PNEUMATIC VICE

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 PNEUMATIC VICE

MAIN PROJECT REPORT

Submitted in partial fulfillment of the requirement for the award of degree

of

Bachelor of Technology

in

Mechanical Engineering

Submitted by

AMIT JAISWAL (5808614)

Under the esteemed guidance of

DR. .........................,B.Tech, M.Tech.,Ph.D

Head of Department

Of

Mechanical Engineering

.................................. ENGINEERING COLLEGE

(Affiliated to ...................................... University)

2014-2015

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 TABLE OF CONTENTS
S.NO. TOPIC PAGE NO.
1 CANDIDATE’S DECLARTION 4
2 CERTIFICATE 5
3 ACKNOWLEDGEMENT 6
4 ABSTRACT 7
5 ROLE AND RESPONSIBILITIES 8
6 PERSONAL ENGINEERING ACTIVITY 9
7 INTRODUCTION 9
8 MAIN COMPONENTS 11
9 PROCEDURE OF PROJECT 12
10 ADVANTAGES 15
11 DISADVANTAGES 18
12 APPLICATIONS 19
14 MAIN PNEUMATIC COMPONENTS 21
15 SAFTY 31
16 PNEUMATIC SYSTEM DIAGRAM 33
17 COSTING 34
18 COST ESTIMATION 35
19 CONCLUSION 36

CANDIDATE’S DECLARTION

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I hereby certify that the work which is being presented by Amit Jaiswal, Ajay
Singh Chauhan, Rajeev Kumar, Raman Kumar, Vijay Kumar in partial fulfillment
of requirement for the award of degree of B.Tech. in MECHANICAL ENGINEERING
submitted at KALPI INSTITUTE OF TECHNOLOGY under KURUKSHETRA
UNIVERSITY, KURUKSHETRA is an authentic record of my own work carried out
under the supervision of Er. Harish Kumar Sharma (HOD) and Er. Vikas Kunnar.

Project Member:

Amit Jaiswal [5808614]

Ajay Singh Chauhan [5808615]
Rajeev Kumar [5808608]
Raman Kumar [5808606]
Vijay Kumar [5808613]

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 CERTIFICATE

This is certify that the dissertation entitled “ PNEUMATIC VICE ” by RAJEEV

KUSHWAHA, AMIT JAISWAL, SANDEEP ANAND SHARMA, MANISH KUMAR
TRIVEDI, PERVEZ KHAN,& DIVYANSH submitted to the Department of
mechanical engineering, Kalpi Institute Of Technology, Ambala in the partial
fulfillment of requirement for the award of Degree of Bachelor of Technology in
mechanical engineering is a record of bonafide work done by him under my
supervision and guidance during the session 2014-15. This work has not been
submitted to any other university or institute for the award of any degree or
diploma.

Head of department & project Guide

Mr.........................

Department of mechanical engineering

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 ACKNOWLEDGEMENT

First of all we would like to thank our project guide Mr. ......................
Assistant Professor, Mechanical engineering Department, Kurukshetra
University who has given valuable support during the course of our
project by clarifying our doubts and guiding us with her novel ideas.

We would like to thank Prof. .........................., Head of department,

mechanical engineering, Kurukshetra University.

We extend our sincere thanks to our Dean ....................................

Department of mechanical engineering for giving us this wonderful
opportunity to work in desired area of interest.

We extend our sincere thanks to all teaching staff of mechanical

engineering department, those who helped us in completing this
project successfully.

Lastly we also thank the people who directly or indirectly gave us

encouragement and support throughout the project.

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 ABSTRACT

Pneumatic systems are safer than electromotive systems because they can work
in inflammable environment without causing fire or explosion. Apart from that,
overloading in pneumatic system will only lead to sliding or cessation of
operation. Unlike electromotive components, pneumatic components do not burn
or get overheated when overloaded.

The operation of pneumatic systems does not produce pollutants. The air
released is also processed in special ways. Therefore, pneumatic systems can
work in environments that demand high level of cleanliness. One example is the
production lines of integrated circuits.

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Role and Responsibilities

My roles and responsibilities includes:

 Prepare a requirement document to reach expectations of project and to

come up with functionalities which are needed to be implemented.
 Documentation of expected output for various aspects with accepted
margin error was also documented.
 To design overall system based on workflow requirements.
 Discussion with the project guide and Head of Department on ways to
improve the design and to optimize performance.
 Choosing suitable components and methods based on the configurations
availability and requirements.
 Testing and remedies.
 Recommendations

As a trainee mechanical engineer, I wanted to work on a project work that would

showcase my engineering knowledge. I got the opportunity to work on
PNEUMATIC VICE. This project was very important as it evaluated my skills and
talents in my company.

