SYNOPSIS

INTRODUCTION

LITERATURE SURVEY

CUTTING MACHINE

BLOCK DIAGRAM & EXPLANATION

CIRCUIT DIAGRAM & DESCRIPTION

COMPONENTS DESCRIPTION

ASSEMBLY DIAGRAM

WORKING PRINCIPLE

LIST OF MATERIALS

BILL OF MATERIALS

COST ESTIMATION

APPLICATIONS & ADVANTAGES

CONCLUSION

BIBLIOGRAPHY

PHOTOGRAPHY
 SYNOPSIS

The aim of our project 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 facilities.

In our project the IR sensors are sued to avoiding the accident. The
system automatically stops, when the IR sensor detecting the any parts of the
operator inside the machine.
 INTRODUCTION

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 form 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 kept 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.
 LITERATURE SURVEY

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.

Safety field buses 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.
PNEUMATICS

The word ‘pneuma’ comes from Greek and means breather wind. The

word pneumatics is the study of air movement and its phenomena is derived

from the word pneuma. Today pneumatics is mainly understood to means the

application of air as a working medium in industry especially the driving and

controlling of machines and equipment.

Pneumatics has for some considerable time between used for carrying

out the simplest mechanical tasks in more recent times has played a more

important role in the development of pneumatic technology for automation.

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 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 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) PıVı = P2V2

In this equation the pressure is the absolute pressured which for free is

about 14.7 Psi and is of courage 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 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 is 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 1200 stage models are particularly suitable for

pneumatic applications , with preference going to the two stage design as

soon as the discharge pressure exceeds 6 bar , because it in capable of

matching the performance of single stage machine at lower costs per driving

powers in the range .

 GENERAL DETAILS OF PNEUMATICS

PNEUMATIC CYLINDER
Introduction
A pneumatic cylinder simply converts air pressure into linear motion.

FACTOR TO BE CONSIDERED FOR THE SELECTION OF

PNEUMATIC CYLINDERS

When selecting a pneumatic cylinder, you must pay attention to:

 how far the piston extends when activated, known as "stroke"

 surface area of the piston face, known as "bore size"
 action type
 pressure rating, such as "50 PSI"
 type of connection to each port, such as "1/4" NPT"
 must be rated for compressed air use
 mounting method

 Action Types
By "action type", we mean how the cylinder acts when pressure is applied and
removed.
A "single-acting" cylinder has a single port for compressed air.

When air pressure is removed, the cylinder does nothing to retract the piston.
Whatever the piston pushed out must push the piston back in.
A cylinder that is "single-acting with spring return" has hookups like the
"single-acting" cylinder.

When air pressure is removed, the spring pushes the piston back into the
resting position.

In some cases the cylinder is sealed and the trapped air performs as an "air
spring".

A single-acting cylinder with spring return requires more air pressure to

activate because you are pushing against both the load and the spring.

A "double-acting" cylinder has two ports for compressed air.

Note that a double-acting cylinder requires a more complex solenoid valve.

When you want to return the piston to its resting position, you must not only
apply pressure to the second port, but also open up the first port so that the
gas in it can be expelled.
A double-acting cylinder consumes more air than the equivalent single-
acting cylinder, because you need air to push the cylinder in each
direction.

Commercial Pneumatic Cylinders

Pneumatic cylinders are available commercially in a wide range of sizes and

designs.

Using a commercial pneumatic cylinder is not a guarantee of safety - you can

still do bad things with good parts - but it does provide additional safety
margins that improviced pneumatic cylinders simply can not provide.

Commercial pneumatic cylinders are surprisingly affordable and easy to find.

HEAVY DUTY PNEUMATIC CYLINDER

 Heavy-Duty
Pneumatic Cylinder

Utility through air power

Changes and improvements in the electric motor industry have

produced linear motors making deep incursions in places where hydraulic
cylinders formerly held sway. Hydraulic systems are great for brute force
operations but are difficult to keep clean, and high pressures in some
applications can pose a hazard for work crews. The working fluid is also
toxic to the environment, so accidents can be costly to clean. On the other
hand, electric motors can be precisely controlled but command a higher cost.

