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AUTOMATIC PUNCHING

MACHINE USING
PNEUMATIC SYSTEM
TEAM MEMBERS:
R.GAUTTHAM (711112114009)
A.S.KARTHI (711112114016)
T.LOGESHWARAN (711112114022)
M.MAYILSAMY (711112114302)
FACULTY GUIDANCE
Mr. T.GANDHIRAM B.E.

ABSTRACT
The

proposed work describes the design and fabrication


of prototype of automatic punching machine controlled
by relays and sensors. Punching or pressing process is
the one of most important and necessary processing step
in manufacturing industries.
By automating this process one can have a greater
control over the process. Solenoid valves are used for
control the system.
This system can replace the existing manual model. It is
possible to achieve good results in the form of reduced
manufacturing lead time, reduced cost and increase
safety of the worker.

PROBLEM IDENTIFICATION
PLC

system is interfaced with the conventional punching process


for achieving the automation.
By using such kind of PLC for achieving automation will increase
the capital investments of every manufacturing sectors.
In addition, mechanical and electrical installation cost will also be
included.
If the machinery cost is high, obviously it will influence the total
production cost. Thus resulting in the increase of final products
retail price.
In manual or conventional methods of pressing the disadvantages
are:
* Higher material handling time
* Manufacturing lead time
* Angular misalignment of the sheet
* Reduced safety for the worker

INTRODUCTION
Sheet

metal has replaced many cast , forged and


machined products.
Punching or pressing is the initial and main operation in
the process sequence.
Automation is defined as Technology concerned with
application of mechanical, electrical, computer based
system to operate and control system.
It may reduce manufacturing lead time, increase
productivity and to improve worker safety.
It has easier implementation of mass production as well
as greater control on technical parameters .

PNEUMATIC CYLINDERS
Double acting cylinders(DAC) use the force of air to
move in both extend and retract strokes.
Force of the compressed air make the cylinder to extent
and retract.

ADVANTAGES:

Force builds up in both directions of movement.


Constant force(dependent on stroke).
Strokes of several meters are possible.

SENSORS
A

sensor is a device which receives and respond to a


signal.
It plays a major role in automation sector.
Main

criteria to use sensors are cost reduction ,


rationalization
automation
,
flexibility
and
environmental protection.
The sensors used in this project is INDUCTIVE
PROXIMITY SENSORS -DC TYPE.

RELAYS
A relay

is an electromechanical device that is actuated by


an electrical current.
It has wide variety of applications throughout industry and
automation systems.
It is used because of their simplicity , long life ,
high reliability.

Circuit Diagram

Relay

SWITCH MODE POWER SUPPLY


Switch

Mode Power Supply(SMPS) transfer electric


power from a source (AC mains) to the load by
converting the characteristics of current and voltage.
SMPS uses a switching a regulator to convert
electric power efficiently. SMPS always provide a
well regulated power to the load irrespective of the
input variation.
SMPS regulates the output power by varying the on
to off time using minimum voltage so that
efficiency is very high compared to the linear power
supply.

5/2 SOLENOID VALVE


A valve is a device that regulates the flow of fluid
(gases, liquids, fluidized solids or slurries) by opening
and closing or partially obstructing passage ways.
A 5/2 way directional valve from the name itself has
5 ports equally spaced and 2 flow positions. The
compressed air flows the passage it makes the retract
or extend a double acting cylinder.

Circuit Diagram

Solenoid Valve

MODELLING

ELECTRO PNEUMATIC CIRCUIT DIAGRAM

DIAGRAM EXPLANATION
A0, A1

- Sensor for loading purpose


B0, B1 - Sensor for punching purpose
C0,C1 - Sensor for unloading purpose
S1, S2, S3 - 5/2 Spring actuated solenoid valve
RL1 to RL6 - Relay
Cylinder A - Loading Purpose
Cylinder B - Punching Purpose
Cylinder C - Unloading purpose

COMPONENTS USED
Pneumatic Cylinders
5/2 spring actuated solenoid valve
Compressor
Filter, Reservoir, Lubricator(FRL) Unit
Relay
Switch Mode Power Supply(SMPS)

WORKING METHODLOGY
When

the switch S1 is pressed, the air supply will


flow to all valves of the system.
The sensor A1 is actuated, then the cylinder A is
fully extended and work piece is placed manually
infornt of cylinder A and the cylinder rod clamp the
work piece.
The sensor senses the work piece position and it
actuates the sensor B1.
The sensor B1 is actuated, then the cylinder B is
fully extended and punching operation performed
on the work piece.
The punching operation can carried out at a given
pressure from the compressor unit.

Continued.,
Before

that , the air from the compressor is filtered by


using Filter, Reservoir, Lubricator(FRL) unit.
The sensor B0 is actuated, then the cylinder B is fully
retracted and back to original position.
The sensor A0 is actuated, then the cylinder B is fully
retracted and unclamped the work piece.
The sensor C0 is actuated, then the cylinder C is fully
extended and move the punched work piece.
And hence the cycle repeats.

start

PROCESS

FLOWCHART
Cylinder A extend
Cylinder B extend
Cylinder B retract
Cylinder A retract
Cylinder C extend
Cylinder C retract
stop

CALCULATION
GIVEN
Cylinder A rod diameter = 12mm
Cylinder B rod diameter = 12mm
Cylinder C rod diameter = 10mm
Compressor pressure = 5 Bar

FORMULAE
Force = Pressure Area
Area =
where,
Pressure in N/m
Force in N
Area in mm2

FORCE CALCULATION
Cylinder A = Pressure Area
= 5105

F = 44.41N
Cylinder B = Pressure Area
= 5105

F = 44.41N
Cylinder C =
Pressure Area
= 5105

F = 39.26 N

COST ESTIMATION
S.NO

NAME OF THE MATERIAL

QUANTITY PRICE in (Rs.)

1.

Pneumatic cylinder

4500

2.

5/2 Spring actuated solenoid valve

1500

3.

Inductive proximity sensor

1200

4.

12V/2A switch mode power supply

550

5.

12V Relay

6.

Multi colour wire

7.

Fasteners

8.

Cardboard

9.

Steel tube

10
4
20
-

150
160
100
200
400
8760/-

Total cost

ADVANTAGES
Less

environmental pollution
Less Noise process
Simple construction
Higher work efficiency
Easy maintenance
Light weight
Faster production
High safety for workers

CONCLUSION
In

this project, a working model of punching machine


using pneumatic system is discussed.

By

using sensors, a good control over the system can


be achieved , manufacturing time is reduced by
developing a automatic feeding mechanism.

The

workers safety can be increased by reducing the


human participation in the process.

REFERENCE
1. International journal of Advanced Mechanical
Engineering ISSN 2250-3234
Volume4,
Number 5(2014), pp.509-517 Research India
Publications
http://www.ripublication.com
2. Applied Hydraulics and Pneumatics, Pearson
Publication.

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