AIR COMPRESSOR CRANK AND SLOTTED LINK MECHANISM

Submitted in partial fulfillment of the requirement for the award of DIPLOMA IN MECHANICAL ENGINEERING BY

Under the guidance of

------------------------

2005-2006 DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE number: _________________________

This is to certify that the project report titled “PNEUMATIC JACK” submitted by the following students for the award of the Diploma engineering is record of bonafide work carried out by them. Done by Mr. /Ms._______________________________

In partial fulfillment of the requirement for the award of Diploma in Mechanical Engineering During the Year – (2005-2006) _________________ Head of Department

_______________ Guide

Coimbatore –641651. Date: Submitted for the university examination held on ___________

_________________

________________

Internal Examiner Examiner

External

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ACKNOWLEDGEMENT ---------------------------------------------------------------------------------

ACKNOWLEDGEMENT At this pleasing moment of having successfully completed our project, we wish to convey our sincere thanks and gratitude to the management of

our

college

and

our

beloved

chairman

…………………………………………………, who provided all the facilities

to us.

We would like to express our sincere thanks to our

principal

for

………………………………………,

forwarding us to do our project and offering adequate duration in completing our project. We

are

also

Department Prof.

grateful

to

the

Head

of

…………………………………….., for

her constructive suggestions & encouragement during our project. With deep sense of gratitude, we extend our earnest

&

sincere

thanks

to

…………………………………………………….., of

Mechanical

for

her

kind

encouragement during this project.

our

guide

Department guidance

&

We also express our indebt thanks to our TEACHING MECHANICAL

and

NON

TEACHING

ENGINEERING

staffs

of

DEPARTMENT,

……………………….(COLLEGE NAME).

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AIR COMPRESSOR USING CRANK AND SLOTTED LINK MECHANISM -------------------------------------------------------------------------------------

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CONTENTS ---------------------------------------------------------------------------------

CONTENTS

CHAPTER NO

1

TITLE Synopsis

PAGE NO

2 3 4 5 6 7 8 9 10 11 12

Introduction Components and Description compressor Design and drawing Working principle Generally used Materials Advantages and Disadvantages Applications List of materials Cost estimation Conclusion Bibliography Photography

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Chapter-1 ---------------------------------------------------------------------------------------

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SYNOPSIS -------------------------------------------------------------------------------------CHAPTER-1 SYNOPSIS The objective of this experiment is to investigate the kinematics motion of a Crank and Slotted Lever Quick Return mechanism. The investigation is to show that it is indeed a quick return mechanism and to evaluate the increase in efficiency that this would offer if applied to a machine tool.

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Chapter-2 ---------------------------------------------------------------------------------------

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INTRODUCTION ---------------------------------------------------------------------------------------

CHAPTER-2 INTRODUCTION

Definition of a Mechanism A mechanism is a simplified model, usually in the form of a line diagram, which is used to reproduce the motion occurring in a machine. The purpose of this reproduction is to enable the nature of the machine. The purpose of this reproduction is to enable the nature of the motion to be investigated without the encumbrance of the various solid bodies which form the machine elements The various parts of the mechanism are called links or elements. Where two links are in and a relative motion is possible, then they are known as a pair. An arbitrary set of a links which form a closed chain that is capable of relative motion, and that can be made into a rigid structure by the addition of a single link, is known as a kinematics chain. To form a mechanism from a kinematics chain one of the links must be fixed. However as any of the links can be fixed, it follows that there are as many mechanism as there are links in the chain. The technique

obtaining different mechanism by fixing the various links in turn is known as inversion.

Degrees of automation are of two types, viz.

Full automation. Semi automation.

In semi automation a combination of manual effort and mechanical power is required whereas in full automation human participation is very negligible.

