TABLE OF CONTENT

CHAPTER CONTENT PAGE NO

NO.
1. INDRODUCTION 1
2. LITERARTIRE REVIEW 2
3. FACTORS DETERMINING THE CHOICE OF
MATERIALS 10
3.1 PROPERTIES 10
3.2 MANUFACTURING CASE 11
3.3 QUALITY REQUIERD 11
3.4 AVAILABLITY OF MATERIAL 11
3.5 COST 13

4. COMPONENTS AND DESCRIPTION 14

4.1 AIR COMPRESSOR 14
4.2 DIRECTION CONTROL VALVE 19
4.3 CYLINDER 24
4.3 CONNECTING HOSSES 26
4.4 BEARING WITH BEARING CAP 27
4.5 WHEEL ARRANGEMENT 28
4.6 VECHICLE MODEL FREAME 30
4.7 ROTATING PLATES 32

5. DESIGN AND DRAWINGS 35

5.1 PNEUMATIC CYLINDER 35
5.2 DESIGN OF BALL BEARING 36
5.3 SPECIFICATION 40

6. WORKING PRINCIPLE 48
6.1 PRINCIPLES OF WORKING 49

7 ADVANTAGES,DISADVANTAGES&
APPLICATIONS 51
7.1 ADVANTAGES 51
7.2 DISADVANTAGES 51
7.3 APPLICATIONS 52
8 LIST OF MATERIALS 53

9 COST ESTIMATION 54
9.1 MATERIAL COST 53
9.2 LABOUR COST 54
9.3 OVERHEAD CHARGES 54

10 CONCLUSION 56
 SYNOPSIS

This project work titled “THREE AXIS PNEUMATIC MODERN TRAILERS”

has been conceived having studied the difficulty in unloading the materials. Our

survey in the regard in several automobile garages, revealed the facts that mostly some

difficult methods were adopted in unloading the materials from the trailer.

Now the project has mainly concentrated on this difficulty, and hence a suitable

arrangement has been designed. Such that the vehicles can be unloaded from the

trailer in three axes without application of any impact force. By pressing the Direction

control valve activated. The compressed air is goes to the pneumatic cylinder through

valve. The ram of the pneumatic cylinder acts as a lifting the trailer cabin. The

automobile engine drive is coupled to the compressor engine, so that it stores the

compressed air when the vehicle running. This compressed air is used to activate the

pneumatic cylinder, when the valve is activated.

 CHAPTER-1

INTRODUCTION

Automation can be achieved through computers, hydraulics, hydraulics,

robotics, etc., of these sources, hydraulics form an attractive medium. Automation

plays an important role in automobile. Nowadays almost all the automobile vehicle is

being atomized in order to product the human being. The automobile vehicle is being

atomized for the following reasons.

 To achieve high safety

To reduce man power

To increase the efficiency of the vehicle

To reduce the work load

To reduce the fatigue of workers

To high responsibility

Less Maintenance cost

 CHAPTER-2

LITERATURE SURVEY

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.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic is an attractive medium for low cost mechanization

particularly for sequential (or) repetitive operations. Many factories and plants already

have a compressed air system, which is capable of providing the power (or) energy

requirements and the control system (although equally pneumatic control systems may

be economic and can be advantageously applied to other forms of power).

The main advantage of an all pneumatic system are usually economic and

simplicity the latter reducing maintenance to a low level. It can also have out standing

advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made

available. In sufficient quantity and at a pressure to suit the capacity of the system.

When pneumatic system is being adopted for the first time, however it wills indeed the

necessary to deal with the question of compressed air supply.

 The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, 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.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for compressed

air plant and have proved highly successful and supply air for pneumatic control

application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

 Turbo compressors are employed where large capacity of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic control

application unless built in multistage designs and are seldom encountered in

pneumatic service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating compressor is

by far the most common type. Reciprocating compressors lap be had is sizes from the

smallest capacities to deliver more than 500 m³/min. In single stage compressor, the

air pressure may be of 6 bar machines discharge of pressure is up to 15 bars.

