process by means
of programmed, commonly combined with automatic feedback control to ensure proper execution
of instructions. The resulting system is capable of operating without human intervention. According
to their control structure automation can be classified as Open-loop system and Closed-loop system.
An open loop system is one that does not have feedback mechanism within the system. The output
performance of the system relies upon the characteristics of individual components and their
interaction in the circuit. In the closed-loop systems a feedback mechanism is used for controlling
the system dynamics such a displacement, velocity acceleration etc. The value of the output being
monitored is compared with the desired output and the system controls are accordingly adjusted till
this difference is zero.
In recent years, the major developments witnessed in the field of automation include:
• Flexible manufacturing systems (FMS)
• Computer-aided manufacturing (CAM)
• Information Technology (IT)
• Robots
• Numerically controlled(NC) device
• Computer integrated manufacturing(CIM)

2. DESIGN AND DEVELOPMENT OF PNEUMATIC SYSTEMS

The solution to a control problem is worked out according to a system with documentation
playing an important role in communicating the final result. The circuit diagrams are drawn using
standard symbols and labeling. Comprehensive documentation is required including most of the
following:
• Function diagram
• Circuit diagram
• Description of the operation of the system
 • Technical data of the components.
Supplementary documentation comprises
• Parts list of all components in the system
• Maintenance and fault-finding information
• Spare parts list

There are two primary methods for constructing circuit diagrams:

• The intuitive methods
• The methodical design of a circuit diagram in accordance with prescribed rules and
instructions.
Component Selection Part List:
Ite
Qty Component designation
m
1. 3 Double-acting cylinders
2. 2 5/2 pilot operated directional control valve
3. 1 5/2 directional control valve with double solenoid control
4. 4 Flow control valve, adjustable, for one direction of flow, largely
independent of viscosity and pressure differential, with by-pass check
valve
5. 1 3/2 directional control valves with roller
6. 3 3/2 directional control valve, rollers with idle return
7. 1 ON time delay, relay unit
8. 1 Change over switch with idle return roller
9. 1 Distributor manifold
10. 1 Drill Head Unit
11. 1 Hose
12. 1 Air service unit (Filter regulator Assembly)

In order to develop control circuitry for multi cylinder applications, it is necessary to draw
the motion diagram to understand the sequence of actuation of various signal input switches-limit
switches and sensors. Multi cylinder applications with three cylinders A, B and C. The status of the
cylinder displacement and actuation of set and reset signals at double piloted directional control
value is shown by functional diagram.

Functional Diagram:

Fig.1: Functional Diagram

Sequence of Operation:

Loading & Clamping Drilling

Unloading
Z1 Z2 Z3
Fig.2: Sequence of Operation

Sequential motion of cylinders:

It is possible to have the following sequence of operation with three cylinder
A+ B C
Loading & Unloading idle idle
A- B+ C
Retracting Clamping idle
A B C+
idle idle drilling
A B C–
idle idle Retracting
A B- C
idle unclamp idle

Pneumatic Circuit Diagram of three (03) Double Acting Cylinders:

Fig. 3: Pneumatic Circuit diagram of 3 cylinders

Z1 – Cylinder-1, Z2-Cylinder-2, Z3 – Cylinder-3

Valve 1 – double solenoid pilot operated 5/2 DCV
Valve 2 & 3 – pilot impulse 5/2 DCVs (double piloted)
S1, S2, S3
3/2 roller operated limit switch idle return rollers S4 3/2 roller operated normal roller
VFCV
Variable Flow Control Valve, RS
Reset switch
The 3 double acting cylinders are controlled with 5/2 directional control directional values.
The valves are equipped with visual display and manual override in case of double solenoid valve.
Valve-1 has the solenoid coils designated as Y1 and Y2 valve-2 & 3 are piloted operated valves
designated by 12 & 14.When signal voltage is applied to the solenoid coil Y1 the cylinder (Z1)
extends, when voltage is applied to Y2 the cylinder (Z1) retracts.
The Normal and Idle return rollers type valves used to operate cylinder 2 & 3. The extension and
retraction of the cylinder 1 is controlled by the on time delay relay. The extension and retraction of
the cylinder 2 & 3 are controlled by one way flow control valves. Ladder diagram (sometimes called
ladder logic) are a type of electrical notation and symbolize frequently used to illustrate how
electromechanical switches and relays are inter-connected.
The two vertical lines are called ‘rails’ and attach to opposite poles of a power supply, usually 24
volts AC. L1 designates the ‘hot’ AC wire and L2 the ‘neutral’ (grounded) conductor.
Horizontal lines in a ladder diagram are called ‘rungs’, each one representing a unique parallel
circuit branch between the poles of the power supply.
Typically, wires in control system are marked with numbers and / or letter for identification. The
rule is all permanently connected (electrically common) points must bear the same label13.