NEED FOR AUTOMATION:

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of these sources, pneumatics form an attractive medium for low cost automation. 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 vehicle accident



To reduce the fatigue of workers



To high responsibility



Less Maintenance cost

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Chapter-3 ---------------------------------------------------------------------------------------

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COMPONENTS AND DESCRIPTION ---------------------------------------------------------------------------------------

CHAPTER-3 COMPONENTS AND DESCRIPTION

1. PNEUMATIC CYLINDER 2. HOSE COLLAR AND CONNECTOR 3. FRAME STAND 4. CAM

1. PNEUMATIC CYLINDER:

Pneumatic cylinder consist of A) PISTON

B) CYLINDER

The cylinder is a double acting cylinder one, which means that the air pressure operates forward and backward. The air from the compressor is ed through the regulator which controls the pressure to required amount by adjusting its knob.

A pressure gauge is attached to the regulator for showing the line pressure. Then the compressed air is ed through the 5/2 solenoid valve for supplying the air to the cylinder.

One hose take the output of the directional Control (Solenoid) valve and they are attached to one end of the cylinder by means of connectors. One 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: 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

Parts of Pneumatic Cylinder Piston: The piston is a cylindrical member of certain length which reciprocates inside the cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter and it is fitted to the top of the piston rod. It is one of the important parts which convert the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively soft rubber which is capable of providing good sealing with low friction at the operating pressure. The purpose of piston is to provide means of conveying the pressure of air inside the cylinder to the piston of the oil cylinder.

Generally piston is made up of  Aluminium alloy-light and medium work.  Brass or bronze or CI-Heavy duty.

The piston is single acting spring returned type. The piston moves forward when the high-pressure air is turned from the right side of cylinder. The piston moves backward when the solenoid valve is in OFF condition. The piston should be as strong and rigid as

possible. The efficiency and economy of the machine primarily depends on the working of the piston. It must operate in the cylinder with a minimum of friction and should be able to withstand the high compressor force developed in the cylinder and also the shock load during operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise. b. It should be frictionless. c. It should withstand high pressure.

Piston Rod

The piston rod is circular in cross section. It connects piston with piston of other cylinder. The piston rod is made of mild steel ground and polished. A high finish is essential on the outer rod surface to minimize wear on the rod seals. The piston rod is connected to the piston by mechanical fastening. The piston and the piston rod can be separated if necessary.

One end of the piston rod is connected to the bottom of the piston. The other end of the piston rod is connected to the other piston rod by means of coupling. The piston transmits the working force to the oil cylinder through the piston rod. The piston rod is

designed to withstand the high compressive force. It should avoid bending and withstand shock loads caused by the cutting force. The piston moves inside the rod seal fixed in the bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air from the bottom of the cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the compressor and act on the pinion. The cylinder is thus closed by the cover plates on both the ends such that there is no leakage of air. An inlet port is provided on the top cover plate and an outlet ports on the bottom cover plate. There is also a hole drilled for the movement of the piston.

The cylinder cover plate protects the cylinder from dust and other particle and maintains the same pressure that is taken from the compressor. The flange has to hold the piston in both of its extreme positions. The piston hits the top plat during the return stroke and hits the bottom plate during end of forward stroke. So the cover plates must be strong enough to withstand the load. Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the help of ‘L’ bends and bolts.

Cylinder Tube Materials: LIGHT DUTY 1. Plastic 2. Hard drawn

MEDIUM DUTY

HEAVY DUTY

Hard drawn brass tube

hard drawn brass tube.

Aluminium

Aluminium tube

Castings

4. Hard drawn

Hard drawn steel tube tube. Brass, Bronze, Iron or

Brass tube

Castings, welded steel tube

End Cover Materials:

LIGHT DUTY

1. Aluminium stock (Fabricated) 2. Brass stock (Fabricated) 3. Aluminium Castings

MEDIUM DUTY

HEAVY DUTY

Aluminium stock

Hard tensile

(Fabricated)

Castings

Brass stock (Fabricated) Aluminium, Brass, iron or steel Castings.

