Doorpneu plc 2014

B.E.PROJECTS

CONTACT 9444863248

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AUTOMATIC PNEUMATIC CONTROLLED DOOR AND

CLOSING SYSTEM USING PLC

AUTOMATIC PNEUMATIC CONTROLLED DOOR AND

CLOSING SYSTEM USING PLC

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

“DIPLOMA IN MECHANCIAL ENGINEERING (MTMR)”

SUBMITTED BY:

1. A.MANIKANDAN 4. S.NANDAKUMAR 2. M.ARUNKUMAR 5.S.RAMESH KUMAR 3. N.JEEVAKUMAR 6. S.MUTHUKUMAR

Under guidance of

Mr. A.CHOCKALINGAM, M.E.,

OCTOBER 2014.

DEPARTMENT OF MECHANICAL ENGINEERING (MTMR)

A M K TECHNOLOGICAL POLYTECHNIC COLLEGECHEM BARAMBAKKAM, CHENNAI – 602 103

A M K TECHNOLOGICAL POLYTECHNIC COLLEGECHEM BARAMBAKKAM, CHENNAI – 602 103

BONAFIDE CERTIFICATE

This is to certify that this Project work on

“ AUTOMATIC PNEUMATIC CONTROLLED DOOR

AND CLOSING SYSTEM USING PLC ”

submitted by …………………… ……………. Reg. No. ……………

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING (MTMR)

This is the bonafide record of work carried out by him under our supervision

during the year 2014

Submitted for the Viva-voce exam held on ……………..

H.O.D PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr.A. VIJAY KISHORE, M.TECH., MISTE.., encouragement

and valuable advice.

we thank our Esquired Head of Department Mr R. RAJKUMAR,

A.M.I.E, M.E., for presenting his felicitations on us.

We are grateful on our Entourages Mr. A.CHOCKALINGAM,

M.E., for guiding in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the

Mechanical Engineering (MTMR) Department.

Ultimately, we extend our thanks to all who had rendered their co-

operation for the success of the project.

CONTENTS

CONTENTS

Chapter No. TITLE

1. SYNOPSIS

2. CONSTRUCTION

3. WORKING PRINCIPLE

4. MECHANICAL ASSEMBLY DIAGRAM

5. PNEUMATIC CIRCUIT DIAGRAM

6. INTRODUCTION TO PLC

7. PNEUMATIC COMPONENT DETAILS

8. FINISHING AND PAINTING

9. COST ESTIMATION

10. CONCLUSION

11. BIBLIOGRAPHY

12. PHOTO VIEW

SYNOPSIS

SYNOPSIS

To increase the productivity and to overcome skilled labour shortage,

most of the manufacturing industries are going for automation. The main

aim for us to select this project work is to acquire practical knowledge in the

field of automation using Pneumatic system.

We selected “AUTOMATIC DOOR OPENING AND CLOSING USING

PENUMATIC SYSTEM USING PLC ” as our project work and the gate is

automatically opened by the double acting cylinder which is actuated

through the 5/2 way double solenoid directional control valve . The solenoid

valve is actuated by the INFRA RED SENSOR which is placed in front of

the gate.

The IR sensor has one IR transmitter and one IR receiver .when any

object crosses between these two sensor ,the solenoid valve is actuated and

hence the gate opened automatically.

CONSTRUCTION

CONSTRUCTION

The construction of this project is shown in fig.

This project consist of

1. M.S fabricated cabin with sliding door.

2. Pneumatic control system

3. Electrical control system (PLC unit)

4. Power supply.

1. M.S FABRICATED CABIN WITH SLIDING DOOR:

The cabin is fabricated at the size of 1”x3/4”x3/4”

(Height x Breath x width) with the M.S ‘L’ angle material 25mm x 25mm x

2.5mm thickness. A sliding door arrangement is made at the front portion of

the cabin and the other sides are closed with 28-gauge thickness tin sheet.

The cabin is extended at both sides of cabin as shown in

figure for mounting the pneumatic component and the sliding door.