Discharge pressure in the range of 250 bars can be obtained with high pressure

reciprocating compressors that of three & four stages.

Single stage and 1200 stage models are particularly suitable for pneumatic

applications , with preference going to the two stage design as soon as the discharge

pressure exceeds 6 bar , because it in capable of matching the performance of single

stage machine at lower costs per driving powers in the range .

 CHAPTER-3

FACTORS DETERMINING THE CHOICE OF

MATERIALS

The various factors which determine the choice of material are discussed below.

1. Properties:

The material selected must posses the necessary properties for the proposed

application. The various requirements to be satisfied can be weight, surface finish,

rigidity, ability to withstand environmental attack from chemicals, service life,

reliability etc.

The following four types of principle properties of materials decisively affect

their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical
 The various physical properties concerned are melting point, Thermal

Conductivity, Specific heat, coefficient of thermal expansion, specific gravity,

electrical Conductivity, Magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

compressive shear, bending, torsional and buckling load, fatigue resistance, impact

resistance, elastic limit, endurance limit, and modulus of elasticity, hardness, wear

resistance and sliding properties.

The various properties concerned from the manufacturing point of view are.

● Cast ability,

● weld ability,

● Brazability,

● forge ability,

● merchantability,

● surface properties,

● shrinkage,

● Deep drawing etc.

 2. Manufacturing Case:

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may demand the

use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material.

For example, it would never be desirable to go for casting of a less number of

components which can be fabricated much more economically by welding or hand

forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply. It then becomes obligatory

for the designer to use some other material which though may not be a perfect

substitute for the material designed.

The delivery of materials and the delivery date of product should also be kept

in mind.
 5. Space Consideration:

Sometimes high strength materials have to be selected because the forces

involved are high and the space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an

important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance of

the designed part are involved in the selection of proper materials.

 CHAPTER-4

COMPONENTS AND DESCRIPTION

MAJOR PARTS

The major parts “PNEUMATIC THREE AXIS MODERN TRAILLER” are

described below:

▪ Air compressor

▪ Direction Control Valve

▪ Cylinder

▪ Connecting hoses

▪ Flow control valve

▪ Bearing with bearing cap

▪ Wheel arrangement

▪ Vehicle model frame

▪ Rotating Plates

1. Air Compressor

COMPRESSORS

The main function of the air compressor is to compress the air up to the required

pressure. The maximum capacity of the compressor is 10105 to 12 105 N/m2.

This is a two stages or two-cylinder reciprocating air compressor. The two cylinders

are for low and high compression. The air pressure is measured at various places by

the use of pressure gauges. V-belt and pulley are used to drive the compressor.

Compressors can be broadly classifieds into two groups. They are:

▪ Positive Displacement Compressor

▪ Dynamic Compressors

Positive Displacement Compressor

Successive volumes of air isolated and then compressed to a higher pressure.

There are essential two forms of positive displacement compressor, reciprocating and

rotary.

Dynamic compressors

These are rotary continuous machines in which a high speed rotating element

accelerates the air and converts the resulting velocity head into pressure.

Positive displacement compressors work on the principle of increasing the pressure

of a definite volume in an enclosed chamber. Dynamic (turbo) compressor employs

 rotating vanes or impellers to impart velocity and pressure to the flow of the air being

handled.

The pressure comes from the dynamic effects such as centrifugal force.

SELECTION CRITERIA FOR COMPRESSORS

A number of factors are involved in the selection criteria of a suitable air

compressor. These are dealt here briefly

1. Pressure

First of all, the pressure needed must be determined. Most air operated system and

tools are designed to operate at a pressure from 6 105 to 7 105 N/m2. A

compressor of normal make and type would normally be suitable if this can assure a

pressure 6 105 N/m2 in the distribution line laid down for a pneumatic tools and

system.

2. Capacity

Another important factor in compressor selection is the capacity or volume of air required.

This factor is sometimes extremely difficult to evaluate. Obviously, the unit selected

should be large enough to supply all the air devices, which will be operating at any
given time. If all the air operation is continuous, the capacity required is simply the

sum of air compression of each individual tool.