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PERSONAL ENGINEERING ACTIVITY

As a mechanical engineer, before undertaking any task I checked the feasibility of

the project. In this project, my role is as team members. This report provides an
insight into the design and fabrication of a PNEUMATIC VICE.

I wanted to know more details of the project before commencing; hence, I

researched the topic thoroughly by referring to journals and articles online.
Additionally, I obtained more information by taking references about the topic.

INTRODUCTION
An incredible range of manufacturing systems use the force and power of fluids
such as water, oil and air. Powered clamps open and close with the force of
pressurized air or oil, large presses shape and form metal with hydraulic pressure,
and assembly torque tools fasten components with pressurized air. In each
example, fluid power provides the energy necessary to exert significant
mechanical forces. Systems that use air are called pneumatic systems while
systems that use liquids like oil or water are called hydraulic system. The
pneumatic systems will be the subject of the first three sessions in the course
starting from this session.

Pneumatics is all about using compressed air to make a process happens.

Compressed air is simply the air we breathe squeezed into a small space under
pressure. You might remember that air under pressure possesses potential energy
which can be released to do useful work.

Their principle of operation is similar to that of the hydraulic power systems. An

air compressor converts the mechanical energy of the prime mover into, mainly,
pressure energy of the compressed air. This transformation facilitates the
transmission, storage, and control of energy. After compression, the compressed
air should be prepared for use.
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A pneumatic system consists of a group of pneumatic components connected
together so that a signal (compressed air) is passed through the system to make
something happen at the output. These groups of components can be divided
into five categories according to their function in the pneumatic circuit as follows:

1. Supply elements: these elements are the sources of power that drives the
system which are the compressors.

2. Input elements: these elements are used to send signals to the final control
elements and come in two forms; either as components that is actuated by
the operator like push buttons or sensors that determine the status of the
power elements such as limit switches and proximity sensors.

3. Processing elements: these elements may perform operations on the input

signals before sending the signal to the final control elements such as non-
return valves, directional control valves and presser control valves.

4. Final control elements: to control the motion of actuators such as

directional control valves.

5. Power elements (actuators): these are the outputs of the pneumatic system
which use the stored potential energy to perform a certain task such as
pneumatic cylinders and motors.

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MAIN COMPONENT OF PNEUMATIC VICE
 Compressor

 Direction Control Valve

 Flow Control Valve

 Double Acting Cylinder

 Bench Vise

 Pneumatic Pipe

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PROCEDURE OF PROJECT:

 First of all we have to take a plate as per our requirement (335*210 mm).
 Make a multiple hole (as per req.) of 13 mm for clamping of plate on a
machine table.

Take batch vice of 3 mm stock length capacity. vice is in ruff casting form so some

machining process are like milling, drilling, grinding are to be carried out on it to

make as per our requirement.

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 Now we have taken a vice and fix it on a plate and fit it with the help of
bolts (hexagonal).
 We have used the ½ bolts 30 mm long.

 We have taken a cylinder of bore diameter of 50 mm, rod diameter 20

mm & length of cylinder is 100 mm.
 The rod of cylinder is fitted with the help of fabrication work.

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  Cylinder is supported by its end with a rectangular block.

 We have provided a clamp for easy movement of the pneumatic vice.

We provide two hard metal pieces to clamping object in a vice.

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 THE ADVANTAGES OF PNEUMATIC SYSTEMS

Pneumatic control systems are widely used in our society, especially in the
industrial sectors for the driving of automatic machines. Pneumatic systems
have a lot of advantages.

 High effectiveness
Many factories have equipped their production lines with compressed air
supplies and movable compressors. There is an unlimited supply of air in our
atmosphere to produce compressed air. Moreover, the use of compressed air is
not restricted by distance, as it can easily be transported through pipes. After
use, compressed air can be released directly into the atmosphere without the
need of processing.

 High durability and reliability

Pneumatic components are extremely durable and cannot be damaged easily.
Compared to electromotive components, pneumatic components are more
durable and reliable.

 Simple design
The designs of pneumatic components are relatively simple. They are thus
more suitable for use in simple automatic control systems.

 High adaptability to harsh environment

Compared to the elements of other systems, compressed air is less affected by
high Temperature, dust, corrosion, etc.