Now an alternative to both approaches is offered by Numatics,

Franklin, TN, in the shape of their In Force cylinder line. The first member
under that sobriquet is the ASP Series, designed to function in strenuous
cylinder applications, such as packaging equipment, industrial furnaces,
construction equipment, and automotive and motorcycle assembly lines. The
steel cylinder is honed to a fine finish and then surface hardened by a
Nitrotec process, which creates a thin (0.001-in.), uniform and extremely
hard (64 to 71 Rc) iron nitride layer infused with a film of iron oxide. The
result is a smooth, corrosion-free sealing surface and high abrasion
resistance.

For added ruggedness, the ASP Series includes a graphite-filled, cast

iron rod bushing made to a greater length than in standard cylinders. The use
of cast iron provides maximum resistance against premature wear, while the
added length adds improved alignment and support of the piston rod, as well
as providing maximum load bearing support. The high-strength steel
(100,000 psi min. yield) piston rod, in diameters from 5/8- to 3½-in., has a
ground, polished and chrome-plated surface, which provides maximum life
for both the rod bushing and the seals. The piston seal is carboxilated nitrile
with Teflon compound for self-lubrication. The “T “ seal configuration with
back-up rings prevents rolling, and seals at all pressures. All units in the ASP
Series include a wear band, a stable lubricating strip located on the piston
(the latter made of aluminum, the only non-steel component in the
assembly). To maximize separation between load bearing points, the band
was placed at the rear of the piston. The end caps are machined from
precision square steel blocks and have a black oxide finish for corrosion
protection. Additionally, a recess on both ends of the piston-mating surface
enables the air to work on a larger piston area for effortless breakaway, even
at low pressures.
 The ASP Series of pneumatic
cylinders has a nominal pressure rating of
250 psi, and is being offered initially in eleven
bore sizes from 1.5- through 14.0-in. Standard operating temperatures are
-10° to 165°F. There are 21 standard NFPA mounting options, all
accomplished with one-piece mounts on units with bores up to 8.0 in.; i.e.,
there are no welded-on lugs. The NPTF ports have an enhanced design for a
smooth flow path into and out of the cylinder. Options include stroke
adjusters, high temperature rod boots and more.

Pneumatic cylinders

Pneumatic cylinders or air cylinders are mechanical devices used to

impart a force from a fluid, typically compressed air.

Pneumatic cylinders are available in a variety of styles, including tie

rod, compact, round body, rotary, gripper, escapement, guided, and rodless
cylinders. Other features of pneumatic actuators include the ability to have
multiple strokes or a full stroke with intermediate stopping points,
adjustments to control the amount of extension or retraction of a given
actuator, and locks that can serve as safety mechanisms in case the machine
experiences a loss of air pressure.

A typical pneumatic cylinder consists of a piston, piston rod, and a body or

tube. Compressed air enters at one end of the tube, imparting force on the
piston, which is then displaced (moves) in order to balance the force exerted
on the piston. Air cylinders, or actuators as they are also called, are available
in a variety of sizes, shapes, and have varying strokes. Typical cylinder sizes
range from a small 2.5mm air cylinder, which might be used for picking up a
small transitor or other electronic component, to 400mm diameter air
cylinders which would impart enough force to lift a car. Some pneumatic
cylinders reach 1000mm in diameter, and are used in place of hydraulic
cylinders for special circumstances where leaking hydraulic oil could impose
an extreme hazard.

Air Cylinders are available in a variety of styles. Some examples include:

Single acting cylinders--cylinders that use the force imparted by air to move
in one direction, and a spring to return to the "home" position. Double acting
cylinders--cylinders that use the force of air to move in both extend and
retract strokes. Rotary air cylinders--actuators that use air to impart a rotary
motion Rodless air cylinders--actuators that use a mechanical or magnetic
coupling to impart force, tyically to a table or other body that moves along the
length of the cylinder body, but does not extend beyond it.

Pneumatic cylinders are generally less expensive than hydraulic or electric

cylinders of similar size and capacity.
 PNEUMATIC DETAILS

PNEUMATIC COMPONENTS AND ITS SPECIFICATION

The pneumatic auto feed drilling machine consists of the following

components to full fill the requirements of complete operation of the machine.