The main function of the air compressor is to compress the air up to the

required pressure. The maximum capacity of the compressor is 10 105 to 12 105

N/m2. This is a two stages or two-cylinder reciprocating air compressor. The two

cylinders are for low and high compression. The air pressure is measured at various

places by the use of pressure gauges. V-belt and pulley are used to drive the

compressor.

3. Pressure Gauge

Pressure gauge is used for measuring the outlet pressure of air from the

compressor. The gauge used is Bourdon type pressure gauge. The maximum capacity

of this gauge is 10 105 to 12 105 N/m2. The gauge is fitted at the outlet of the air

compressor.

2. Directional Control Valves

Pneumatic valves:

The pneumatic cylinder is regulated and controlled by pneumatic valves. These

valves are actuated manually, mechanically, electrically, pneumatically, and by

various combined mode of actuation.

Need of Valves

DIRECTIONAL CONTROL VALVES To control the to and fro motion of

cylinder, the fluid energy has to be regulated, controlled and reversed with a

predetermined sequence in a pneumatic system.

Similarly one may have to control the quantity of pressure and flow rate to

generate the desired level of force and speed of actuators. To achieve these functions,

valves are used. Valves are fluid power elements used for controlling and regulating

the working medium.

The main functions of the valves are,

● Start and stop the fluid energy

● Control the direction of flow of compressed air

● Control the flow rate of the fluid

● Control the pressure rating of the fluid
Although various types of valves are available, they are mainly classified as

below, ● Direction control valves

● Direction control check valves

● Flow control valves

● Pressure control valves

The main purpose of a valve in a pneumatic circuit is to control outputs. Valves

can be divided into a number of groups according to what they control.

Directional control valves

Directional control valve on the receipt of some external signal, which might be

mechanical, electrical or a fluid pressure pilot signal, charges the direction of or stops,

or starts the flow of fluid in some part of the pneumatic/hydraulic circuit.

SOLENOID VALVE

A solenoid is an electrical mechanical device that can convert electrical power

to mechanical force and motion. It consists mainly of plunger, mostly a T type

plunger, wire or coil and a C-frame. The working principle is such that when an
electric current is passed through a coiled wire, a magnetic field sets up around the

wire. Because of coiled wire, the magnetic field would be several times stronger

around and through its center.

The solenoid force is directly fed to the spool of the direction control valve to shift it.

This force is applied through the T-plunger that is surrounded by the coil, also called

the armature. To select a proper electromagnet, the forces resisting the actuation of the

magnet, i.e. the force of friction and spring force have to be kept at their minimum so

that the electromagnet can develop a force greater than the resultant of the resisting

force.

Mostly in the case of dc magnets, the body and the armature may be made of

one piece whereas the ac magnets require both the parts to be made from thin

laminated sheets to obstruct flow of eddy current and to avoid increase of the solenoid

body-temperature.

Whether one has to go for a dc or ac magnet, depends fully on the requirement

of the control system. However in majority of pneumatic direction control valves, only

dc magnets are used as the overall requirement of force and response time is quite

suitable for such application.

OPERATION OF SOLENOID VALVE

With solenoid valves, a current through a solenoid is used to implement

switching between positions.

When a current flows through the solenoid, a magnetic field is produced which

pulls the laminated steel core into the coil, the force depending on the current through

the solenoid? The larger the current the greater the force exerted.

Solenoids used with valves tend to have operating voltages of 12V D.C., 24V D.C.,

110V D.C., or 110V A.C.

PULLED IN BY CURRENT THROUGH

COIL

1. Pressure control valves

These are used to control the pressure in part of the pneumatic/hydraulic circuit.
 2. Flow control valves

These are used to control the rate of flow of a fluid through the valve.

A directional control valve on the receipt of some, external signal, which might be

mechanical, electrical or a fluid pilot signal, changes the direction of stops, or starts

the flow of fluid in some part of the pneumatic/hydraulic circuit. They can be used to

carry out such functions as:

1. Controlling the direction of motion of an actuator

2. Selecting alternative flow paths for a fluid.

3. Stopping and starting the flow of fluid.

Carrying out logic functions such as AND, OR, NAND

Actuators:-

An actuator is a device that is used to apply a force to an object

Fluid power actuators can be classified into two groups:

▪ Linear actuators are used to move an object or apply a force in a straight line.