 Safety
 Pneumatic systems are safer than electromotive systems because they can
work in inflammable environment without causing fire or explosion. Apart
from that, overloading in pneumatic system will only lead to sliding or
cessation of operation. Unlike electromotive components, pneumatic
components do not burn or get overheated when overloaded.

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 Easy selection of speed and pressure
The speeds of rectilinear and oscillating movement of pneumatic systems are
easy to adjust and subject to few limitations. The pressure and the volume of air
can easily be adjusted by a pressure regulator.

 Environmental friendly
The operation of pneumatic systems does not produce pollutants. The air
released is also processed in special ways. Therefore, pneumatic systems can
work in environments that demand high level of cleanliness. One example is the
production lines of integrated circuits.

 Economical
 As pneumatic components are not expensive, the costs of pneumatic
systems are quite low. Moreover, as pneumatic systems are very durable,
the cost of repair is significantly lower than that of other systems.

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 ADVANTAGE OF PNEUMATIC VICE

 Quick operation.
 Stable and rigid design.
 Extremely high clamping force.
 High accuracy and repeatability.
 Reduces production costs.
 Design is compact and very simple to operate requiring almost no
maintenance.
 Can be mounted horizontally or vertically.

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 DISADVANTAGE OF PNEUMATIC SYSTEMS

Although pneumatic systems possess a lot of advantages, they are also subject to
many limitations.

 Relatively low accuracy

As pneumatic systems are powered by the force provided by compressed air,
their operation is subject to the volume of the compressed air. As the volume
of air may change when compressed or heated, the supply of air to the system
may not be accurate, causing a decrease in the overall accuracy of the system.

 Low loading
As the cylinders of pneumatic components are not very large, a pneumatic
system cannot drive loads that are too heavy.

 Processing required before use

Compressed air must be processed before use to ensure the absence of water
vapour or dust. Otherwise, the moving parts of the pneumatic components
may wear out quickly due to friction.

 Uneven moving speed

As air can easily be compressed, the moving speeds of the pistons are
relatively uneven.

 Noise
Noise will be produced when compressed air is released from the pneumatic
components.

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 THE APPLICATION OF PNEUMATIC SYSTEMS

The application of pneumatic systems is very extensive. The following are

some examples.

(a) Transport system

Figure shows a simplified industrial transport system. When the button
switch is pushed, the cylinder will push one of the goods from the shelf onto
the transfer belt. When the button switch is released, the cylinder will retract
automatically. Fig. 34b shows the circuit diagram of the transport system.

(a) Operation of a pneumatic transport system

(b) Pneumatic circuit diagram of a pneumatic transport system

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(b) Vehicle door operation system
Pneumatic systems can be used to operate the doors of public vehicles (Fig.
35a). Assuming that the opening and closing of the doors are controlled by
two button switches ON and OFF. When the button switch ON is pressed, the
doors will open. When the button switch OFF is pushed, the doors will close.
Fig. 35b shows a pneumatic system that can be used to operate the doors of
vehicles.

(a) Operation of a pneumatic system that

(b) Pneumatic circuit diagram controls the movement of vehicle doors.

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 MAIN PNEUMATIC COMPONENTS

 PNEUMATIC CYLINDER

The basic, rod-style industrial cylinder consists of a tube sealed by end caps. A rod attached to an
internal piston extends through a sealed opening in one of the ends. The cylinder mounts to a machine
and the piston rod acts upon the load. A port at one end of the cylinder supplies compressed air to one
side of the piston, causing it (and the piston rod) to move. The port at the other end lets air on the
opposite side of the piston escape —usually to atmosphere. Reversing the roles of the two ports makes
the piston and rod stroke in the opposite direction. Rod-style cylinders function in two ways: Double-
acting cylinders use compressed air to power both the extend and retract strokes, moving the rod back
and forth. This arrangement makes them ideal for pushing and pulling loads. Controlling the rate at
which air exhausts determines rod speed. Single-acting cylinders have compressed air supplied to only
one side of the piston; the other side vents to atmosphere. Depending on whether air is routed to the
cap or rod end determines whether the rod extends or retracts.

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 Pneumatic components can be divided into two categories:
1. Components that produce and transport compressed air.
2. Components that consume compressed air.

All main pneumatic components can be represented by simple

pneumatic symbols. Each symbol shows only the function of the component it
represents, but not its structure. Pneumatic symbols can be combined to form
pneumatic diagrams. A pneumatic diagram describes the relations between
each pneumatic component, that is, the design of the system.