1. Flow control Valve

3. Connectors

4. Hoses

1. Flow control Valve

Technical Data

Port size : 0.635 x 10 ֿ² m

Pressure : 0-8 x 10 ⁵ N/m²

Media : Air

Quantity : 1

2. Connectors Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass
3. Hoses

Technical date

Max pressure : 10 x 10 ⁵ N/m²

Outer diameter : 6 mm = 6 x 10 ˉ ³m

Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m

 CUTTING MACHINE

WORK HOLDING DEVICES

A cutting machine for sheet material comprising a frame, a
stationary knife on the frame and a reciprocating blade cooperating with the
stationary knife. A motor on the frame is connected to a gear reducer that is in
turn connected to a single push rod through a crank. The push rod is
operatively connected to a torque tube that is connected adjacent its ends by
link means to the reciprocating blade. Rotation of the crank by the gear
reducer will actuate the single push rod and the torque tube operatively
connected thereto to reciprocate the reciprocating blade. Spring means for
assisting movement of the reciprocating blade are readily adjusted from
exterior of the frame of the cutting machine. A rotatable cam follower on the
reciprocating blade engages a guide block on the frame for moving the
reciprocating blade into proper cooperative engagement with the stationary
knife in use.
A cutting machine for sheet material, comprising a frame, knife means
on said frame including a stationary knife and a reciprocating blade
cooperating therewith, motor means on said frame having an output shaft, a
crank on said output shaft, a single push rod connected to and operatively
activated by said crank, a torque tube mounted on the frame, said push rod
operatively connected to said torque tube for actuating the torque tube, said
torque tube being operatively connected to the reciprocating blade by link
means for actuating the reciprocating blade in response to rotation of said
output shaft, and spring means connected between the frame and the
reciprocating blade for facilitating motion of the reciprocating blade, said
spring means comprising at lease one tension spring and means for adjusting
the tension of said tension spring said adjusting means including at lease one
tension control arm pivotally connected to the frame adjacent one end of the
arm, and an adjustable bolt affixed between the frame and the tension control
arm for adjusting the position of the tension control arm, and the tension of
the spring affixed thereto, said adjustment bolt being readily accessible from
an exterior portion of the cutting machine.

A cutting machine as in claim 1 including a rotatable cam follower on

the reciprocating blade cooperating with guide block means on the frame for
guiding the movement of the reciprocating blade into cooperative engagement
with the stationary blade.

A cutting machine as in claim 2, wherein the guide block means

comprises a guide block affixed to the frame, and a guide block spring on the
guide block that engages with the rotatable cam follower.

A cutting machine as in claim 3, wherein the guide block means

includes an adjustment screw carried by the guide block and engaging the
guide block spring for adjusting the position of the guide block spring with
respect to the rotatable cam follower.
A cutting machine as in claim 1 wherein said spring means comprises
a first tension spring and a second tension spring, and said adjusting means
comprises a first tension control arm and a second tension control arm, the
first tension spring connected at one end to the first tension control arm and
operatively connected at the other end to the reciprocating blade, the second
tension spring connected at one end to the second tension
 Cutting tools are used in metalworking for roughing, drilling, semi-
finishing, and finishing applications. They are used in making metal objects
and also in the production of metal parts. Additionally, wood boring tools like
auger bits and lathes are also called cutting tools.

Efficient, quality cutting tools can lead to reduced production costs and a
more competitive and attractive products. In order to function properly, the
materials that cutting tools are comprised of must be made of materials which
are harder than the materials they are intended to cut.

CUTTING TOOL USES

Cutting tools are used to cut and shape metals and other materials.
They require the use of specific geometry shapes and blade angles. Without
this, accurate cuts, finishes, drill angles and sizes are impossible to produce.
Cutting tools used on metal surfaces must be able to get the job done without
contacting and marring the material.

Cutting tools can also be specifically designed for use on abrasive

materials. Super-hard cutting tools can be used in the production of non-
metallic materials like graphite, ceramics, plastics, Kevlar, and glass fiber
composites. Cutting tools are also used on non-ferrous metals such as high-
silicon aluminums, metal composites, copper, brass, and bronze.
TYPES OF CUTTING TOOLS

There are many different types of cutting tools and they come in
hundreds of shapes, sizes, and intended uses. They can also be customized for
specific part manufacturing processes. Some of the most commonly used
cutting tools include:

Angle Cutters

These are milling cutters with their cutting face angled in relation to its
axis of rotation. They are typically used in machine applications.