▪ Linear actuators can be divided into two types.

They are
 1. Single acting cylinders

2. Double acting cylinders

A single acting cylinder is powered by fluid for the movement of the piston in

one direction with it being returned in the other direction by an internal spring or an

external force, a double acting cylinder is powered by fluid in both directions.

▪ Rotary actuators are used to move an object in a circular path. Rotary

actuators are the fluid power equivalent of an electric motor.

3. PNEUMATIC CYLINDERS

Cylinders are the one, which offers the rectilinear motion to mechanical elements.

Cylinders are classified as light, medium, and heavy duty with respect to their

application.

Single acting cylinders

In this type, the cylinder can produce work only in one direction. The return

movement of the piston is effected by a built in spring or by application of an external

force. The spring is designed to return the piston to its initial position with a

sufficiently high speed.

 Types of single acting cylinders:

● Diaphragm cylinder

● Rolling diaphragm cylinder

Double acting cylinder

The force exerted by the compressed air moves the piston in two directions in a

double acting cylinder. They are used particularly when the piston is required to

perform work not only on the advance movement but also on the return. In principle,

the stroke length is unlimited, although buckling and bending must be considered

before we select a particular size of piston diameter, rod length and stroke length.

We use cylinders that are double acting type (i.e.) the compressed air can be passed to

either end of the cylinder. These cylinders are made up of cast iron.

[Link] Air Seal

 Air seal is used to prevent the leakage of air pressure from the cylinder.

Normally it is made up of neoprene rubber. If there are any air leakages in the system,

it will reduce the efficiency.

Wiper Seal:

Wiper seal is provided at the entrance of the cylinder to avoid dust materials

from the environment. It is made up of neoprene rubber.

Circlip

Circlip is used to protect the out coming of air seal and wiper seal from the

cylinder. It is made up of steel.

“O” Ring

The “O” rings are fitted into the grooves of piston to maintain perfect seal between

the piston and the cylinder wall. They are mostly made up of neoprene rubber.
CYLINDER TECHNICAL DATA:

Barrel:
It is made of cold drawn aluminimum 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 on 400mm bore and above.
 4. CONNECTORS:

In our 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 Aliminium

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.

5. FLOW CONTROL VALVE

In any fluid power circuit, flow control valve is used to control the speed of the

actuator. The floe 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.

6. BEARING WITH BEARING CAP:

 The bearings are pressed smoothly to fit into the shafts because if hammered

the bearing may develop cracks. Bearing is made upof steel material and bearing cap

is mild

steel.

INTRODUCTION

Ball and roller bearings are used widely in instruments and machines in order

to minimize friction and power loss. While the concept of the ball bearing dates back

at least to Leonardo da Vinci, their design and manufacture has become remarkably

sophisticated.

This technology was brought to its p resent state o f perfection only after

a long period of research and development. The benefits of such specialized

research can be obtained when it is possible to use a standardized bearing of the

proper size and type.

However, such bearings cannot be used indiscriminately without a careful

study of the loads and operating conditions. In addition, the bearing must be provided

with adequate mounting, lubrication and sealing. Design engineers have usually two

possible sources for obtaining information which they can use to select a bearing for

their particular application:

a) Textbooks
 b) Manufacturers’

Catalogs Textbooks are excellent sources; however, they tend to be overly

detailed and aimed at the student of the subject matter rather than the practicing

designer. They, in most cases, contain information on how to design rather than how

to select a bearing for a particular application. Manufacturers’ catalogs, in turn, are

also excellent and contain a wealth of information which relates to the products of the

particular manufacturer. These catalogs, however, fail to provide alternatives – which

may divert the designer’s interest to products not manufactured by them. Our

Company, however, provides the broadest selection of many types of bearings made

by different manufacturers.

