Design and Fabrication of Pneumatic Multipoint Grease Gun

Abstract
Automation in the modern world is inevitable. Any multipoint machine aimed at the economical
use of man, machine, and material worth the most. Lubrication is the lifeline for any industry.
Machines in various industries like textile, printing, machine tools, automobile industries and
excavators are to be lubricated in order to reduce the friction created between moving parts. If
machines are not properly lubricated at regular intervals, they are seized thus incurring heavy
losses. The manufacturers of machinery are recommended to lubricate various points at a
periodic interval. The lubrication of various points of machinery is also a difficult task in
industries where more number of machines have been installed and needed lubrication like
printing machinery, excavators, textile machinery etc., where the number of points to be
lubricated may range from 40 to 50. In the above cases, lubrications are not only a time
consuming process, but also results in workman fatigue. The centralized multipoint lubricating
system is used for easy and economical lubrication of multiple points from one centrally located
distributor. It is designed to deliver the right amount of lubricant at the right time to every point
by means of distributors connected by hoses.
 INTRODUCTION
When two or more surfaces are in moving contact with each other friction is created between
them. Lubricants are used to reduce this friction. In the process, they also reduce the wear which
the friction causes. Lubrication also counters corrosion by providing a protective film on the
concerned surface. In the early years of industrial revolution lubrication of machinery was
anything but systematic. Lubricants were used haphazardly chiefly when friction began to wear
out machinery rather than to prevent it from happening. But as more and more sophisticated
machinery were developed a whole range of lubricants were delivered to the concerned surfaces
in the quantities and at speeds appropriate to the situation. Mechanization is broadly defined as
the replacement of manual effort by mechanical power. Pneumatics 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 both the power or
energy requirements and the control system (although equally pneumatic control systems may be
economical and can be advantageously applied to other forms of power). The main advantages of
an all-pneumatic system are usually economy and simplicity, the latter reducing maintenance to a
low level. It can also have outstanding advantages in terms of safety. 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 the 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 maybe push type or pull type.
The push type solenoid is one in which the plunger is pushed when the solenoid is energized
electrically. The pull type solenoid is one in which the plunger is pulled when the solenoid is
energized.
Components Used
The components used in this project are:

1. Pneumatic cylinder
2. Solenoid valve
3. Storage tank

Solenoid valve

A solenoid valve is an electromechanically operated valve.Solenoid valves differ in the

characteristics of the electric current they use, the strength of the magnetic field they generate,
the mechanism they use to regulate the fluid, and the type and characteristics of fluid they
control. The mechanism varies from linear action, plunger-type actuators to pivoted-armature
actuators and rocker actuators. The valve can use a two-port design to regulate a flow or use a
three or more port design to switch flows between 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 safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.

Solenoid valves.

Operation

There are many valve design variations. Ordinary valves can have many ports and fluid
paths. A 2-way valve, for example, has 2 ports; if the valve is open, then the two ports are
connected and fluid may flow between the ports; if the valve is closed, then ports are isolated. If
the valve is open when the solenoid is not energized, then the valve is termed normally
open (N.O.). Similarly, if the valve is closed when the solenoid is not energized, then the valve is
termed normally closed. There are also 3-way and more complicated designs. A 3-way valve has
3 ports; it connects one port to either of the two other ports (typically a supply port and an
exhaust port). Solenoid valves are also characterized by how they operate. A small solenoid can
generate a limited force. If that force is sufficient to open and close the valve, then a direct
acting solenoid valve is possible. An approximate relationship between the required solenoid
force Fs, the fluid pressure P, and the orifice area A for a direct acting solenoid valve is:

Where d is the orifice diameter. A typical solenoid force might be 15 N (3.4 lbf). An application
might be a low pressure (e.g., 10 psi (69 kPa)) gas with a small orifice diameter (e.g., 3⁄8 in
(9.5 mm) for an orifice area of 0.11 in2 (7.1×10−5 m2) and approximate force of 1.1 lbf (4.9 N)).

When high pressures and large orifices are encountered, then high forces are required. To
generate those forces, an internally piloted solenoid valve design may be possible. In such a
design, the line pressure is used to generate the high valve forces; a small solenoid controls how
the line pressure is used. Internally piloted valves are used in dishwashers and irrigation systems
where the fluid is water, the pressure might be 80 psi (550 kPa) and the orifice diameter might
be 3⁄4 in (19 mm).