2. PNEUMATIC CONTROL SYSTEM:

The sliding door is fitted with the end of piston rod of

double acting cylinder.

The cylinder is actuated by the 5/2 way double solenoid

direction control valve. The solenoid valve is actuated through the IR sensor

relay. The pneumatic control circuit is shown in fig.

PNEUMATIC CIRCUIT DIAGRAM FOR AUTOMATIC DOOR OPENING AND CLOSING

IR SENSOR UNIT;

To DETECT the object an I.R. sensor is used..The I.R. sensor is fixed at

the front of the door which is held in between the two plates.

WORKING PRINCIPLE

WORKING PRINCIPLE

The working principle is shown in fig.

The IR transmitter and IR receiver sensor is mounted in front of the

door and both are facing each other. Hence IR receiver continuously

receives IR rays if any object crossing or disturbing these IR rays.

The relay in the sensor energies, the NO contact in the relay

becomes NC and the solenoid valve coil gets ON and allows the

pressurized air to the double acting cylinder. The door is opened after

entering in to cabin the person may press the push button to close

the door.

PNEUMATIAC CIRCUIT DIAGRAM

PNEUMATIC CIRCUIT DIAGRAM

INTRODUCTION TO PROGRAMMABLE

LOGIC CONTROLLER

PROGRAMMABLE LOGIC CONTROLLER

It is a solid-state equipment, designed to perform the function of logical

decision-making Industrial Control Applications.

It acts as a total replacement for hard-wired relay logic with an

effective reduction in wiring and panel size and of course, with increase in

flexibility and reliability.

It has been experienced that majority of the faults with systems using

PLC’s are due to external cause like, malfunctioning of field or external

devices such as sensors, limit switches, push buttons etc.

The Keyence PLC is a unique product by itself offering the most

advanced features in a compact size. It finds application in areas like small

SMPS, Conveyors, Industrial Washing machine, Welding machine, Screen

Printing machine, Generator control, Small automation process etc.

FEATURES OF KEYENCE PLC:

Compact

Economical

Easily mountable

Choice of selecting either AC (220V)/24V DC

R (24V) DC powered PLC

High speed counter input upto 4 KHz

Pulse catch inputs 500 µs or more

Variety of function blocks and powerful instruction set

Availability in 3 modules 6/4, 10/8 and 16/12

Source or sink type inputs

Relay outputs

Sink type DC outputs

BLOCK DIAGRAM:

INPUT

POWER SUPPLY

PROCESSOR

PROGRAMMING DEVICE

OUTPUT

The Block Diagram of PLC is shown in the Figure. The PLC is

designed to replace relays, timers, counters, etc. The necessary voltage and

current requirements for the internal working of the PLC are given by the

Power supply. The field elements are interfaced to the input or output

sections. Typical input elements are push buttons, limit switches, proximity

switches, relay contacts, selector switches, thumb wheels etc. Typical

output elements are solenoid valves, relay coils, indicator lights, LED

displays etc. These field elements are selected by the end user.

The necessary power supply for the Input and Output elements are

provided externally to the PLC. The power supply for PLC is supplied to

operate only the internal electronics and not to power the field elements.

ADVANTAGES OF USING PLC OVER CONVENTIONAL

ELECTRICAL RELAY PANELS:

1. Maximum Reliability

2. Logic easily changeable

3. Single PLC can be used in multiple applications by mere change of

programme.

4. Indicator lights provided at the major diagnostic points to simplify

trouble shooting.

5. Powerful software features like timers, counters, table operations etc.

in conjunction with optional display to assist trouble shooting.

6. Availability of unlimited number of N0 / NC contacts for Input and

Output Internal Logic Coils (Flags).

7. Very compact and rugged design leading to less down loading time.

8. Smaller cabinet size leading to less floor space requirements

9. Easy installation

10.Low cost

PNEUMATIC COMPONENTS

DETAILS

DESCRIPTION OF PNEUMATIC COMPONENTS

1. Double acting air cylinder with piston arrangement.

2. Spool valve (2 position 5 ports valve)

3. Pneumatic fittings

a. Bulk head union

b. Flexible hoses

c. Air compressors

DOUBLE ACTING AIR CYLINDER WITH PISTON

ARRANGEMENT:

It consists of a piston inside a cylindrical housing called a barrel.