For this reason, we are interested in providing a condensed overview of the

subject matter in an objective manner, using data obtained from different texts,

handbooks and manufacturers’ literature. This information will enable the reader to

select the proper bearing in an expeditious manner. If the designer’s interest exceeds

the scope of the presented material, a list of references is provided at the end of the

Technical Section. At the same time, we are expressing our thanks and are providing

credit to the sources which supplied the material presented here.

 Construction and Types of Ball Bearings

A ball bearing usually consists of four parts: an inner ring, an outer ring, the

balls and the cage or separator.

To increase the contact area and permit larger loads to be carried, the balls run

in curvilinear grooves in the rings. The radius of the groove is slightly larger than the

radius of the ball, and a very slight amount of radial play must be provided. The

bearing is thus permitted to adjust itself to small amounts of angular misalignment

between the assembled shaft and mounting. The separator keeps the balls evenly

spaced and prevents them from touching each other on the sides where their relative

velocities are the greatest. Ball bearings are made in a wide variety of types and sizes.

Single-row radial bearings are made in four series, extra light, light, medium, and

heavy, for each bore, as illustrated in Fig. 1-3(a), (b), and (c).

100 Series 200 Series 300 Series Axial Thrust Angular Contact Self-

aligning Bearing Fig. 1-3 Types of Ball Bearings

 The heavy series of bearings is designated by 400. Most, but not all,

manufacturers use a numbering system so devised that if the last two digits are

multiplied by 5, the result will be the bore in millimeters. The digit in the third place

from the right indicates the series number. Thus, bearing 307 signifies a medium-

series bearing of 35-mm bore. For additional digits, which may be present in the

catalog number of a bearing, refer to manufacturer’s details.

Some makers list deep groove bearings and bearings with two rows of balls.

For bearing designations of Quality Bearings & Components (QBC), see special pages

devoted to this purpose. The radial bearing is able to carry a considerable amount of

axial thrust.

However, when the load is directed entirely along the axis, the thrust type of

bearing should be used. The angular contact bear- ing will take care of both radial and

axial loads. The self-aligning ball bearing will take care of large amounts of

angular misalignment. An increase in radial capacity may be secured by using rings

with deep grooves, or by employing a double-row radial bearing. Radial bearings are

divided into two general classes, depending on the method of assembly. These are the

Conrad, or nonfilling-notch type, and the maximum, or filling-notch type. In the

Conrad bearing, the balls are placed between the rings as shown in Fig. 1-4(a).
 Then they are evenly spaced and the separator is riveted in place. In the

maximum-type bearing, the balls are a (a) (b) (c) (d) (e) (f) 100 Series Extra Light

200

Series Light 300 Series Medium Axial Thrust Bearing Angular Contact Bearing Self-

aligning Bearing Fig. 1-3 Types of Ball Bearings Fig. 1-4 Methods of Assembly

for Ball Bearings (a) Conrad or non-filling notch type (b) Maximum or filling notch

type

7. WHEEL ARRANGEMENT:

The wheels are fitted to the body of the vehicle with the help of end bearing

and bearing caps. The wheels are made up of fiber material.

8. TRAILER BODY:-

The trailer body is made up of mild steel sheet metal. This frame is look like a

small model trailer.

9. ROTATING PLATES:-

The rotating plates are fixed in the bottom the trailer body, so that the cylinder will

rotates in the required side. The plates are made up of mild steel materials.
 CHAPTER-5

DESIGN AND DRAWINGS

1. PNEUMATIC CYLINDER

Design of Piston rod:

Load due to air Pressure.

Diameter of the Piston (d) = 40 mm

Pressure acting (p) = 6 kgf/cm²

Material used for rod = C 45

Yield stress (σ y) = 36 kgf/mm²

Assuming factor of safety = 2

Force acting on the rod (P) = Pressure x Area

= p x (Πd² / 4)

= 6 x {( Π x 4² ) / 4 }

P = 73.36 Kgf
Design Stress(σ y) = σy / F0 S

= 36 / 2 = 18 Kgf/mm²

= P / (Π d² / 4 )

∴d = √4p/Π[σy]