In some solenoid valves the solenoid acts directly on the main valve. Others use a small,
complete solenoid valve, known as a pilot, to actuate a larger valve. While the second type is
actually a solenoid valve combined with a pneumatically actuated valve, they are sold and
packaged as a single unit referred to as a solenoid valve. Piloted valves require much less power
to control, but they are noticeably slower. Piloted solenoids usually need full power at all times
to open and stay open, where a direct acting solenoid may only need full power for a short period
of time to open it, and only low power to hold it. A direct acting solenoid valve typically
operates in 5 to 10 milliseconds. The operation time of a piloted valve depends on its size;
typical values are 15 to 150 milliseconds. Power consumption and supply requirements of the
solenoid vary with application, being primarily determined by fluid pressure and line diameter.
For example, a popular 3/4" 150 psi sprinkler valve, intended for 24 VAC (50 - 60 Hz)
residential systems, has a momentary inrush of 7.2 VA, and a holding power requirement of 4.6
VA. Comparatively, an industrial 1/2" 10000 psi valve, intended for 12, 24, or 120 VAC systems
in high pressure fluid and cryogenic applications, has an inrush of 300 VA and a holding power
of 22 VA. Neither valve lists a minimum pressure required to remain closed in the un-powered
state.

The solenoid valve (small black box at the top of the photo) with input airline (small green tube)
used to actuate a larger rack and pinion actuator (gray box) which controls the water pipe valve.

Internally piloted

While there are multiple design variants, the following is a detailed breakdown of a typical
solenoid valve design. A solenoid valve has two main parts: the solenoid and the valve. The
solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the
valve mechanically. A direct acting valve has only a small flow circuit, shown within
section E of this diagram (this section is mentioned below as a pilot valve). In this example, a
diaphragm piloted valve multiplies this small pilot flow, by using it to control the flow through a
much larger orifice.

Solenoid valves may use metal seals or rubber seals, and may also have electrical interfaces to
allow for easy control. A spring may be used to hold the valve opened (normally open) or closed
(normally closed) while the valve is not activated.
A-Input side
B- Diaphragm
C- Pressure chamber
D- Pressure relief passage
E- Electro Mechanical Solenoid
F- Output side

The diagram to the right shows the design of a basic valve, controlling the flow of water
in this example. At the top figure is the valve in its closed state. The water under pressure enters
at A. B is an elastic diaphragm and above it is a weak spring pushing it down. The diaphragm
has a pinhole through its center which allows a very small amount of water to flow through it.
This water fills the cavity C on the other side of the diaphragm so that pressure is equal on both
sides of the diaphragm, however the compressed spring supplies a net downward force. The
spring is weak and is only able to close the inlet because water pressure is equalized on both
sides of the diaphragm.
Once the diaphragm closes the valve, the pressure on the outlet side of its bottom is reduced, and
the greater pressure above holds it even more firmly closed. Thus, the spring is irrelevant to
holding the valve closed. The above all works because the small drain passage D was blocked by
a pin which is the armature of the solenoid E and which is pushed down by a spring. If current is
passed through the solenoid, the pin is withdrawn via magnetic force, and the water in
chamber C drains out the passage D faster than the pinhole can refill it. The pressure in
chamber C drops and the incoming pressure lifts the diaphragm, thus opening the main valve.
Water now flows directly from A to F. When the solenoid is again deactivated and the
passage D is closed again, the spring needs very little force to push the diaphragm down again
and the main valve closes. In practice there is often no separate spring; the elastomer diaphragm
is molded so that it functions as its own spring, preferring to be in the closed shape.

From this explanation it can be seen that this type of valve relies on a differential of pressure
between input and output as the pressure at the input must always be greater than the pressure at
the output for it to work. Should the pressure at the output, for any reason, rise above that of the
input then the valve would open regardless of the state of the solenoid and pilot valve.

Components

Example core tubes. Non-magnetic core tubes are used to isolate the fluid from the coil. The core
tube encloses the plugnut, the core spring, and the core. The coil slips over the core tube; a
retaining clip engages the depression near the closed end of the core tube and holds the coil on
the core tube.

 Solenoid valve designs have many variations and challenges.