Boring Tools

Used to cut or finish the inner diameter of drilled holes.

Router Bits

Rotating tools that come in a wide variety of shapes and are used with
routers to shape edges.

Drill Bits

Rotary cutting tool used to drill holes.

Endmills

Similar to a drill bit, it is used in industrial milling applications and

made of high speed steel or tungsten carbide.
Broaches

Used for the precision sizing and finishing of material surfaces.

Grinding Wheels

Used for finishing, shaping, and metal removal.

Deburring tools

Removes sharp metal splinters, burrs, flashing and other rough finishes
left by cutting and machining.

Fly Cutters

Similar to a lathe tool, but mounted in a special holder. Uses one or more
single-pointed tools to plane a surface.

Abrasive Saw Blades

Cutting devices used with saws and other hand-held cutters.

Knife Blades

Industrial class tools used to shear and cut metal, primarily using the
force of pressure to make a cut.

Turning Tools

Used on lathes for finishing the outside diameter of a piece of material.

Countersinks

Cut angled holes into a piece of work material.

CUTTING SPEED

The cutting speed in a drilling operation refers to the peripheral speed

of a point on the surface of the drill in contact with the work. It is usually
expressed in meters per minute. The cutting speed (V) may be calculated as
V = π / 1000 m per min
Where, V is the cutting speed in m/min
d is the diameter of the drill in meter
n is the rpm of the drill spindle.

CUTTING SPPED FOR DRILLING IN METER PER MINUTE

Material H.S.S. Drills C.S. Drills
Soft cast iron 30 –45 12 – 23
Medium cast iron 21 – 30 9 - 15
Malleable iron 24 – 27 9 – 14
Mild steel 24 – 25 9 – 17
Stainless steel 18 – 21 7.5 – 10.5
Aluminium and Alloys 60 – 90 24 – 45
Brass and Bronze 60 – 90 24 – 45
Copper 18 – 30 7.5 - 15

FEED
 The feed of a cutting is the distance moved by the cut into work for one
revolution of the spindle. It is expressed in millimeters per revolution. Feed
also can be expressed in millimeters per minute.
Cutting speed and feed depends upon the following factors.
1. Workpiece material.
2. Cutting tool material.
3. Surface finish required.
4. Type of cutting fluid used.
5. Rigidity of the machine and work holding device.
6. Range of speed available.
7. Depth of hole.

DEPTH OF CUT

The depth of cut in drilling is equal to one half of the drill diameter.
Thus if ‘d’ be the diameter of the drill, the depth of cut (t) may be expressed
as:
t = d/2 mm.
 BLOCK DIAGRAM

Machine
IR Sensor Control Relay Cutting
Power supply
Unit Machine
 BLOCK DIAGRAM EXPLANATION

RELAY

A relay is an electrical switch that opens and closes under control of

another electrical circuit. In the original form, the switch is operated by an
electromagnet to open or close one or many sets of contacts. It was invented
by Joseph Henry in 1835. Because a relay is able to control an output circuit
of higher power than the input circuit, it can be considered, in a broad sense,
to be a form of electrical amplifier.

POWER SUPPLY

The power supply section is an important one. It should delivery

constant output regulated supply for successful working of the
project. A 12V-0-12V / 1 Amp transformer is used for our purpose, the
primary of this transformer is connected to the mains supply through a
ON/OFF switch and a fuse holder for protecting from overload and short
circuit protection.

IR TRANSMITTER AND RECEIVER SECTION

The sensor contains two divisions. Transmitting section & the

receiving section. The transmitting section consists of a 555 which acts a
vibrator in combination of the resistance connected it starts to glow or
produce infrared rays from the IR led transmitting section.

The rays produced from the IR led are produced as a square wave.
These rays are transmitted towards the receiver section.