Attached to one end of the piston is a rod which the rod end has one port.

This rod end port is used for entrance of air and extends outside one end of

the cylinder. At another end is a port for exit of air.

Double acting cylinder can be extended and retracted pneumatically.

The smallest bore size of an double acting cylinder is 1 1/8 inch. The piston,

which is made of ductile Iron, contains u-cup packing to seal against leakage

between the piston and barrel. The ports are located in the end caps, which

are secured to the barrel by bolts and nuts.

DIRECTING CONTROL VALVES:

A direction control valve is used to change the direction of air flow as

and when required by the system for reversing the machine tool devices. A

direction control valve may be classified, according to the construction of

the internal moving parts, as

1. Rotary spool Type.

2. Sliding Spool Type.

3. Solenoid operated valves

SOLENOID OPERATED VALVES:

Solenoid valves are electromechanical devices like relays and

contractors. A solenoid valve is used to obtain mechanical movement in

machinery by utilizing fluid or air pressure. The fluid or air pressure is

applied to the cylinder piston through a valve operated by a cylindrical

electrical coil. The electrical coil along with its frame and plunger is known

as the solenoid and the assembly of solenoid and mechanical valve is known

as solenoid valve. The solenoid valve is thus another important

electromechanical device used in control of machines. Solenoid valves are

of two types,

1. Single solenoid spring return operating valve,(5/2)

2. Double solenoid operating valve.

In fig 1 is shown a single solenoid spring return valve in its de-energized

condition. The symbol for the solenoid and the return are also shown. The

solenoid valve is shown connected to the cylinder to help readers understand

the solenoid valve action. In the de energized condition, the plunger and the

valve spool position as shown in figure 1.

In this position of spool, port P is connected to port A and port B is

connected to tank or exhaust (i.e. atmosphere) if air is used. Spring pressure

(S) keeps the spool in this condition as long as the coil is de energized.

Fluid pressure from port P through port A is applied to the left side of the

cylinder piston. Thus the cylinder piston moves in the right direction. Now

when the solenoid coil is energized, plunger is attracted and it pushes the

spool against spring pressure.

The new position of plunger and spool are shown in fig 2.

In this position of spool, port A gets connected to tank and port P gets connected

to port B. Thus pressure is applied to the cylinder piston from right and moves

the piston rod to the left. At the same time fluid in the other side is drained out to

the tank. When the solenoid coil is again de energized, the spring (S) will move

the spool to its original position as shown in figure 1. Thus, normally when the

solenoid coil is de energized the piston rod remains extended.

PNEUMATIC FITTINGS:

There are no nuts to tighten the tube to the fittings as in the

conventional type of metallic fittings. The tube is connected to the fitting by

a simple push ensuring leak proof connection and can be released by

pressing the cap and does not require any special tooling like spanner to

connect (or) disconnect the tube from the fitting.

SPECIFICATION OF THE FITTING:

Body Material - Plastic

Collect/Thread Nipple - Brass

Seal - Nitrate Rubber

Fluid Used - Air

Max. Operating Pressure - 7 Bar

Tolerance on OD of the tubes - 1 mm

Min. Wall thickness of tubes - 1 mm.

FLEXIBLE HOSES:

The Pneumatic hoses, which is used when pneumatic components

such as actuators are subjected to movement. Hose is fabricated in layer of

elastomer or synthetic rubber, which permits operation at high pressure. The

standard outside diameter of tubing is 1/16 inch. If the hose is subjected to

rubbing, it should be encased in a protective sleeve.

ADVANTAGES AND LIMITATIONS

ADVANTAGES:

The Pneumatic arm is more efficient in the technical field

Quick response is achived

Simple in constructions

Easy to maintain and repair

Cost of the unit is less when compared to other robotics

No fire hazrd problem due to over loading

Comparatively the operation cost is less

The operation of arm is faster because the media to operate is air

Continuous operation is possible without stopping.