 Common components of a solenoid valve:
 Solenoid subassembly
  Retaining clip (a.k.a. coil clip)
 Solenoid coil (with magnetic return path)
 Core tube (a.k.a. armature tube, plunger tube, solenoid valve tube, sleeve, guide
assembly)
 Plugnut (a.k.a. fixed core)
 Shading coil (a.k.a. shading ring)
 Core spring (a.k.a. counter spring)
 Core (a.k.a. plunger, armature)
 Core tube–bonnet seal
 Bonnet (a.k.a. cover)
 Bonnet–diaphragm–body seal
 Hanger spring
 Backup washer
 Diaphragm
 Bleed hole
 Disk
 Valve body

Seat

The core or plunger is the magnetic component that moves when the solenoid is energized. The
core is coaxial with the solenoid. The core's movement will make or break the seals that control
the movement of the fluid. When the coil is not energized, springs will hold the core in its
normal position.

The plugnut is also coaxial.

The core tube contains and guides the core. It also retains the plugnut and may seal the fluid. To
optimize the movement of the core, the core tube needs to be nonmagnetic. If the core tube were
magnetic, then it would offer a shunt path for the field lines. In some designs, the core tube is an
enclosed metal shell produced by deep drawing. Such a design simplifies the sealing problems
because the fluid cannot escape from the enclosure, but the design also increases the magnetic
path resistance because the magnetic path must traverse the thickness of the core tube twice:
once near the plugnut and once near the core. In some other designs, the core tube is not closed
but rather an open tube that slips over one end of the plugnut. To retain the plugnut, the tube
might be crimped to the plugnut. An O-ring seal between the tube and the plugnut will prevent
the fluid from escaping.

The solenoid coil consists of many turns of copper wire that surround the core tube and induce
the movement of the core. The coil is often encapsulated in epoxy. The coil also has an iron
frame that provides a low magnetic path resistance.

Materials

The valve body must be compatible with the fluid; common materials are brass, stainless
steel, aluminium, and plastic. The seals must be compatible with the fluid. To simplify the
sealing issues, the plugnut, core, springs, shading ring, and other components are often exposed
to the fluid, so they must be compatible as well. The requirements present some special
problems. The core tube needs to be non-magnetic to pass the solenoid's field through to the
plugnut and the core. The plugnut and core need a material with good magnetic properties such
as iron, but iron is prone to corrosion. Stainless steels can be used because they come in both
magnetic and non-magnetic varieties. For example, a solenoid valve might use 304 stainless steel
for the body, 305 stainless steel for the core tube, 302 stainless steel for the springs, and 430 F
stainless steel (a magnetic stainless steel) for the core and plugnut.

Types

 Many variations are possible on the basic, one-way, one-solenoid valve described above:
 one- or two-solenoid valves;
 direct current or alternating current powered;
 different number of ways and positions;

Common uses

Solenoid valves are used in fluid power pneumatic and hydraulic systems, to control cylinders,
fluid power motors or larger industrial valves. Automatic irrigation sprinkler systems also use
solenoid valves with an automatic controller. Domestic washing machines and dishwashers use
solenoid valves to control water entry into the machine. They are also often used in paintball gun
triggers to actuate the CO2 hammer valve. Solenoid valves are usually referred to simply as
"solenoids."

Solenoid valves can be used for a wide array of industrial applications, including general on-off
control, calibration and test stands, pilot plant control loops, process control systems, and various
original equipment manufacturer applications.

History and commercial development

In 1910, ASCO Numatics became the first company to develop and manufacture the solenoid
valve.

Pneumatic Systems:

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 mean s the application of air as a working medium in
industry especially in driving and controlling of machines and equipment. Pneumatics has been
considered to be used to carry out simple mechanical tasks. But, in today’s world it is playing an
important role by becoming one of the major sources for automation, and the recent
developments in this field has made it a useful technology in the field of complex automated
application. Pneumatic systems operate on a supply of compressed air which must be available
insufficient quantity and at a pressure to suit the capacity of the system. When the pneumatic
system is being adopted for the first time, however it will indeed be necessary to deal with the
section of compressed air supply. The key part of any pneumatic machine is supply of
compressed air is by means reciprocating compressor. A compressor is a machine that takes in
air, gas at a certain pressure and delivers the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered. And the
volume expressed is that of the air at intake conditions the compressibility of the air was first
investigated by Robert Boyle in 1962 and found that the product of pressure and volume of a
particular quantity of gas is constant. This is usually written as: PV = C (or) In this equation the
pressure is the absolute pressure which is about 14.7 Psi. 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 mechanizations 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 a pneumatic system is it is economically cheap and simple in
design, also reducing maintenance costs. It can also have an outstanding advantage in terms of
safety.[16] 2.3 Pneumatic power Pneumatic systems use pressurised gas to transmit and control
power. Pneumatic systems typically use air as the fluid medium because air is safe, free and
readily available the advantages of pneumatics

