FABRICATION OF PNEUMATIC PAPER CUP MAKING MACHINE MACHI NE
ABSTRCT
Generally the cups and and plate are made in plastics. plastics. The plastics are harmful harmful and it has many disadvantages to us. By naturally we get leaves, papers by using this we can make cups. It is very cheap and it does does not have any chemical effects. The paper cup is made by a pneumatic pneumatic machine. machine. The machine machine is operated operated by the pneumatic system. By using this we can produce cup at high production rate. By using using differe different nt shape die we can produc producee differ different ent shape shape and size size cups. cups.
The
machine size is comfortable to suit any where.
The air enters to the flow control valve and gives pressure to the double acting acting cylinder cylinder.. The directio direction n is control control by the directio direction n 5! control control valve. valve. The move moveme ment nt of pist piston on will will be vari varied ed by ad"u ad"ust stin ing g the the flow flow contro controll valv valve. e. ad"usting the speed, the production rate will be varied
By
INTRODUCTION
The pneumatic paper making press is used to different shapes of cup in faster production rate. The principle of operation is the same as the conventional simple simple press. The differen difference ce is only in the type of drive and the type type of fi#tures used.
The following points reveals why we have to make use of this type of press
•
$neumatic paper making press reduces the manual work.
•
This type of machine reduces working time.
By using this machine the bearings can be inserted in the various lengths of shat %up to &''mm(.
WORKING PRINCIPLE
In this paper cup making machine there is a double acting cylinder which is a pneumatic device a punch, die, screw rod, top plate, bottom plate, direction control valve, flow control valve, connectors and hoses. ) compressor supplies high pressure air to the cylinder, whose flow is controlled by a flow control valve. The air passes through a direction control valve. This is used to actuate the piston and to specify its direction of movement. The piston is connected to a ram.
)t the end of the ram punch is fastened. The die in the ram can be replaced. The piston, ram and punch are the moving parts in this machine. The die is fi#ed on the base of the machine by screw rods. The height of the base can be ad"usted by rotating the screw rod. The whole unit is fi#ed on the column. *hen the air flows through the flow control valve, its volume is restricted to the specified amount. Then the direction control valves control the part of cylinder which it should occupy.
*hen it occupies part ) of the cylinder, it moves the ram downwards along with the punch. The punch, punches the paper kept over the die. The paper will be wet. To recover the wetness and make the shape stable a heating coil is placed in the die. +e#t, direction control valves are actuated which makes the air to flow in part B of cylinder. ue to air in part ) is released to the atmosphere by a valve. This makes the punch to move upwards. The cup can be taken out and the ne#t paper can be placed over the die for the ne#t cycle.
.
ADVANTAGES
This product is an alternative for plastic cups and plates. -asily decomposing product. heaper and easily available material is used. -co friendly product. The pneumatic arm is more efficient in the technical field. /uick response is achieved 0imple in construction. -asy to maintain and repair. ost of the unit is less. +o fire hazard problem due to over loading. omparatively the operation cost is less. ontinuous operation is possible without stopping. It reduces the manual work. It reduces the production time. 1ccupies less floor space. •
2ess skilled operator is sufficient.
DISADVANTAGES
•
*hile working, the compressed air produces noise therefore a silencer may be used.
•
3igh tor4ue can not be obtained.
•
Initial cost is high.
•
ylinder stroke length is constant.
•
+eed a separate compressor.
LITERATURE SURVEY PNEUMATICS
The word pneuma6 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 e4uipment. $neumatics 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. $neumatic systems operate on a supply of compressed air which must be made available in sufficient 4uantity and at a pressure to suit the capacity of the system. *hen the pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the 4uestion of compressed air supply.
The key part of any facility for supply of compressed air is by means using reciprocating compressor. ) compressor is a machine that takes in air, gas at a certain pressure and delivered the air at a high pressure. ompressor capacity is the actual 4uantity of air compressed and delivered and the volume e#pressed 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 7obert Boyle in 89&! and that found that the product of pressure and volume of a particular 4uantity of gas. The usual written as $: ;
%or( $< :< ; $! :!
In this e4uation the pressure is the absolute pressured which for free is about 8=.> $si and is of courage capable of maintaining a column of mercury, nearly ?' inches high in an ordinary barometer. )ny gas can be used in pneumatic system but air is the mostly used system now a days.