The receiver section consists of a IR receiver which receives the

transmitted rays. These received rays are amplified using RC network the
received square pulse is buffered.
 +12V +12V

10K

10K

10K
1K

10K

10K

10K
1K
O UTPUT

O UTPUT
47 K B C 5 47 B C 5 47
47 K

BC 547 B C 547
LD 271 T IL 8 1 LD 271 T IL 8 1

1K

1K
IR L E D P H O T O D IO D E IR L E D P H O T O D IO D E

G ND G ND
T R A N S M IT T E R R E C E IV E R T R A N S M IT T E R R E C E IV E R

+12V

10K

10K

10K
1K

O UTPUT
47K B C 5 47

B C 5 47
LD 27 1 T IL 8 1

1K
IR L E D P H O T O D IO D E

G ND
T R A N S M IT T E R R E C E IV E R

IN F R A R E D T R A N S M IT T E R & R E C E IV E R
 IC 555 DETAILS

555 OPERATION

The IC 555 timer connected for Monostable operation. The circuit has an external
resistor and a capacity “C”. The voltage across the capacitor is used for the threshold
voltage to pin 6. When the trigger arrives at pin 2, the circuit produces a rectangular
output pulse from pin3.

The monostable 555 timer produces a single pulse whose width is determined by
the external R and C. The pulse begins with the leading edge of the input trigger.

A one-shot operation like this has a number of applications in digital and

switching circuits.

When operating in the monostable mode, the 555 timer is often referred to as a
one-shot multivibrator because it produces only one output pulse for each input trigger.

The duration of this output pulse can be precisely controlled with an external
resistor and capacitor.

The 555 timer is an 8 pin IC. Pin 1 is connected to ground and pin 8 is connected
to the positive supply. The trigger goes into pin2 and the output comes from pin3.
IC 555 TIMER PIN DIAGRAM

GND VCC

TRIGGER IC 555 DISCHARGE

OUTPUT THRESHOLD

RESET CONTROL
VOLTAGE

The pin details as shown below.

Pin No 1: Ground terminal

Pin No 2: Trigger terminal – if the voltage at this terminal is more than

1/3 of Vcc. The output remains low.

Pin No 3: Output terminal.

Pin No 4: Reset terminal – If the voltage applied to this terminal is zero, the
output and discharge terminals go to zero potential, during normal
operations, high voltage is applied to the terminal.
Pin No 5: Control voltage terminal. This terminal is used to change the
threshold and trigger voltage levels. Usually a 0.01fd capacitor is
connected to it. For suppressing supply voltage noises and ripple voltages.

Pin No 6: Threshold terminal : If the voltage applied to its terminal is more

than threshold voltage, output goes to low level.

Pin No 7: Discharge terminal – This terminal is used to discharge an external

connected capacitor during the time when output is low.

Pin No 8: Supply voltage terminal.

 COMPONENTS DESCRIPTION

POWER SUPPLY

The power supply section is an important one. It should delivery

constant output regulated supply for successful working of the
project. A 12V-0-12V / 1 Amp transformer is used for our purpose, the
primary of this transformer is connected to the mains supply through a
ON/OFF switch and a fuse holder for protecting from overload and
short circuit protection.

TRANSFORMER RECTIFIER FILTER IC REGULATOR LOAD

TRANSFORMER

A transformer is a static device, which is used to transform electric

power of same frequency in another circuit. It can lights or lower the
voltage the circuit but with a corresponding decrease or increase in current.
It works with the principle of mutual inductance in our project we are using
step down transformer for providing a necessary supply for the electronic
circuits. In our project we are using a (0-12)V transformer.

FILTER
The filter is an electronic circuit, which is employed to reduce the
rectifier output ripple. This is achieved by passing the AC output
component around the load by a shunt capacitor or limiting the magnitude at
a low value in the load by a series inductance are combination of this two
more efficient.

CAPACITOR FILTER

The capacitance is so chosen that the alternating currents find the load
reactance shunt in C. Only a small alternating current component passes in
R, producing a small ripple voltage.

The capacitance alters the conditions under which the diode operates.
When the diode output voltage is increasing, the capacitor stores energy, by
charging the peak of the input cycle. With falling source voltage starts to
fall faster than the capacitor voltage can fall, as determined by the time
constant of C and the load. The capacitor continuous to maintain the load
voltage at a higher value and lower ripple than if a capacitor was not present.
The diode delivers a charging pulse of current pulse of current in each cycle,
and then disconnects sources form the load.