 Air used in pneumatic systems can be directly exhausted in to the surrounding

environment and hence the need of special reservoirs and no-leak system designs are
eliminated.
 Pneumatic systems are simple in design and economical.
 Control of pneumatic systems is easier
 The disadvantages
 Pneumatic systems exhibit spongy characteristics due to compressibility of air
 Pneumatic pressures are quite low due to compressor design limitations (less that 250 psi)

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. [9] The key part of any
pneumatic system for supply of compressed air is by means using reciprocating compressor. A
compressor is a machine that takes in air, gas at a certain pressure and delivers it at a higher
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 compressor. Warm and moist suction air will result in increased precipitation
of condense from the compressed air.

Pneumatic technology deals with the study of behaviour and applications of

compressed air in our daily life in general and manufacturing automation in particular.
Pneumatic systems use air as the medium which is abundantly available and can be
exhausted into the atmosphere after completion of the assigned task.

1.Basic Components of Pneumatic System:

Components of a pneumatic system

a) Air filters: These are used to filter out the contaminants from the air.

b) Compressor: Compressed air is generated by using air compressors. Air compressors are
either diesel or electrically operated. Based on the requirement of compressed air, suitable
capacity compressors may be used.
c) Air cooler: During compression operation, air temperature increases. Therefore, coolers are
used to reduce the temperature of the compressed air. d) Dryer: The water vapor or moisture in
the air is separated from the air by using a dryer.
e) Control Valves: Control valves are used to regulate, control and monitor for control of
direction flow, pressure etc.

f) Air Actuator: Air cylinders and motors are used to obtain the required movements of
mechanical elements of pneumatic system.
g) Electric Motor: Transforms electrical energy into mechanical energy. It is used to drive the
compressor.
h) Receiver tank: The compressed air coming from the compressor is stored in the air receiver.

Actuators are output devices which convert energy from pressurized hydraulic oil or compressed
air into the required type of action or motion. In general, hydraulic or pneumatic systems are
used for gripping and/or moving operations in industry. These operations are carried out by using
actuators.

Actuators can be classified into three types.

1. Linear actuators: These devices convert hydraulic/pneumatic energy into linear motion.
2. Rotary actuators: These devices convert hydraulic/pneumatic energy into rotary motion.
3. Actuators to operate flow control valves: these are used to control the flow and pressure of
fluids such as gases, steam or liquid.
The construction of hydraulic and pneumatic linear actuators is similar. However, they differ at
their operating pressure ranges. Typical pressure of hydraulic cylinders is about 100 bar and of
pneumatic system is around 10 bar.

Single acting cylinder

Single acting cylinder

These cylinders produce work in one direction of motion hence they are named as single acting
cylinders. Figure 6.4.1 shows the construction of a single acting cylinder. The compressed air
pushes the piston located in the cylindrical barrel causing the desired motion. The return stroke
takes place by the action of a spring. Generally, the spring is provided on the rod side of the
cylinder.

Double acting cylinder

Double acting cylinder

The main parts of a hydraulic double acting cylinder are: piston, piston rod, cylinder
tube, and end caps. These are shown in Figure 6.4.2. The piston rod is connected to
piston head and the other end extends out of the cylinder. The piston divides the
cylinder into two chambers namely the rod end side and piston end side. The seals
prevent the leakage of oil between these two chambers. The cylindrical tube is fitted
with end caps. The pressurized oil, air enters the cylinder chamber through the ports
provided. In the rod end cover plate, a wiper seal is provided to prevent the leakage of
oil and entry of the contaminants into the cylinder. The combination of wiper seal,
bearing and sealing ring is called as cartridge assembly. The end caps may be attached
to the tube by threaded connection, welded connection or tie rod connection. The
piston seal prevents metal to metal contact and wear of piston head and the tube.
These seals are replaceable. End cushioning is also provided to prevent the impact
with end caps.

Pneumatic controllers

In automated industrial processes, it is always essential to keep the process variables such as
temperature, flow rate, system pressure, fluid level, etc. at the desired value for safety and
economical operation. Consider an example where the flow of water through a pipe has to be
kept constant at some predetermined value (Fig. 6.5.1). Let the value of flow to be measured is
‘V’ (process variable PV). This flow rate is compared with the required flow value say ‘V1’ (set
point SP). The difference between these two values is the error which is sent to the controller. If
any error exists, the controller adjusts the drive signal to the actuator, informing it to move the
valve to give the required flow (zero error). This type of control system is called closed loop
control system. It mainly includes a controller, actuator and a measuring device.