SELECTION OF PNEUMATICS:
@echanization is broadly defined as the replacement of manual effort by mechanical power. $neumatics is an attractive medium for low cost mechanization particularly for se4uential or repetitive operations.
@any factories and plants
already have a compressed air system, which is capable of providing both the power or energy re4uirements and the control system %although e4ually pneumatic control systems may be economic and can be advantageously applied to other forms of power(.
The main advantages of an allApneumatic system are usually economy and simplicity, the latter reducing maintenance to a low level. It can also have out of standing advantages in terms of safety.
PRODUCTION OF COMPRESSED AIR
$neumatic systems operate on a supply of compressed air, which must be made available, in sufficient 4uantity and at a pressure to suit the capacity of the system. *hen pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the 4uestion of compressed air supply. The key part of any facility for supply of compressed air is by means using reciprocating compressor. ) compressor is a machine that takes in air, gas at a certain pressure and delivered the air at a high pressure. ompressor capacity is the actual 4uantity of air compressed and delivered and the volume e#pressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature. lean condition of the suction air is one of the factors, which decides the life of a compressor. *arm and moist suction air will result in increased precipitation of condense from the compressed air. ompressor may be classified in two general types.
8. $ositive displacement compressor. !. Turbo compressor
$ositive displacement compressors are most fre4uently employed for compressed air plant and have proved highly successful and supply air for pneumatic control application. The types of positive compressor
8. 7eciprocating type compressor !. 7otary type compressor
Turbo compressors are employed where large capacity of air re4uired 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.
COMPONENTS AND DESCRIPTION
The pneumatic $aper cup making machine consists of the following components to fulfill the re4uirements of complete operation of the machine.
•
$neumatic cylinder
•
irection control valve
•
low control value
•
$unch
•
ie
•
Bottom plate
•
Top $late
•
0crew 7od
•
onnectors
•
3oses
CYLINDER:
The cylinder is a double acting cylinder one, which means that the air pressure operates alternatively %forward and backward(.
The air from the
compressor is passed through the regulator which controls the pressure to re4uired amount by ad"usting its knob. ) pressure gauge is attached to the regulator for showing the line pressure. Then the compressed air is passed through the directional control valve for supplying the air alternatively to either sides of the cylinder. Two hoses take the output of the directional ontrol valve and they are attached to two ends of the cylinder by means of connectors. 1ne of the outputs from the directional control valve is taken to the flow control valve from taken to the cylinder. The hose is attached to each component of pneumatic system only by connectors.
CYLINDER TECHNICAL DATA:
Barrel:
It is made of cold drawn aluminium honed to !5mm.
Pist! R":
@.0. hard hrome plated
Seals:
+itrile %Buna C +( -lastomer
E!" C#ers:
ast iron graded fine grained from !5mm to ?''mm
Pist!:
)luminium.
Me"ia:
)ir.
Te$%erat&re Ra!'e:
'Dc to E5Dc
C&s(i!s:
)d"ustable standard on =''mm bore and above .
DIRECTIONAL CONTROL VALVE
To control the to and fro motion of cylinder, the fluid energy has to be regulated, controlled and reversed with a predetermined se4uence in a pneumatic system
0imilarly one may have to control the 4uantity of pressure and flow rate to generate the desired level of force and speed of actuators.
To achieve these
functions, valves are used. :alves are fluid power elements used for controlling and regulating the working medium.
The main functions of the valves are,
•
0tart and stop the fluid energy
•
ontrol the direction of flow of compressed air
•
ontrol the flow rate of the fluid
•
ontrol the pressure rating of the fluid
FLOW CONTROL VALVE:
These are used to control the rate of flow of a fluid through the valve. ) directional control valve on the receipt of some, e#ternal 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 pneumatichydraulic circuit. They can be used to carry out such functions asF
8.
ontrolling the direction of motion of an actuator
!.
0electing alternative flow paths for a fluid. ?. 0topping and starting the flow of fluid
P&r%se:
This valve is used to speed up the piston movement and also it acts as an one C way restriction valve which means that the air can pass through only one way and it can6t return back.