(a) Compressor
A compressor can compress air to the required pressures. It can
convert the mechanical energy from motors and engines into the potential
energy in compressed air (Fig. 2). A single central compressor can supply
various pneumatic components with compressed air, which is transported
through pipes from the cylinder to the pneumatic components. Compressors
can be divided into two classes: reciprocator and rotary.

(a) Compressor used in laboratories (c) Pneumatic symbol of compressor

(b) Pressure regulating component

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Pressure regulating components are formed by various components, each of
which has its own pneumatic symbol:
(i) Filter – can remove impurities from compressed air before it is fed to the
pneumaticcomponents.
(ii) Pressure regulator – to stabilize the pressure and regulate the operation of
pneumaticcomponents
(iii) Lubricator – To provide lubrication for pneumatic components.

(a) Pressure regulating component

(b) Pneumatic symbols of the pneumatic components within a pressure

regulating component

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3 The consumption of compressed air
Examples of components that consume compressed air include
execution components (cylinders), directional control valves and assistant
valves.

(a) Execution component

Pneumatic execution components provide rectilinear or rotary
movement. Examples of pneumatic execution components include cylinder
pistons, pneumatic motors, etc. Rectilinear motion is produced by cylinder
pistons, while pneumatic motors provide continuous rotations. There are
many kinds of cylinders, such as single acting cylinders and double acting
cylinders.

(i) Single acting cylinder

Therefore, it can only produce thrust in one direction (Fig. 4). The piston
rod is propelled in the opposite direction by an internal spring, or by the
external force provided by mechanical movement or weight of a load.

Fig. 4 Cross section of a single acting cylinder

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 Fig. 5 (a) Single acting cylinder

(b) Pneumatic symbol of a single acting cylinder

The thrust from the piston rod is greatly lowered because it has to overcome
the force from the spring. Therefore, in order to provide the driving force for
machines, the diameter of the cylinder should be increased. In order to match
the length of the spring, the length of the cylinder should also be increased,
thus limiting the length of the path. Single acting cylinders are used in
stamping, printing, moving materials, etc.

(ii) Double acting cylinder

In a double acting cylinder, air pressure is applied alternately to the

relative surface of the piston, producing a propelling force and a retracting
force (Fig. 6). As the effective area of the piston is small, the thrust produced
during retraction is relatively weak. The impeccable tubes of double acting
cylinders are usually made of steel. The working surfaces are also polished and
coated with chromium to reduce friction.

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 (b) Pneumatic symbol of a double

Fig. 7 (a) Double acting cylinder acting cylinder

(c) Directional control valve

Directional control valves ensure the flow of air between air ports by
opening, closing and switching their internal connections. Their classification is
determined by the number of ports, the number of switching positions, the
normal position of the valve and its method of operation. Common types of
directional control valves include 2/2, 3/2, 5/2, etc. The first number
represents the number of ports; the second number represents the number of
positions. A directional control valve that has two ports and five positions can
be represented by the drawing in Fig. 8, as well as its own unique pneumatic
symbol.

Fig. 8 Describing a 5/2 directional control valve

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(i) 2/2 Directional control valve

The structure of a 2/2 directional control valve is very simple. It uses

the thrust from the spring to open and close the valve, stopping compressed
air from flowing towards working tube ‘A’ from air inlet ‘P’. When a force is
applied to the control axis, the valve will be pushed open, connecting ‘P’ with
‘A’ (Fig. 9). The force applied to the control axis has to overcome both air
pressure and the repulsive force of the spring. The control valve can be driven
manually or mechanically, and restored to its original position by the spring.

Fig. 9 (a) 2/2 directional control valve

(c) Pneumatic symbol of a 2/2 directional control valve

(ii) 3/2 Directional control valve

A 3/2 directional control valve can be used to control a single acting

cylinder (Fig. 10). The open valves in the middle will close until ‘P’ and ‘A’ are
connected together. Then another valve will open the sealed base between ‘A’
and ‘R’ (exhaust). The valves can be driven manually, mechanically, electrically
or pneumatically. 3/2 directional control valves can further be divided into
two :

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Normally open type (N.O.) and normally closed type (N.C.) (Fig. 11).

Fig. 10 (a) 3/2 directional control valve

(b) Cross section

(c) Normally closed type

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 (d) Normally open type

(iv) 5/2 Directional control valve

When a pressure pulse is input into the pressure control port ‘P’, the
spool will move to the left, connecting inlet ‘P’ and work passage ‘B’. Work
passage ‘A’ will then make a release of air through ‘R1’ and ‘R2’. The
directional valves will remain in this operational position until signals of the
contrary are received. Therefore, this type of directional control valves is said
to have the function of ‘memory’.