Closed loop control system

The control can be achieved by using control electronics or by pneumatic process control. The
pneumatic systems are quite popular because they are safe. In the process industries like refinery
and chemical plants, the atmosphere is explosive. Application of electronics based systems may
be dangerous in such cases. Since the pneumatic systems use air, there are very scant chances of
any fire hazards. Even though electrical actuators are available, but most of the valves employed
are driven by pneumatic signals.

The pneumatic components which can be used to implement the mentioned task are as
follows:
• double acting cylinder
• 3/2 push button valve
• 3/2 roller valve
• shuttle valve
• 3/2 foot pedal actuated valve
• 5/3 pneumatic actuated direction control valve
• compressed air source and connecting piping

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

The usual written as

PV = C (or) 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.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made available,
in sufficient quantity and at a pressure to suit the capacity of the system. When pneumatic system
is being adopted for the first time, however it wills indeed the necessary to deal with the question
of compressed air supply. The key part of any facility for supply of compressed air is by means
using reciprocating compressor. A compressor is a machine that takes in air, gas at a certain
pressure and delivered the air at a high pressure.

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

Positive displacement compressor.

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

  Reciprocating type compressor
 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.

PNEUMATICS COMPONENTS

SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by mechanical

power. Pneumatics 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 both 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 advantages of an all-pneumatic system are usually economy and simplicity, the latter
reducing maintenance to a low level. It can also have outstanding advantages in terms of safety.

PNEUMATIC COMPONENTS AND ITS DESCRIPTION

 The pneumatic bearing press consists of the following components to fulfil the
requirements of complete operation of the machine.
  Pneumatic cylinder
 Solenoid valve
 Flow control value
 Regulator or pressure control valve
 Pressure gauge
 Connectors and
 Hoses

CYLINDER:

The cylinder is a double acting cylinder one, which means that the air pressure operates
alternatively (forward and backward). The air from the compressor is passed through the
regulator which controls the pressure to required amount by adjusting its knob. A pressure
gauge is attached to the regulator for showing the line pressure.

Then the compressed air is passed through the directional control valve for supplying the air
alternatively to either sides of the cylinder. Two hoses take the output of the directional
control valve and they are attached to two ends of the cylinder by means of connectors. One
of the outputs from the directional control valve is taken to the flow control valve from taken
to the cylinder.

Pneumatic cylinder

An air cylinder is an operative device in which the state input energy of compressed

air i.e. pneumatic power is converted in to mechanical output power, by reducing the pressure

of the air to that of the atmosphere.

a) Single acting cylinder:

Single acting cylinder is only capable of performing an operating medium in only one
direction. Single acting cylinders equipped with one inlet for the operating air pressure, can
be production in several fundamentally different designs. Single cylinders develop power in
one direction only. Therefore, no heavy control equipment should be attached to them, which
requires to be moved on the piston return stoke single action cylinder requires only about half
the air volume consumed by a double acting for one operating cycle.

B) Double acting cylinders:

A double acting cylinder is employed in control systems with the full pneumatic
cushioning and it is essential when the cylinder itself is required to retard heavy messes. This
can only be done at the end positions of the piston stock. In all intermediate position a
separate externally mounted cushioning derives most be provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end of the stock is
required. As a result, the sit in the cushioning chamber is again compressed since it cannot
escape but slowly according to the setting made on reverses. The air freely enters the cylinder
and the piston stokes in the other direction at full force and velocity.

CYLINDER TECHNICAL DATA:

Barrel:

It is made of cold drawn aluminium honed to 25mm.

Piston Rod:

M.S. hard Chrome plated

Seals:

Nitrile (Buna – N) Elastomer

End Covers:

Cast iron graded fine grained from 25mm to 300mm

Piston:

Aluminium.

Media:

Air.

Temperature Range:

0^c to 85^c

Cushions:

Adjustable standard - 400mm bore and above.

SOLINOID CONTROL VALVE:

Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air

The directional valve is one of the important parts of a pneumatic system. Commonly known
as DCV, this valve is used to control the direction of air flow in the pneumatic system. The
directional valve does this by changing the position of its internal movable parts. This valve
was selected for speedy operation and to reduce the manual effort and also for the
modification of the machine into automatic machine by means of using a solenoid valve.