RECTIFIERS

A rectifier is defined as a electronic device used for converting AC

voltage into unidirectional voltage.
A rectifier utilizes unidirectional conductions device like vacuum
diode or PN-junction diode.
Rectifier are classified depending upon the period of conductions as,
1. Half wave rectifier
 2. Full wave rectifier
In our circuit we need continuous supply without any interruption.
Hence we use Full wave rectifier whose output is free from interruption.

VOLTAGE REGULATORS
A voltage regulators is an electronic circuit that provides a stable DC
voltage independent of the load current, temperature and AC line voltage
variations although voltage regulators can be designed using op-amps, it is
quicker and easy to use IC regulator. Further more, the IC voltage regulators
are versatile and relatively inexpensive and are available with futures such as
programmable output, current / voltage boosting and floating operations for
high voltage applications.

Some important Types of Linear IC Voltage Regulator are,

1. Fixed positive / negative output regulators
2. Adjustable output voltage regulators
0

μF / μF /
μF /
 RELAY

A relay is an electrical switch that opens and closes under control of

another electrical circuit. In the original form, the switch is operated by an
electromagnet to open or close one or many sets of contacts. It was invented
by Joseph Henry in 1835. Because a relay is able to control an output circuit
of higher power than the input circuit, it can be considered, in a broad sense,
to be a form of electrical amplifier.

These contacts can be either Normally Open (NO), Normally Closed (NC),
or change-over contacts.

 Normally-open contacts connect the circuit when the relay is

activated; the circuit is disconnected when the relay is inactive. It is
also called Form A contact or "make" contact. Form A contact is ideal
for applications that require to switch a high-current power source
from a remote device.
 Normally-closed contacts disconnect the circuit when the relay is
activated; the circuit is connected when the relay is inactive. It is also
called Form B contact or "break" contact. Form B contact is ideal for
applications that require the circuit to remain closed until the relay is
activated.
 Change-over contacts control two circuits: one normally-open contact
and one normally-closed contact. It is also called Form C contact.
 Relays are electromagnetic devices by which operation of one or
more circuits are controlled by operation of some mechanical contact, and
with their help they control operation of other circuits. In telegraphy also
similar relays are used where they find their use mostly as polarised relays.
They are required to produce impulses at rather high speed are also used to
receive signals at high speed on the receiving side. They are generally
provided with one moving contact known as tongue. In telephony the relays
that are used, vary widely in their nature from 1 to as many as 20 sets of
contacts provided in each and these contact also vary in their nature.

There are mainly four types of contacts as given below.

i) Make Contacts: In this contacts which are normally broken are
made when the relay is operated.
ii) Break Contacts: These are the normally made contacts that are
broken by the operation of the relay.
iii) Change over contacts: In this the movable contacts while changing
its positions by the operation of the relay breaks with one contacts
and makes with the others.
iv) Make-Before-Break Contact: In this type when the relay is
operated, one normally broken is first made and then only a second
normally contact is broken.
Theory of Operation Of The Relay
When a current is passed through the coil of the relay a magnetic flux
is produced through the core whose path is completely through the yoke the
armature and it moves against the force exerted by the different spring
contacts and when it moves the pin also moves up thereby moving all. The
spring contacts fixed to th e pin and so the various contacts are operated.

Effect of coil inductance on the relay operations

The minimum current at which the relay is just operated as known as

the operator current and the maximum current at which the relay is just
released is known as the release current. It is clear that the magnitude of the
operator current is much higher than that of the release currents in
connection with the relay remains up operated may be smaller in value than
the operates for current and the hold current which is the minimum current at
which the operated relay remains help up may be higher in value than the
release current. Owing to the appreciable inductance due to large number of
turns of relay coil, the current in the relay coil takes some time to reach its
maximum steady value and it increases exponentially. The value of the
relay coil attains the operate for current value after sometime from the
moment the current begins to flow through the relay coil. The time that
elapses before the relay operates from the moment its circuit is enclosed
known as operate lag.
 The relay releases after sometime from the moment the circuit
is broken when the current reaches the release current value and the time that
elapses till it releases.