∴ Minimum diameter √ 4 x 75.36 /={Π x 2.3

= of rod required for the load 18}mm

= √ 5.33 = 2.3 mm
We assume diameter of the rod = 15 mm

Design of cylinder thickness:

Material used = Cast iron

Assuming internal diameter of the cylinder = 40 mm

Ultimate tensile stress = 250 N/mm² = 2500 gf/mm²

Working Stress = Ultimate tensile stress / factor of safety

Assuming factor of safety = 4

= 2500 / 4 = 625 Kgf/cm²
Working stress ( ft )

According to ‘LAMES EQUATION’

Minimum thickness of cylinder ( t ) = ri {√ (ft + p) / (ft – p ) -1 }

Where,
 ri = inner radius of cylinder in cm.

ft = Working stress (Kgf/cm² )

p = Working pressure in Kgf/cm²

∴ Substituting values we get,

t = 2.0 { √ (625 + 6) / ( 625 – 6) -1}

t = 0.019 cm = 0.19 mm

We assume thickness of cylinder = 2.5 mm

Inner diameter of barrel = 40 mm

Outer diameter of barrel = 40 + 2t

= 40 + ( 2 x 2.5 ) = 45 mm

Design of Piston rod:

Diameter of Piston Rod:

Force of piston Rod (P) = Pressure x area = p x Π/4 (d² )

= 6 x (Π / 4) x (4)²

= 73.36 Kgf
Also, force on piston rod (P) = (Π/4) (dp) ² x ft
P = (Π/4) x (dp)² x 625

73.36 = (Π/4) x (dp)² x 625

∴ dp² = 73.36 x (4/Π) x (1/625)

= 0.15

dp = 0.38 cm = 3.8 mm

By standardizing dp = 15 mm

Length of piston rod:

Approach stroke = 160 mm

Length of threads = 2 x 20 = 40mm

Extra length due to front cover = 12 mm

Extra length of accommodate head = 20 mm

Total length of the piston rod = 160 + 40 + 12 + 20

= 232 mm

By standardizing, length of the piston rod = 230 mm

2. DESIGN OF BALL BEARING

Bearing No. 6202

Outer Diameter of Bearing (D) = 35 mm

Thickness of Bearing (B) = 12 mm

Inner Diameter of the Bearing (d) = 15 mm

r₁ = Corner radii on shaft and housing

r₁ = 1 (From design data book)

Maximum Speed = 14,000 rpm (From design data book)

Mean Diameter (dm) = (D + d) / 2

= (35 + 15) / 2

dm = 25 mm

WAHL STRESS FACTOR

Ks = 4C – 1 + 0.65
4C – 4 C

= (4 X 2.3) -1 + 0.65
(4 X 2.3 )-4 2.3

Ks = 1.85
 SPECIFICATION

1. Double acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 160 mm = 0.16 m

Quantity : 1

Seals : Nitride (Buna-N) Elastomer

End cones : Cast iron

Piston : EN – 8

Media : Air

Temperature : 0-80 º C
Pressure Range :
8 N/m²

2. Solenoid Valve

Technical data

Max pressure range : 0-10 x 10 ⁵ N/m²

Quantity : 3

3. Flow control Valve

Technical Data
Port size : 0.635 x 10 ֿ² m

Pressure : 0-8 x 10 ⁵ N/m²

Media : Air

Quantity : 1
4. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass
5. Hoses

Technical date

Max pressure : 10 x 10 ⁵ N/m²

Outer diameter : 6 mm = 6 x 10 ˉ ³ m

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

 CHAPTER-6

WORKING PRINCIPLE

Since pneumatic circuit plays a vital role in this device, it is very necessary to

explain the working of this circuit.

Initially starting with air compresses, its function is to compress air from a low

inlet pressure (usually atmospheric) to a higher pressure level. This is an accomplished by

reducing the volume of the air.

Air compressors are generally positive displacement units and are either of the

reciprocating piston type or the rotary screw or rotary vane types. The air compressor

used here is a typically small sized, two-stage compressor unit. It also consists of a

compressed air tank, electric rotor and pulley drive, pressure controls and instruments for

quick hook up and use. The compressor is driver by a 1 HP motor and designed to

operate in 10 – 100 PSI range. If the pressure exceeds the designed pressure of the

receiver a release value provided releases the excesses air and thus stays a head of any

hazards to take place.