Piston Materials:

LIGHT DUTY 1.Aluminium Castings 2.

MEDIUM DUTY Aluminium Castings

HEAVY DUTY Aluminium Forgings,

Brass (Fabricated) Bronze (Fabricated)

Aluminium Castings. Bronze (Fabricated)

3.

Iron and Steel

Brass, Bronze, Iron or

Castings

Steel Castings.

LIGHT DUTY 1. Aluminium

MEDIUM DUTY Aluminium, Brass

HEAVY DUTY High Tensile

Castings 2. Light Alloy

And Steel Castings

Steel Castings High Tensile

Mount Materials:

(Fabricated)

Steel Fabrication

Piston Rod Materials:

MATERIAL MILD STEEL

FINISH Ground and polished hardened,

REMARKS Generally preferred chrome

STAINLESS STEEL

ground and polished. Ground and Polished

plated Less scratch resistant than chrome plated piston rod

2. PU CONNECTIORS, REDUCER AND HOSECOLLAR:

In our pneumatic 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 Aluminium 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.

3. FRAME STAND: This is a ing frame and made up of mild steel.

CAM INTRODUCTION Cams are mechanical member having miscellaneous contour surfaces which transmit a desired motion to a follower by direct ; and the cam mechanisms are used to create mathematical functions, motion (movement in a prescribed, exact path) mechanisms and mechanical computers, with the help of cams it is very easy, accurate and efficient to produce a given motion, velocity and acceleration. In the design of cams it is essential that the kinetics (relative motions), dynamics (masses, accelerations, clasticities of ) and the design (practical construction, proportion of parts and fabrication accuracy) be considered thoroughly. In the case of high speed cams, a detailed study of the cam contour

and its characteristic velocity and acceleration curves, which concerns with vibrations, dynamic loads, noise etc., is also essential. EMPIRICAL DESIGN A radial cam can be considered to be a wedge rolled in plane of the paper having a length of one cycle wedge cam equal to the circumference. The empirical design of cam is used to construct a simple cam requiring a given total rise in a given time for low cam speeds. This method calls for two important conditions it., the cam should have a smooth contour free of sharp changes such that the steepness of displacement curve is not more than 30 (It may be noted that steepness of the curve can be reduced for the same given rise, by employing a bigger size cam).

This is desirable to avoid jamming of the

translating follower on the sides. The profile of the cam is developed by fixing the cam and moving the follower around the cam at its respective relative positions. Enough points should be considered in order to obtain smooth and reliable cam contour. With the roller follower, the lay out is drawn for the centre of the roller and then the cam curve is drawn tangent to the rollers. ECCENTRIC

It is best suited for rise-return-rise cam which has no dwells. In eccentric, the displacement, velocity and acceleration curves have a continuous sine or cosine curve characteristic. It is more compact and cheaper to fabricate than a cam. CAM PROFILE LAY OUT Having specified the displacement time diagram, it becomes simple to design the cam profile further.

However, the important points needing

consideration are: Space limitations of interference, wear or strength problems, whether the cam designed will actually give the displacement time characteristics.

All these problems are obviously related with the size and shape of the cam and follower, and it becomes necessary to consider that cam profile in some detail, either analytically or graphically. For most purposes, the information required by the designer can readily be determined with sufficient accuracy by using graphical means. However, where extreme accuracy is necessary, than special analytical methods in conjunction with high speed digital computers need to be considered. Every cam design is based upon the following three points:

i)

The displacement-time diagram is always given for a point on the follower which may be used to draw the follower in its correct position at any time.

ii)

The cam profile will be tangent to the follower at all times and will thus be determined by the envelope of the follower profiles drawn in successive positions.

iii)

Cam profile has, therefore, to be drawn on the basis of principle of inversion, i.e., cam should be kept fixed and the frame carrying the follower rotated in the direction opposite to that specified for cam rotation and then the envelope of follower profiles is drawn.