It is clear that greater the value of the time constant greater will
be the time at which the current reaches a particular fraction of the steady
value both during operation and release. For a given steady value of the
coil, greatest the I/R value greater will be the lag.
 + 12V

4 .7 K
10K
1K

R E LA Y

1 2 V /1 0 0 O H M S

BC 547
IN 4 0 0 7 + 12V

4 .7 K
10K
1K

R E LA Y

1 2 V /1 0 0 O H M S
BC 547

IN 4 0 0 7
 ACCIDENT PREVENTER FOR CUTTING MACHINE

6 4

3
1

Parts of the Accident preventer for cutting machine

1.Pneumatic Cylinder
2. Moving Cutter (Male Die)
7
3. Solenoid Valve
2 4. Control Circuit

8 9
 WORKING PRINCIPLE

Cutting is a process which is often taken out in all

mechanical field. Here we are having a cutting machine attached

with pneumatic system. Pneumatic system is the first step for

automation. In this system when we give pressure from the

compressor, it will activate the cylinder with cutting tool. Here we

are having a solenoid valve which is used to control the cylinder

input.

Here we are attached a electrical circuit for protection

purpose. When a person placed his hand in the sensor part which

is near the cutting part, the supply for the solenoid valve will be in

off position. When no interrupt is sensed then only the solenoid

valve give pressurized air to the cylinder. Then only we can cut

any thing.
LIST OF MATERIALS
 LIST OF MATERIALS

Sl. No.
Name of the Parts Quantity
01. Resistor 1
02. Capacitor 1
03. IR transmitter 1
04. IR Receiver 1
05. Stand 1
06. Pneumatic Valve 1
07. Pneumatic cylinder 1
08. Cutting Tool 1
09. Hose 1
10. Power supply 1
11. Connector 1
12. Solenoid Valve 1
13. Relay 1
14. Bolts and Nuts 7
BILL OF MATERIALS
 BILL OF MATERIALS

S.NO Name of the Parts Quantity Material

1 Resistor 1 Mild Steel

2 Capacitor 2 Mild Steel

3 IR transmitter 2 Mild Steel

4 IR Receiver 1 Mild Steel

5 Stand 1 Mild Steel

6 Pneumatic Valve 1 Brass

7 Pneumatic cylinder 1 Brass

8 Cutting Tool 1 Steel

9 Hose 1 Brass

10 Power supply 4 Plastic

11 Connector 6 Cast Iron

12 Solenoid Valve 1 Cast Iron

13 Relay 1 -

14 Bolts and Nuts - Cast Iron

COST ESTIMATION
COST ESTIMATION

1. MATERIAL COST:

Sl. No. Name of the Parts Quantity Cost (Rs.)

01. 1 200
Resistor
02. Capacitor 2 300

03. IR transmitter 2 250

04. IR Receiver 1 250

05. Stand 1 350

06. Pneumatic Valve 1 200

07. Pneumatic cylinder 1 200

08. Cutting Tool 1 250

09. Hose 1 200

10. Power supply 2 400

11. Connector 4 300

12. Solenoid Valve 6 200

13. Relay 1 120

Bolts and Nuts - 30
14.

TOTAL 3250
 1. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW,

GAS CUTTING:
Cost = 2200/-
3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 3250 + 2200
= 5450/-

Overhead Charges = 900/-

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

= 3250 + 2200 + 900
= 6350/-

Total cost for this project = 6350/-

 APPLICATIONS & ADVANTAGES
APPLICATIONS

 All Heavy Cutting Machine

 All Ramming Machine
 In all foundries
 In all Machine Shop
 All the industries

ADVANTAGES

 This system is more safety to the operator

 Simple type of automatic accident avoiding system
 Quick in response
 Simple in construction
 It is very useful in all industries

DISADVANTAGES

 The addition cost is required (sensor, Control unit cost)

 CONCLUSION

First of all 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
decdicated to themselves as a TRIBUTE.
 BIBLIOGRAPHY

1. Introduction to microprocessor for Engineers and Scientists

- P.K. GHOSH & P.K. SRIDHAR

2. Microprocessor & Programmed logic.

- KENNETH L. SHORT.

3.Fundamentals of Microprocessors & microcomputer.

- B. RAM

4.Microprocessor & Microcomputer based System Design.

- MOHAMMED RAFIQUZZAMAN.

5. Microcontroller Applications.

- B.P. SINGH.

6. Microcontroller Architecture, programming & application.

- A. KENNETH AYALA

7. Electronics for you-Volume 9.