(a) Cross section

(b) Pneumatic symbol

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(c) Control valve
A control valve is a valve that controls the flow of air. Examples include
non-return valves, flow control valves, shuttle valves, etc.

(i) Non-return valve

A non-return valve allows air to flow in one direction only. When air
flows in the opposite direction, the valve will close. Another name for non-
return valve is poppet valve (Fig. 13).

(a) Non-return valve

(c) Pneumatic symbol

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 (ii) Flow control valve
A flow control valve is formed by a non-return valve and a variable
throttle
(Fig. 14).

(a) Flow control valve

(b) Cross section

(c) Pneumatic symbol

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 AIR COMPRESSOR
An air compressor is a device that converts power (using an electric motor, diesel or gasoline engine,
etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of several methods, an
air compressor forces more and more air into a storage tank, increasing the pressure. When tank
pressure reaches its upper limit the air compressor shuts off. The compressed air, then, is held in the
tank until called into use. The energy contained in the compressed air can be used for a variety of
applications, utilizing the kinetic energy of the air as it is released and the tank depressurizes. When tank
pressure reaches its lower limit, the air compressor turns on again and re-pressurizes the tank.




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 SOLENOID VALVE

A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current
through a solenoid: in the case of a two-port valve the flow is switched on or off; in the case of a three-
port valve, the outflow is switched between the two outlet ports. Multiple solenoid valves can be placed
together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut off,
release, dose, distribute or mix fluids. They are found in many application areas. Solenoids offer fast and

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safe switching, high reliability, long service life, good medium compatibility of the materials used, low
control power and compact design.

Besides the plunger-type actuator which is used most frequently, pivoted-armature actuators and rocker
actuators are also used.

A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is controlled by an
electric current through a solenoid coil. Solenoid valves are the most frequently used control elements
in fluidics. Their tasks are to shut off, release, dose, distribute or mix fluids. They are found in many
application areas.

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For controlling the air flow in and out of the engine we use a 3/2 pilot operated normally closed valve.
The symbol of the 3/2 valve is as shown:

Valve Symbol

The specifications of the valve are the following:

• Orifice: 12mm.

• Operating pressure range: 2-10bar

• Flow rate: 3000Litres/minute

• Coil width: 32mm.

• Duty cycle: Continuous

The construction and the working of the 3/2 solenoid valve can be explained with the help of the
following diagram:

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Fig. Construction and Working

The figure shows the operation of a pilot operated 3/2 pneumatic valve. The solenoid operates the small
pilot valve directly. Because this valve has a small area, a low operating force is requires. The pilot valve
applies line pressure to the top of the control valve causing it to move down, closing the exhaust port.
When it contacts the main valve disc there are two forces acting on the valve stem. The pilot valve
applies a downwards force of P×D, where P is the line pressure and D is the area of the control valve.
Line pressure also applies an upwards force P×E to the stem, where E is the area of the main valve. The
area of the control valve, D, is greater than area of the main valve E, so the downwards force is the
larger and the valve opens.

When the solenoid de-energizes, the space above the control valve is vented. Line and spring pressure
on the main valve causes the valve stem to rise again.

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Directional control valves are one of the most fundamental parts in hydraulic machinery as well and
pneumatic machinery. They allow fluid flow into different paths from one or more sources. They usually
consist of a spool inside a cylinder which is mechanically or electrically controlled. The movement of the
spool restricts or permits the flow, thus it controls the fluid flow.

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 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.

PARTS OF A SOLENOID VALVE:

A. COIL:

The solenoid coil is made of copper wire. The layers of wire are separated by insulating layer. The entire
solenoid coil is covered with a varnish that is not affected by solvents, moisture, cutting oil or often
fluids. Coils are rated in various voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6
Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are designed for such frequencies
as 50 Hz to 60 Hz.

B. FRAME:

The solenoid frame serves several purposes. Since it is made of laminated sheets, it is magnetized when
the current passes through the coil. The magnetized coil attracts the metal plunger to move. The frame
has provisions for attaching the mounting. They are usually bolted or welded to the frame. The frame
has provisions for receivers, the plunger. The wear strips are mounted to the solenoid frame, and are
made of materials such as metal or impregnated less fiber cloth.

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C. SOLENOID PLUNGER

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is made of steel laminations
which are riveted together under high pressure, so that there will be no movement of the lamination
with respect to one another. At the top of the plunger a pin hole is placed for making a connection to
some device. The solenoid plunger is moved by a magnetic force in one direction and is usually returned
by spring action.