A solenoid is an electrical device that converts electrical energy into straight line
motion and force. These are also used to operate a mechanical operation which in turn
operates the valve mechanism. Solenoids may be push type or pull type. The push type
solenoid is one in which the plunger is pushed when the solenoid is energized electrically.
The pull type solenoid is one is which the plunger is pulled when the solenoid is energized.
The name of the parts of the solenoid should be learned so that they can be recognized when
called upon to make repairs, to do service work or to install them.

Parts of a Solenoid Valve

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

Position-1

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

Poisition-2

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

FLOW CONTROL VALVE:

Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air

(b) Purpose:
 This valve is used to speed up the piston movement and also it acts as an one – way
restriction valve which means that the air can pass through only one way and it can’t return
back.

By using this valve, the time consumption is reduced because of the faster movement
of the piston.

REGULATOR (OR) PRESSURE CONTROL VALVE:

Specification:

1. Port size : ¼” BSP

2. Port size for pressure gauge : 1/8” BSP

3. Inlet pressure : 15 bar Maximum

4. Outlet pressure : 0.5 to 7 bar

5. Flow capacity : 650 NI/min*

6. Set pressure : 6 bar

7. Pressure drop : 1 bar

8. Mounting position : Vertical

* Flow capacity at 7 bar pressure

Pressure control valves may be designed to vary the pressure to a desired level within
limits and to maintain it at certain level. The air is passed through the throttling orifice by
adjusting its knob in the desired direction. By adjusting the knob, we can get different
pressure ranges so that the load applied by the piston can also be varied.

Technical data:

Port size : 1/8” BSP

Pressure range : 0 – 10 kg/cm2

Pressure gauges are usually fitted with the regulators. So, the air pressure adjusted in
the regulator is indicated by the pressure gauge and also the pressure indicated in the pressure
gauge is the line pressure of the air taken to the cylinder.

connectors:
 In our pneumatic system there are two types of connectors used; one is the hose
connector and the other is the reducer. Hose connectors normally comprise an adapter
(connector) hose nipple and cap nut. These types of connectors are made up of brass or
Aluminium or hardened steel. Reducers are used to provide inter connection between two
pipes or hoses of different sizes. They may be fitted straight, tee, “V” or other
configurations. These reducers are made up of gunmetal or other materials like hardened
steel etc.

Need for pneumatic power

Pneumatic system use pressurized gases to transmit and control power, as the name
implies, pneumatic systems typically use air as fluid medium, because air is a safe, low cost
and readily available fluid. It is particularly safe environments where an electrical spark could
ignite leaks from the system components. There are several reasons for considering the use of
pneumatic system instead of hydraulic system, Liquid exhibit greater inertia than gases.
Therefore, in hydraulic system the weight of the oil is a potential problem. To design and
development a material handling system for automation /semi automation of industries by
using pneumatic control system, which is used for low cost automation.

Block Diagram:
 Working Principle
The timer is set to the required duration of cycle. The timer sets on the 3/2 way pneumatic
valve this makes the pneumatic cylinder to actuate in downward direction to move the
secondary piston down to push the grease into the distributor block. The distributor block has
the facility to individual turn the grease nozzles 1, 2…n individually on /off. Thus, the grease
is forced through the grease nozzle to the desired machine point.
 CONCLUSION
From the Pneumatic Multipoint Lubrication system, it is concluded that the cost and man
power require for the lubricating the various grease points can be eliminated. The loss of
rease during greasing reduces as compared with the manual greasing. The system provides
safety to the lubricating component and the operator. This system enables the greasing to the points
which are not reachable to operator and down time also reduces.
 REFERENCES
[1] Dispenser Charging and Delivery Cycle by Gade S.V., Waghmare S.L., Wagh P.R.,
Baheti. A. S. Department of Mechanical Engineering, Sinhgad Institute of Technology &
Science Narhe, Pune, India.
[2] T. Kawamura, M. Minami and M. Hirata (2001), "Grease Life Predication for Sealed Ball
Bearings," Tribology Transactions, 44, 2, P256-262.
[3] H. Mikami: "Latest Trends in Lifespan Prediction for Lubrication Grease and Grease,"
Hydraulics & Pneumatics (Japan) 576, Vol.46, No.11, (2007) P42- 46
[4] Scarlett, N.A. (1967), “Use of Grease in Rolling Bearings,” Proc. IMechE. Part 3A, 182,
pp 167-171.