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8/3/2019 CONTROLLED SEMIAUTOMATIC PRINTING OPERATIONOPERATION
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INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY,
ERODE.
DESDES
IGN OFIGN OFPCPC
CONTROLLED SEMIAUTOMATIC PRINTINGCONTROLLED SEMIAUTOMATIC PRINTING
OPERATIONOPERATION
Presented byPresented byM.DINESH BABU & K.SATHEESHWARANM.DINESH BABU & K.SATHEESHWARAN
THIRD YEAR
((B.E.MECHANICAL ENGINEERINGB.E.MECHANICAL ENGINEERING))
E-mailE-mail:[email protected]:[email protected]
Contact no:Contact no: 95002902989500290298,, 9566988285.9566988285.
CONTACT ADDRESS:CONTACT ADDRESS:
THE PROFESSOR AND HEAD,
DEPARTMENT OF MECHANICAL,
INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY,
ERODE - 638316
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ABSTRACT
Manual methods are still frequently used to print (textile-fabrics) work
pieces using the conventional printing method. But in conventional method there are
many disadvantages like time consumption, cost etc. Our main aim is to reduce the
time, and hence the cost of the printing operation. Automation therefore always brings
a considerable rationalization effect, produces a more even printed result and reduces
cost. We have obtained the sequence for the printing operation and we have
constructed a pneumatic circuit by using KV map method for the obtained
sequence. We have simulated the circuit by using AUTOMATION STUDIO software
and verified the sequence. Then we constructed a PLC circuit using DIRECT SOFT
software which is used to automate the printing operation. This PLC circuit has been
incorporated in to the PLC device and we automated the sequence in our FESTO
LAB. After that the cylinders are sized based on the force requirement. This is done
with the help of FESTO manual. Further a Pro/E model is created for machine setup
and cost estimation is done for each component which is involved in this process.
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1. INTRODUCTION:
Pneumatics is a portion of fluid power in which compressed air or other gas is
used to transmit and control power to actuating mechanisms. A pneumatic system
comprises of a compressor plant, pipelines, control valves, drive-members and related
auxiliary appliances. The air is compressed in an air compressor and from the
compressor plant the flow medium is transmitted to the pneumatic cylinder through a
well-laid pipe line system. To maintain optimum efficiency of pneumatic system, it is
of vital importance that the pressure drop between generation and consumption of
compressed air is kept very low.
2. EXISTING PROCESS:
In the existing method most of the processes are carried out manually. Some
of the processes are feeding, transformation of ink from stencil to the work piece,
dispatching, i.e., removing the work piece.
2.1 Problem Identification:
Time consumption because of manual work.
High cost.
Fatigue of the workers involved in this process.
In order to obtain a good quality printing the ink must be transferred from
the stencil to the work piece as quickly as possible. But this cant be
obtained manually.
3. SOLUTION:
Thus in order to obtain a good quality printing, the ink must be transferred
from the stencil to the work piece as quickly as possible. This is done with the help of
automation. Here the work piece which is to be printed moves between the gripper
jaws, which then close. The work piece is lifted off the transfer system, turned and set
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down again on the carrier pin which is perpendicular to the plunger descends down
and printing operation is done. All the above mentioned operations are controlled by
pneumatics.
4. REASON FOR CHOOSING PNEUMATICS:
The force range required lies within 1000N to 1200N.
Quick reaction when compared to other systems.
Air source is readily available.
Cost effective.
5. OBTAINING SEQUENCE:
The sequence of operations of the cylinders A, B, C, D is as follows,
Cylinder A: This cylinder is used for vertical movement of the plunger.
Cylinder B: This cylinder is used for horizontal movement of the plunger.
Cylinder C: The gripper jaws which are used to hold the work piece during
Swivel mechanism, are controlled by this cylinder.
Cylinder D: This cylinder is used for performing swivel operation.
Hence the sequence obtained is as follows:
A1A0B1A1A0B0C1D1C0D0
6. ELECTRO PNEUMATICS:
By using electro pneumatics we are able to control the air flow
electrically and hence we can obtain the air actuation more accurately and also the
space occupied is less comparatively because it replaces many mechanical
components. We have constructed the circuit using KV map method. The traverse
step diagram for the sequence is shown below. From this we obtained the
unminimized equations.
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7. TRAVERSE STEP DIAGRAM:
A1 A0 B1 A1 A0 B0 C1 D1 C0 D0
D
C
B
A
8. UNMINIMIZED EQUATIONS:
A1 = a0 b0 c0 d0 A0 = a1 b0 c0 d0 B1 = a0 b0 c0 d0
A1 = a0 b1 c0 d0 A0 = a1 b1 c0 d0 B0 = a0 b1 c0 d0
C1 = a0 b0 c0 d0 D1 = a0 b0 c1 d0 C0 = a0 b0 c1 d1
D0 = a0 b0 c0 d1
. The modified flow diagram is shown. From the modified flow diagram we
calculated the minimized equations. These minimized equations will be used in
constructing the circuit diagram.