Solenoid operated valves are usually provided with cover over either the solenoid or the entire valve.
This protects the solenoid from dirt and other foreign matter, and protects the actuator. In many
applications it is necessary to use explosion proof solenoids.

WORKING OF SOLENOID VALVE:

The solenoid valve has 5 openings. This ensures 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’

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 close

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5/2 Way Solenoid Valve Sectional View

SOLENOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve or solenoid valve. This
solenoid cut off valve is controlled by the electronic control unit.

In our project separate solenoid valve is used for flow direction of vice cylinder. It is used to flow the air
from compressor to the single acting cylinder.

 FLOW CONTROL VALVE:

In any fluid power circuit, flow control valve is used to control the speed of the actuator. The flow
control can be achieved by varying the area of flow through which the air in passing.

When area is increased, more quantity of air will be sent to actuator as a result its speed will increase. If
the quantity of air entering into the actuator is reduced, the speed of the actuator is reduced.

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Flow Control Valve

Flow control valves facilitate high precision adjustment of flow volumes and are used to precisely
control the piston speed of a drive.

For adjustable speed via exhaust air flow control. The piston moves between air cushions created
through freely flowing supply air and restricted exhaust air. The benefit is improved operating
behaviour, even in the event of load changes

For adjustable speed via supply air flow control. The piston is moved via an air cushion at one end,
created by freely flowing exhaust air and restricted supply air. In contrast with exhaust air restriction,
there is a tendency towards a stick-slip effect.

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Flow Control Valve For Pneumatic Cylinder

 HOSES
Hoses used in this pneumatic system are made up of polyurethane. These hose can with stand at a
maximum pressure level of 10 N/m². Polyurethane combines the best properties of both plastic and
rubber. It offers abrasion and tear resistance, high tensile and elongation values, and low compression
set.

Polyurethane is naturally flexible and exhibits virtually unlimited flexural abilities. Combining good
chemical resistance with excellent weathering characteristics sets polyurethane apart from most other
thermoplastics. It has exceptional resistance to most gasolines, oils, kerosene, and other petroleum
based chemicals, making it an ideal choice for fuel lines (although additives in today’s gasoline and
petroleum products warrant field testing).

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Poly Urathane Tubes

APPLICATIONS OF PU TUBE:

• Any time condensation can occur with small actuators, air grippers and air operated valves.
Condensation in a pneumatic system will cause operating failure and affect the life of pneumatic
equipment.

• Manufacturers of electrical components.

• When you need to eliminate water condensation but you cannot use a membrane or desiccant dryer
(as you cannot use a fast exhaust).

BENEFITS OF PU TUBE:

• Longer life of other pneumatic equipment.

• Prevents operational failure of small actuators, air grippers and pilot operated valves due to
condensation.

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• Avoids corrosion in other pneumatic equipment.

• Diffuses water vapour in the piping to the outside before it liquefies, so we avoid problems such as
dried grease or ozone when using other types of dryers.

• Easy mounting.

 CONNECTORS:
In our system hose connectors are used . Hose connectors normally comprise an adoptee hose nipple.
These types of connectors are made up of brass (or) Aluminum (or) hardened pneumatic steel. For these
type hose connectors no need of hose clamp these are self-locking hose connectors. a Multi way four
way hose connecter.

The universal combination at an attractive price. Can be widely used thanks to resistant materials. Easy
to install thanks to optimised bending radii. Limited reset effect. Attractively priced: the universal
solution for metal fittings. Perfect for standard pneumatic applications – in many different fields. Wide
range of variants Over 1000 types for maximum flexibility in standard applications. Hydrolysis resistant
For applications in damp environments or in contact with water at up to 60 °C. Resistant to pressure
Secure connection when used with pressure ranges of up to 14 bar. Economical for pneumatic
installations in the high pressure ranges.

Hose Connector

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The powerful combination for applications involving pressure ranges up to 16 bar For example, for
applications with the pressure booster Robust, flexible and reliable connection for the automotive
industry. Fulfils the requirements Heat resistant For reliable compressed air supply in high temperature
ranges. Whether with 10 bar at 80 °C or 6 bar at 150 °C – always delivers maximum process security.
Anti-static Electrically conductive tubing combined with a solid-metal fitting Approved for the food
Industry Food and Drug Administration certification for use in the food industry:

Four way hose connector

The hydrolysis-resistant combination with increased functions. Designed to meet the highest demands,
This combination shines in applications which require the highest possible hygiene standards for food.
The cost-effective alternative to stainless steel, perfect for e.g. critical environments such as the splash
zone: resistant to practically all common cleaning agents, with maximum corrosion protection. Resistant
to media Completely resistant to all cleaning agents and lubricants and even permits the transportation
of acids and lyes without any problems.