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Chapter4 ---------------------------------------------------------------------------------------

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COMPRESSOR ---------------------------------------------------------------------------------------

CHAPTER-4

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.

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Chapter-5

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DESIGN AND DRAWINGS ---------------------------------------------------------------------------------------

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 (σy)

=

36 kgf/mm²

Assuming factor of safety

=

2

Force acting on the rod (P) =

P

Design Stress(σy)

Pressure x Area

=

p x (Πd² / 4)

=

6 x {( Π x 4² ) / 4 }

=

73.36 Kgf

=

σy / F0 S

=

36 / 2

=

18 Kgf/mm²

∴d

=

P / (Π d² / 4 )

=

√ 4 p / Π [ σy ]

=

√ 4 x 75.36 / {Π x 18}

=

√ 5.33

= 2.3 mm

∴ Minimum diameter of rod required for the load

=

2.3 mm

We assume diameter of the rod

=

15 mm

Material used

=

Cast iron

Assuming internal diameter of the cylinder

=

40 mm

Design of cylinder thickness:

Ultimate tensile stress

=

250 N/mm²

Working Stress

=

Ultimate tensile stress / factor of safety

=

4

=

2500 / 4

Assuming factor of safety Working stress ( ft )

According to ‘LAMES EQUATION’

=

=

2500 gf/mm²

625 Kgf/cm²

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

=

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 ) =

Design of Piston rod: Diameter of Piston Rod:

0.19 mm

45 mm

Force of piston Rod (P)

Also, force on piston rod (P)

=

Pressure x area =

=

6 x (Π / 4) x (4)²

=

73.36 Kgf

=

(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

=

0.38 cm

=

=

15 mm

dp

By standardizing dp

p x Π/4 (d²)

3.8 mm

Length of piston rod: Approach stroke

=

160 mm

Length of threads

=

2 x 20 =

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 =

By standardizing, length of the piston rod

=

232 mm

230 mm

40mm

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Chapter-6 ---------------------------------------------------------------------------------------

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WORKING PRINCIPLE ---------------------------------------------------------------------------------------

CHAPTER-6 WORKING PRINCIPLE

Kinematics Pairs The relative motion between two links of a pair can take different form. Three types of a pairs are known as lower pairs and these are the frequently occurring ones:Sliding : such as occurs between a piston and a cylinder Turning : such as occurs with a wheel on an axle Screw motion : such as occurs between a nut and a bolt All other cases are considered to be combinations of sliding and rolling are called higher pairs. Strictly screw motion is a higher pair as it combines turning and sliding. Slider – Crank Mechanism The slider- crank mechanism is well known as the basis of a reciprocating engine. As shown in the diagram below it consists of three turning pairs and one sliding pair

In the above diagram, the link 1 is fixed. If we now fix link 2, that is consider an inversion of the mechanism, we obtain the mechanism shown below. This is known as Whiworth’s Quick Return Mechanism.

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Chapter-7 ---------------------------------------------------------------------------------------

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GENERALLY USED MATERIALS ---------------------------------------------------------------------------------------

CHAPTER-7 GENERALLY USED MATERIALS Cylinder Tube Materials: LIGHT DUTY

MEDIUM DUTY

HEAVY DUTY

1. Plastic

Hard drawn brass tube

hard drawn brass tube.

2. Hard drawn

Aluminium

Hard drawn steel tube

Aluminium tube

Castings

4. Hard drawn

tube. Brass, Bronze, Iron or

Brass tube

Castings, welded steel tube

End Cover Materials:

LIGHT DUTY

1. Aluminium stock (Fabricated) 2. Brass stock (Fabricated) 3. Aluminium Castings

MEDIUM DUTY

HEAVY DUTY

Aluminium stock

Hard tensile

(Fabricated)

Castings

Brass stock (Fabricated) Aluminium, Brass, iron or steel Castings.