K = RESET SWITCH

Fig. 6.5.4: Electric Circuit Diagram

3. Operational Analysis
Cost Analysis of Manual and Automated Production Machine (Press):
The machine taken for comparison is a drilling machine. Depending upon the size of the
machine the cost varies. Taking a minimum size of the machine the analysis is done. For manually
operated drilling machine the cost of minimum operated drilling machine the cost of minimum size
machine is approximately around 20000/-. For automatically operated drilling machine the cost of
minimum size machine (after conversion) is approximately around 50000/-.
Let us consider a drilling machine which is used for drilling a 10mm diameter hole in a 5mm
thick mild steel plate. The time needed to produce one hole manually operated drilling machine is
about 2mins. The total time needed including the loading and unloading is about 2 minutes.
Therefore in 1 hour 30 holes of 10mm are made in 30 jobs. There is one day (6 hours) 180 work
pieces are completed. (Total machining time taken in a day is 6 hour). The time needed to produce
one drilled work piece on an automated drilling machine is about 30 seconds. In one hour 120 work
piece are produced. Therefore in one day (6 hours) 720 work pieces are completed. To know the
productivity of both the machines it can be understood from the graph.
Scale: X Axis 1cm=1 hour, Y Axis 1 cm=500 units

8.1.1 Graph Showing Productivity of two Machines (Drill)

AUTOMATED M/C MANUAL OPERATED M/C
1 HOURS-120 UNITS 1 HOURS-30 UNITS
6 HOURS-720 UNITS 1 HOURS-180 UNITS
As seen from the graph the rate of production is very high in case of automated drilling
machine as compared with the manually operated machine. Hence, the productivity is high on the
automatic machine.
Cost, variable cost and rate of production
A business can work out how what volume of sales it needs to achieve to covers it costs.
This is known as the breakeven point. The key to break even is to work out the contribution made
from the sale of each unit. The amount of money each unit sold contributes to pay for the fixed and
indirect cost of the business.

Manually operated machine (Drill):

Fixed Cost of machine (FC)
Variable Cost (VC)
Rate of production
Sales (considering the
Cost of machining Rs 1 per unit)
: Rs. 20,000/-
: Rs. 50,000/-
: 65,700 units / year
: Rs. 65,700/- Year

Automated machine:
Fixed Cost of machine (FC) : Rs. 50,000/-
Variable Cost (VC) : Rs. 1, 25,000/-
Rate of production : Rs. 2, 62,800 units / year
Sales (considering the : Rs. 2, 62,800/-
Cost of machining is Rs 1/- per unit)
(Machining time is taken 6 Hours per day)

Scale: X AXIS 1CM=10000, Y AXIS 1CM=10000

Fig: Manual Operated machines’s BEP

 Scale: X AXIS 1CM=10000, Y AXIS 1CM=10000

Graph 8.2.3 Automated Machine’s BEP

From the BEP we can conclude that even though the initial investment is high but the returns
of the investment is very quick as compared to the manual operated machines and also the profits
are more in case of the automated machines when compared with the manual operated machine with
in the same period of time. From the BEP chart of both the machines we can conclude that why the
automated machines are the first choice.
Conventional Machine (Drill):
180 units are produced in one day. No. of days required to produce 32000 units, From the BEP of
conventional machine BEP chart it is approximately 178 days.
Automated Machines (Drill):
720 units are produced in One day. No. of days required to produce approximately 70000 units,
From the BEP of Automated machine BEP chart it is approximately 97 days.
From the statistics, it shows that even though the initial investment is high, but the BEP
would be reached early approximately 97 days. In case of conventional machine the initial
investment is low as compared to the automated machine, but to obtain the breakeven point it takes
more number of days approximately 178 days and the profit is less.
Hence it can be concluded that automated machines are better than the manual operated
machines both in productivity and accuracy areas.

4. CONCLUSION
The manual controlled machine is converted into automatic machine by using various pneumatic
devices as discussed in the paper. The results indicate that operating time is saved to a greater
extent. Thus the output will be more and even the human intervention is minimized, such that
number of machines can be handled by a single operator. This paper presents the findings, which
demonstrate that any manually operated machine can be converted into automatic machines by
using these devices. But to achieve this one should have the full knowledge of the devices which are
being used. By doing so the existing old machines can be modified and made automatic by which
the initial cost, to procure new automatic machines may be minimized.

View publication stats