Flame-retardant Safe in areas where there is a risk of fire thanks to flame-retardant properties to
Resistant to welding Spatter The economical combination for applications not in close proximity to
welding applications. Also reliable for applications in direct proximity to welding splatter Double-
sheathed tube and special fitting.

 CONTROL UNIT

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A pneumatic multipurpose device is an air-operated device used for many small operations. It is a
portable one. Compressed air is the source of energy for this device. The compressed air is allowed to
pass through the nozzle in such a way that the rotation obtained is utilized for machining.

The nozzles welded to the fan can be rotated in either direction. The rpm and torque of the shaft
depends upon the pressure of the air admitted so by varying the pressure, the RPM and torque can be
varied. Thick tubes interconnect the parts. The Clamps are used at the connecting parts to prevent
leakage. In thread parts seals are used to prevent leakage.

The compressed air from the compressor first enters the control unit. In the control unit the pressure of
the air is controlled and sent to the barrel to rotate the fan in the required direction. The gate valve
controls the pressure and volume of air. Then the pressure is read by a pressure gauge. Later the air is
admitted to the barrel, a shaft is placed and it bikeries the fan.

The shaft is supported by bearing. The bearings are placed in the couplings, which covers the end of
barrel.

 BOLT
A screw, or bolt, is a type of fastener, typically made of metal, and characterized by a helical ridge,
known as a male thread (external thread) or just thread, wrapped around a cylinder. Some screw
threads are designed to mate with a complementary thread, known as a female thread (internal thread),
often in the form of a nut or an object that has the internal thread formed into it. Other screw threads
are designed to cut a helical groove in a softer material as the screw is inserted. The most common uses
of screws are to hold objects together and to position objects.

A screw will almost always have a head on one end which contains a specially formed shape that allows
it to be turned, or driven, with a tool. Common tools for driving screws include screwdrivers and
wrenches. The head is usually larger than the body of the screw, which keeps the screw from being
driven deeper than the length of the screw and to provide a bearing surface. There are exceptions; for
instance, carriage bolts have a domed head that is not designed to be driven; set screws often have a
head smaller than the outer diameter of the screw; J-bolts have a J-shaped head which is not designed
to be driven, but rather is usually sunk into concrete allowing it to be used as an anchor bolt. The
cylindrical portion of the screw from the underside of the head to the tip is known as the shank; it may
be fully threaded or partially threaded.[1] The distance between each thread is called the "pitch".

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The majority of screws are tightened by clockwise rotation, which is termed a right-hand thread; a
common mnemonic device for remembering this when working with screws or bolts is "righty-tighty,
lefty-loosey." Screws with left-hand threads are used in exceptional cases. For example, when the screw
will be subject to counterclockwise torque (which would work to undo a right-hand thread), a left-hand-
threaded screw would be an appropriate choice. The left side pedal of a bicycle has a left-hand thread.

More generally, screw may mean any helical device, such as a clamp, a micrometer, a ship's propeller or
an Archimedes' screw water pump.

 HEX NUT
A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a mating bolt to
fasten a stack of parts together. The two partners are kept together by a combination of their threads'
friction, a slight stretch of the bolt, and compression of the parts. In applications where vibration or
rotation may work a nut loose, various locking mechanisms may be employed: Adhesives, safety pins or
lockwire, nylon inserts, or slightly oval-shaped threads. The most common shape is hexagonal, for
similar reasons as the bolt head - 6 sides give a good granularity of angles for a tool to approach from
(good in tight spots), but more (and smaller) corners would be vulnerable to being rounded off. Also It
takes only 1/6th of a rotation to obtain the next side of the hexagon and grip is optimal.However
polygons with more than 6 sides do not give the requisite grip and polygons with less than 6 sides take
more time to be given a complete rotation.Other specialized shapes exist for certain needs, such as wing
nuts for finger adjustment and captive nuts for inaccessible areas.

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Nuts are graded with strength ratings compatible with their respective bolts; for example, an ISO
property class 10 nut will be able to support the bolt proof strength load of an ISO property class 10.9
bolt without stripping. Likewise, an SAE class 5 nut can support the proof load of an SAE class 5 bolt, and
so on.