By using this valve the time consumption is reduced because of the faster movement of the piston.
PUNCH: The male portion of cutting die is called a punch. It is usually upper movable member fastened to the piston rod. The design of the punch depends up on area to be pierced or blanked, and the pressure re4uired penetrating the work piece material. The method of mounting a punch also depends up on the area to be pierced or blanked. The punch is made up on -+AE material.
DIE
The die is mounted on the bottom plate and it is surrounded by heating coils. These coils are used to heat the $aper and absorb the moisture present in the $aper. 0o heating the $aper gets stiffness. The die is made in -+AE material.
BOTTOM PLATE:
@aterial
F
85
@aterial 0election
F
*eld ability, toughness, low cost, 3ardness, easy to machine, and easily )vailable in the market.
@achines sed
F
2athe, rilling and shaping machines.
/uantity
F
8
TOP PLATE:
@aterial
F
85
@aterial 0election
F
ue to *eld ability, toughness, low
cost, 3ardness, easy to machine, and easily
)vailable in the market. @achines sed
F
2athe, rilling and shaping machines.
/uantity
F
8
SCREW ROD:
@aterial
F
85
@aterial 0election
F
ue to *eld ability, toughness, low
cost, 3ardness, easy to machine, and easily )vailable in the market. @achines sed
F
2athe, rilling and shaping machines.
/uantity
F
=
CONNECTIORS:
In our pneumatic system there are two types of connectors usedH one is the hose connector and the other is the reducer. 3ose connectors normally comprise an adapter %connector( hose nipple and cap nut.
These types of
connectors are made up of brass or )l or hardened steel.
7educers are used to provide inter connection between two pipes or hoses of different sizes.
They may be fitted straight, tee, :J or other
configurations. These reducers are made up of gunmetal or other materials like hardened steel etc.
HOSES: 3oses used in this pneumatic system are made up of polyrethane. These hoses can with stand at a ma#imum pressure level of 8' kgcm!. The various sizes polyurethane tubes and its specifications are shown in the table .
Code No.
Od X Id
Burst
Working
(mm)
Pressure
Pressure
(kgf/cm
(kgf/cm
2)
in. Bending
#t"nd" rd
!"dius
$engt%
2)
(mm)
(m)
Weig%t (g/m)
P&'2
' X 2.
*2
+ ,
,
2
-
P&'*2-
'.* X
*
+ ,
,2
2
-
2.P&'
X'
2
+ ,
,
2
,0
P&0
0X
*2
+ ,
22
,
*0
P&0
0X
2
+ ,
22
,
*'
P&-
-. X
20
+ ,
2
,
2
. P&,
, X .
*
+ ,
20
,
P&,0
,, X 0
2
+ ,
20
,
'
P&,,0
,2 X 0
*
+ ,
20
,
P&,20
,2 X 0
20
+ ,
*
,
0
P&,2-
,2 X -
2
+ ,
*
,
P&,2-
,2. X
*
+ ,
*-
,
02
-.
WORKING PRINCIPLE
In this $aper cup making machine there is a double acting cylinder which is a pneumatic device a punch, die, screw rod, top plate, bottom plate, direction control valve, flow control valve, connectors and hoses.
) compressor supplies high pressure air to the cylinder, whose flow is controlled by a flow control valve. The air passes through a direction control valve. This is used to actuate the piston and to specify its direction of movement. The piston is connected to a ram. )t the end of the ram punch is fastened. The die in the ram can be replaced. The piston, ram and punch are the moving parts in this machine. The die is fi#ed on the base of the machine by screw rods. The height of the base can be ad"usted by rotating the screw rod. The whole unit is fi#ed on the column.
*hen the air flows through the flow control valve, its volume is restricted to the specified amount. Then the direction control valves control the part of cylinder which it should occupy.
*hen it occupies part ) of the cylinder, it moves the ram downwards along with the punch. The punch, punches the $aper kept over the die. The $aper will be wet. To recover the wetness and make the shape stable a heating coil is placed in the die. +e#t, direction control valves are actuated which makes the air to flow in part B of cylinder. ue to air in part ) is released to the atmosphere by a valve. This makes the punch to move upwards. The cup can be taken out and the ne#t $aper can be placed over the die for the ne#t cycle.