9. MODIFIED SIGNAL FLOW DIAGRAM:
X X
Y Y Y Y
d0
c0
b0
a0 A1 B1 C1 X0
a1 Y1 A0
b1
a1 X1 A0
a0 A1 B0
c1
b1
a0
a1
b0
a1
a0 D1
d1
c1
b0
a0 D0
a1
b1
a1
a0
c0
b1
a0
a1
b0
a1
a0 Y0 C0
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10. MINIMISED EQUATION:
__ __ __
A1 = Y X + a0b1 X D1 = Y
__
A0 = Y b0 + b1 X D0 = Y
__B1 = Y X a0 b0 Y1 = a1
B0 = X a0 b0 Y0 = d1
C1 = Y X b0 X1 = a1 b1
__ __
C0 = Y X0 = Y d0
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11. AUTOMATION STUDIO:
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Fig 1. Circuit diagram in AUTOMATION STUDIO
12. ELECTRO PNEUMATICS DIAGRAM:
8
24V0V
STARTY X
A0 B1 X
A1
Y B0
X
A0
Y X A0 B1
X A0 B0
Y C0
D1
Y B0X C1
Y C1
Y C0 D0
XA1 B1
X
A1
Y
Y
D0
D1
Y
A 1 A 0
A 0
A 0
A 1
A 1
A 0 A 1
B 1 B 0
B 0
B 0
B 1
B 1
B 0 B 1
C 1 C 0
C 0
C 0
C 1
C 1
C 0 C 1
D 1 D 0
D 0
D 0
D 1
D 1
D 0 D 1
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Fig 2. Electro pneumatics circuit diagram
13. PROGRAMMABLE LOGIC CONTROLLER:
A PLC is a user-friendly, microprocessor-based specialized computer that carries out
control functions of many types and levels of complexity. Its purpose is to monitor crucial
process parameters and adjust process operations accordingly. The PLC will operate any
system that has output devices that go on and off (known as discrete, or digital, outputs). It
can also operate any system with variable (analog) outputs. The PLC can be operated on the
input side by on-off devices (discrete or digital) or by variable (analog) input devices.
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The PLC circuit is constructed and verified in Direct SOFT software. This is
shown in fig.3. Then an experimental setup which was constructed in FESTO lab is shown in
fig 4. Then a model setup drawn using Pro/E is shown in fig 5.
Fig 3. PLC diagram in Direct SOFT software
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14. EXPERIMENTAL SETUP:
Fig 4. Experimental setup
15. MODEL SETUP:
Fig.5 Model setup (Designed using Pro/E software)
16. SIZING:
Cylinder A
Cylinder BCylinder D
Cylinder C
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Sizing is a process in which the size of the cylinder is calculated and it is
compared with the standard values so that the required size of the cylinder is obtained.
Size of the cylinder A is obtained as follows,
Force = pressure x Area
Force = P x A - R
= P x 10 x 3.14 x d2 - R
4
1000 = 6 x 10 x 3.14 x d2 - 100
4
d = 48.3 mm
Standard value = 50mm (from festo manual)
Similarly sizes of the cylinders B,C,D are calculated using FESTO manual.
Diameter of cylinder B = 40.9 mm (obtained in calculation)
Standard value = 50mm (from festo manual)
Diameter of cylinder C = 24.16mm (Obtained in calculation)
Standard value = 25mm (from festo manual)
Diameter of cylinder D= 4.3mm (obtained in calculation)
Standard value = 5.35mm(from festo manual)
16.1 Stroke Length of Cylinders Used:
Stroke length is obtained from the festo manual with respect to the size of the
cylinder and cylinders are specified based on these values.
Stroke length of the cylinder A: 200 mm
Stroke length of the cylinder B: 500 mm
Stroke length of the cylinder C: 40 mm
Swivel angle of the cylinder D: 1800
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17. COST CALCULATION:
The cost was calculated using FESTO manual and listed below:
Cylinders : Rs. 13,250
5/2 Double acting solenoid valves : Rs.3, 330
Air filter regulator unit : Rs.2, 365
PLC : Rs 12,000
Others(tubes, limit switches, lubricator): Rs. 4,260
Total amount : Rs.35, 205
18. CONCLUSION:
The problems pertaining with manual printing operation are identified.
The cost of operation and the time taken is very high in case of manual printing
operation. A semi-automated printing machine operation sequence has been designed
using KV-map method. The results obtained are verified with the results of
simulations performed in AUTOMATION STUDIO. A PLC circuit is constructed and
is verified in DIRECT SOFT. Detailed cost estimation has been carried out. It is
found that the time has been reduced significantly and the cost is also low in long run.
19. REFERENCES:
[1] Antony Barber, (1997), Pneumatic Handbook 8 th edition, Elsevier Advanced
Technology, Oxford, UK.
[2] FESTO Manual
[3] Croser. P, (1989), Pneumatics-Basic level FESTO Didactic KG, D-7300,
Esslingen.
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