Piston Materials:

LIGHT DUTY 1.Aluminium

MEDIUM DUTY Aluminium Castings

HEAVY DUTY Aluminium Forgings,

Brass (Fabricated) Bronze (Fabricated) Iron and Steel

Aluminium Castings. Bronze (Fabricated) Brass, Bronze, Iron or

Castings

Steel Castings.

LIGHT DUTY 3. Aluminium

MEDIUM DUTY Aluminium, Brass

HEAVY DUTY High Tensile

Castings 4. Light Alloy

And Steel Castings

Steel Castings High Tensile

Castings 2. 3.

Mount Materials:

(Fabricated)

Steel Fabrication

Piston Rod Materials:

MATERIAL MILD STEEL

FINISH Ground and polished hardened,

REMARKS Generally preferred chrome

STAINLESS STEEL

ground and polished. Ground and Polished

plated Less scratch resistant than chrome plated piston rod

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Chapter-8 ---------------------------------------------------------------------------------------

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ADVANTAGES & DISADVANTAGES ---------------------------------------------------------------------------------------

CHAPTER-8 ADVANTAGES AND DISADVANTAGES 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.  Maximum height up to 1 foot can be reached.

DISADVANTAGES

1.

Initial cost is high.

2.

High maintenance cost.

3.

Separate air tank or compressor is required.

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Chapter-9 ---------------------------------------------------------------------------------------

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APPLICATIONS ---------------------------------------------------------------------------------------

CHAPTER-9 APPLICATIONS

 Thus it can be useful for the following types of vehicles; 1) MARUTI, 2) AMBASSADOR, 3) FIAT, 4) MAHINDRA, 5) TATA  All small scale industries

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Chapter-10

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LIST OF MATERIALS ---------------------------------------------------------------------------------------

CHAPTER-10

LIST OF MATERIALS Sl. No. i. ii. iii. iv. v. vi. vii. viii Ix

PARTS

Pneumatic Cylinder Quick exhaust valve Crank and slotted Plate Cam plate Polyethylene Tube Hose Collar and Reducer Stand (Frame) PU connector

Qty. 1 1 1 1 1 1 4

Material M.S Aluminium Aluminium M.S Plastic Polyurethene Brass Mild steel Brass

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Chapter-11

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COST ESTIMATION ---------------------------------------------------------------------------------------

CHAPTER-11

COST ESTIMATION

1. MATERIAL COST: Sl. No. i. ii. iii. iv. v. vi. vii. viii Ix

PARTS

Pneumatic Cylinder Quick exhaust valve Crank and slotted Plate Cam plate Polyethylene Tube Hose Collar and Reducer Stand (Frame) PU connector TOTAL

Qty. 1 1 1 1 1 1 4

Material M.S Aluminium Aluminium M.S Plastic Polyurethene Brass Mild steel Brass =

Amount (Rs)

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

=

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Chapter-12 ---------------------------------------------------------------------------------------

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CONCLUSION ---------------------------------------------------------------------------------------

CHAPTER-12 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 “AIR COMPRESSOR USING CRANK & SLOTTED LINK MECHANISM” 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 an “AIR COMPRESSOR USING CRANK & SLOTTED LINK MECHANISM” 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.

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BIBLIOGRAPHY ---------------------------------------------------------------------------------------

BIBLIOGRAPHY

1.

G.B.S. Narang, “Automobile Engineering”, Khanna Publishers, Delhi, 1991, pp 671.

2. 3.

William H. Crowse, “Automobile Engineering”. MECHANISMS IN MODERN ENGINEERING DESIGN Vol. V. PART I

4. ELEMENTS OF WORKSHOP TECHNOLOGY – VOL II -S.K. HAJRA CHOUDHURY -S.K. BOSE -A.K. HAJRA CHOUDHERY 5.

STRENGTH OF MATERIALS

Web site: www.maritime.org

-I.B. PRASAD

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PHOTOGRAPHY ---------------------------------------------------------------------------------------