A wide variety of nuts exists, from household hardware versions to specialized industry-specific designs
that are engineered to meet various technical standards.

 WASHER
A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used
to distribute the load of a threaded fastener, such as a screw or nut. Other uses are as a spacer, spring
(belleville washer, wave washer), wear pad, preload indicating device, locking device, and to reduce
vibration (rubber washer). Washers usually have an outer diameter (OD) about twice the width of their
inner diameter (ID).

Washers are usually metal or plastic. High quality bolted joints require hardened steel washers to
prevent the loss of pre-load due to Brinelling after the torque is applied.

Rubber or fiber gaskets used in taps (or faucets, or valves) to stop the flow of water are sometimes
referred to colloquially as washers; but, while they may look similar, washers and gaskets are usually
designed for different functions and made differently.

Washers are also important for preventing galvanic corrosion, particularly by insulating steel screws
from aluminium surfaces.

The origin of the word is unknown; the first recorded use of the word was in 1346, however the first
time its definition was recorded was in 1611.

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 SAFETY MEASURES WHEN USING PNEUMATIC CONTROL SYSTEMS

(a) Compressed air can cause serious damage to the human body if they enter
the body through ducts like the oral cavity or ears.

(b) Never spray compressed air onto anyone.

(c) Under high temperature, compressed air can pass through human skin.

(d) Compressed air released from the exhaust contains particles and oil
droplets, which can cause damage to eyes.

(e) Even though the pressure of compressed air in pipes and reservoirs is
relatively low, when the container loses its entirety, fierce explosions may
still occur.

(f) Before switching on a compressed air supply unit, one should thoroughly
inspect the whole circuit to see if there are any loose parts, abnormal
pressure or damaged pipes.

(g) A loose pipe may shake violently due to the high pressure built up
inside it. Therefore, each time before the system pressure is increased,
thorough inspection of the entire circuit is required to prevent

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 accidents.

(h) As the force produced by pneumatic cylinders is relatively large, and the
action is usually very fast, you may suffer serious injuries if you get hit by a
cylinder.

(i) Switches should be installed on the compressed air supply unit to allow
easy and speedy control of air flow.
(j) In case of a leakage, the compressed air supply unit should be turned
off immediately.

(k) The compressed air supply unit must be turned off before changes can
be made to the system.

(l) Stay clear of the moving parts of the system. Never try to move the
driving parts in the mechanical operation valve with your hand.

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PNEUMATIC SYSTEMS DIAGRAM

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 Calculations:

• Perimeter of the Cylinder = 2*π*R=23cm

• R=23/(2*π)
• R=3.66cm
• Diameter of the cylinder D=2R
• D=2*3.66
• D=7.32
• Connecting rod Perimeter = 2*π*r = 2.5cm
• r = 2.5/(2*π)
• r = 0.3978 cm
• Diameter of the connecting rod = d= 2r
• d =2*0.3978
• d = 0.7956
• Total stroke length of the cylinder = 10.5 cm
• Effective stroke length = 6cm
• F =Force exerted on work piece
• F = P*A
• F = (Pcomp – Patm) * A
• F= (Pcomp – Patm) * π/4(D^2 –d^2)
•

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 COSTING

• There are three elements of any products are :

(1) Material (2) Labor (3) Expenses

 Material :
• Direct material :
Material which is processed for final product but it is a part of the product is
direct material cost is this material is called direct from market.
• In – direct material :
Material which does not forms part of the final product but it is a must be
for processing direct material is called in-direct material e.g. – Cotton waste,
oil, etc.
 Labor :
• Direct labor :
The worker who actually performed the work on the directly material
rather mechanically of by machine is called direct labor.
• In-direct labor :
It supervised the activity of the direct labor.
 Expenses:
• Direct Expenses :
The expenses, which can be directly changed on the particular product, are
called expenses.
• In – Direct Expenses :

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 The expenses that cannot be directly or confidently changed on particular
products are called in-direct expenses.

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 COST ESTIMATION

Sr. No. Types of cost Cost

1. Direct material cost ......... /-

2. Direct labour cost .........../-

3. Direct other expenses ............/-

_ Total Cost= ............/-

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 CONCLUSIONS

The project thus gives a system that can easily fixed the workpiece &
work on it. The pneumatic vice provide extremely high clamping force & High
accuracy and repeatability. Pneumatic system can get high production rate. When
compressed air is released from the pneumatic components then noise can
produced. The operation of pneumatic systems does not produce pollutants.

So ,The pneumatic vice can be use easily.

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