LIMITATIONS:

High torque cannot be obtained.

Load Carrying capacity of this unit is not very high (3 – 5 kgs).

While working, the compressed air produces noise, therefore a silencer may be

used.

APPLICATIONS

DISCHARGE OF WORKPIECE:

The arm fed has wide application in low cost automation. It can be

used in automated assembly lines to pick-up the finished product from

workstation and place them in the bins. It can also be used to pick-up the

raw material and place them on the conveyor belts and vice versa.

JOB CLAMPING:

This unit can also be used in clamping operations in certain areas of

mass productions where clamping and unclamping have to be done at high

speeds. The applications of this unit is limited to operations which involves

moderate clamping forces.

TRANSFER OF JOBS BETWEEN WORK STATION:

The gripping method used in a low cost automation to move the

workpiece from one workstation to another. The combination of an angular

rotary motion is the principle behind this method. The gripper holds the

work rigidly. The to and fro motion is achieved by means of the actuating

cylinder.

TOOL CHANGING APPLICATION:

When the pneumatic arms are made smaller in size they can be used

in automatic tool changer in CNC turning and drilling machines, by

attaching suitable tool holding device to the rotary cylinder.

FEATURES OF THE AUTOMATIC GATE

OPENING AND CLOSING

FEATURES OF THE AUTOMATIC GATE

OPENING AND CLOSING

It is compact in size

It can be move

The electrical power consumption is very low

This principle can be utilized at any places

It is simple in construction

Low cost

Less weight and easy to handle

It eliminate the man power

FINISHING PAINTING

FINISHING AND PAINTING

JOB PREPARATION;

Before welding, remove any bend in the L angle with the sludge

hammer on the anvil block. Then it is cut to the required length with the

hacksaw blade and fabricated to required dimensional shape with arc

welding.

FINISHING OPERATION BEFORE PAINTING;

After welding, any slag on the welded area is removed with the

chipping hammer and cleaned with the metal wire brush. Then all the

surfaces are rubbed with the emery sheet.

Metal primer is applied on the surfaces with the brush .After drying the

metal primer, the second coating is applied with the paint.

COST ESTIMATION

COST ESTIMATION

1. Double Acting Cylinder (1x800)-------------- 800.00

2. Solenoid Valve 5/2 Way (1x1100)------------ 1200.00

3. Valve Connectors (10x50) --------- ----------- 500.00

4. M.S Stand ---------------------- 800.00

5. IR SENSOR unit ----------- ------------ 1000.00

6. Power supply unit ------------------ 600.00

7. Tube (5 Meters)---------------------------------- 100.00

8. Transportation Charges-------------------------- 200.00

9. Miscellaneous charges -------------------------- 100.00

10.Report ----------------------------------- 600.00-------------------

TOTAL ------------- 5900.00 -------------------

CONCLUSION

CONCLUSION

We make this project entirely different from other projects. Since

concepts involved in our project is entirely different that a single unit is used

to various purposes which is not developed by any of other team members.

By doing this project we gained the knowledge of pneumatic system

is how automation can be effectively done with the help of pneumatic

system.

It is concluded that any automation system can be done with the help

of pneumatic system.

We have successfully completed the project work on using

Pneumatics system at our Institute.

By doing this project work, we understood the working principle and

uses of various Cylinders, Valves, etc. .

It will be of no doubt that Pneumatics will be an integrated part of any

process in industry in the near future and we developed a through knowledge

in Automation with Pnematics

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. FESTO MANUAL

2. Production technology by Hajra Choudry

3. Hydraulic & pneumatics for Power Production - Harry L – Stewart

4. Fluid mechanics by E.SUNDRAMOORTHY

5. Design with Micron roller – John Peatman

6. Customizing and programming PIC Micro controller – Myke Predko

7. Electronics for you Projects – Volume 1 to 15

8. Sensors – Keyence Manual

9. Micro controller and its application – Kenneth Ayala

10.www.google.com

PHOTOVIEW