 Then having a pressure regulator where the desired pressure to the operated is set.

Here a variable pressure regulator is adopted. Through a variety of direction control value

are available, a hand operated spool value with detent is applied.

The spool value used here is 5 ports, 3 positions. There are two exhaust ports, two

outlet ports and one inlet port. In two extreme positions only the directions can be

changed while the Centro ore is a neutral position and no physical changes are incurred.

The 2 outlet ports are connected to an actuator (Cylinder). The pneumatic activates

is a double acting, single rod cylinder. The cylinder output is coupled to further purpose.

The piston end has an air horning effect to prevent sudden thrust at extreme ends.

PRINCIPLES OF WORKING

❖ The compressed air from the compressor reaches the direction control valve. The

direction control valve changes the direction of flow according to the valve

position handle.

❖ The compressed air pass through the direction control valve and it is admitted into

the front end of the cylinder block. The air pushes the piston for the lifting stroke.
 At the end of the lifting stroke air from the valve reaches the rear end of the

cylinder block. The pressure remains the same but the area is less due to the

presence of piston rod. This exerts greater pressure on the piston, pushing it at a

faster rate thus enabling faster return stroke.

❖ The stroke length of the piston can be changed by making suitable adjustment in

the hand liver valve operating position.

 CHAPTER-7

ADVANTAGES, DISADVANTAGES AND APPLICATIONS

ADVANTAGES:-

It requires simple maintenance cares

Checking and cleaning are easy, because of the main parts are screwed.

Handling is easy. Manual

power not required

Repairing is easy.

Replacement of parts is easy.

DISADVANTAGES

1. Initial cost is high.

2. Separate air tank or compressor is required.

APPLICATIONS

1. All hydraulic and pneumatic dipper applications

 CHAPTER-8

LIST OF MATERIALS

Sl. No. PARTS Qty. Material

i. Pneumatic Double Acting Cylinder 1 M.S

ii. 5/2 Direction Control Valve 1 Aluminium

iii. Wheel 4 Rubber

iv. Bearing with Bearing Cap 4 Fiber

v. Polyethylene Tube - Polyurethene

vi. Hose Collar and Reducer - Brass

vii. Stand (Frame) 1 Mild steel

viii Dash Pad 1 Plastic

Ix Flow control valve 1 Lead-Acid

 CHAPTER-9

COST ESTIMATION
1. MATERIAL COST:

Sl. No. PARTS Qty. Material Amount (Rs)

i. Pneumatic Double Acting 1 M.S

Cylinder

ii. 5/2 Direction Control Valve 1 Aluminium

iii. Wheel 4 Rubber

iv. Bearing with Bearing Cap 4 Fiber

v. Polyethylene Tube - Polyurethene

vi. Hose Collar and Reducer - Brass

vii. Stand (Frame) 1 Mild steel

viii Dash Pad 1 Plastic

Ix Flow control valve 1 Lead-Acid

TOTAL =

2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =
3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

=
=

Overhead Charges = 20% of the manufacturing cost

=

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

=
=

Total cost for this project =

 CHAPTER-10

CONCLUSION

This project work has provided us an excellent opportunity and experience, to use

our limited knowledge. We gained a lot of practical knowledge regarding, planning,

purchasing, assembling and machining while doing this project work. We feel that the

project work is a good solution to bridge the gates between institution and industries.

We are proud that we have completed the work with the limited time successfully.

The “THREE AXIS PNEUMATIC MODERN TRAILER” is working with

satisfactory conditions. We are able to understand the difficulties in maintaining the

tolerances and also quality. We have done to our ability and skill making maximum use

of available facilities. In conclusion remarks of our project work, let us add a few more

lines about our impression project work.

Thus we have developed a “THREE AXIS PNEUMATIC MODERN

TRAILER” which helps to know how to achieve low cost automation. The operating

procedure of this system is very simple, so any person can operate. By using more

techniques, they can be modified and developed according to the applications.