Pneumatic Paper Plate Making Machine
CHAPTER-1
INTRODUCTION
The
pneumatic paper making press is used to different shapes of plate in faster
production rate. The principle of operation is the same as the conventional
simple press. The difference is only in
the type of drive and the type of fixtures used
The following points reveals why we have to make
use of this type of press
- Pneumatic
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 600mm
Title: Fabrication of Pneumatic Paper Plate
Making Machine
CHAPTER-2
LITERATURE
REVIEW
1. Design and Fabrication of Pneumatically
Operated Paper Plate Making Machine Author: Vignesh K, Porkalan S, Pradhap
Kumar M, Prasanna Venkatesh S, Packiyaraj M. In this paper they
compared Pneumatic system versus hydraulic system and mechanical system in
terms of maintenance, cost and accuracy. Their scope of the project was making
the cost of the paper plate making machine as low as possible and increasing
its efficiency.
2. Design for manufacture and assembly of a
paper plate making machine in a developing nation Author: Kudakwashe N.
Masengere, Tawanda Mushiri . This paper is on the layout for
manufacture and meeting of a paper plate making machine for a growing financial
system which can be regionally synthetic within an earnings and expenditure
that fits to maximum small to medium corporations. A deeper know-how of the
paper plate making system changed into carried out with the aid of the
internet, scholarly journals and commercial visits to local businesses.
3. Fabrication of pneumatically operated paper plate
and dish making machine Author: Ashwini Masurkar, Rushikesh Kolape, Sneha More,
Yogesh Mane, prof. Dinesh Pargunde. This paper is based totally on
the manufacture and assembly of an air-cooled paper plate and a dishwasher.
Paper plates particularly contain plastics. And plastic is the maximum risky
substance inside the surroundings. With the assist of this mechanical machine
paper plates are made from any kind of paper and the leaves are also used to
make plates. After learning how the modern gadget makes paper plates, we got
here up with an inexpensive solution for making paper plates and bowls. This
length of paper plate making device is free to healthy anywhere and could be
very cost-effective as properly. On this system we use the most primary
techniques to improve the performance of our undertaking
CHAPTER-3
PROBLEM
STATEMENT
The
problem addressed in this project is the need for an efficient and
cost-effective pneumatic paper plate making machine. Traditional paper plate
making methods are often labor-intensive and time-consuming. Therefore, there
is a requirement to develop an automated system that can produce paper plates
quickly and with minimal human intervention.
3.1 Existing System:
The
existing paper plate making machines available in the market are mostly
mechanical or semi-automatic. They require manual feeding of paper, folding,
and sealing operations, which can be time-consuming and prone to errors. These
machines may lack the precision, speed, and efficiency needed for large-scale plate
production.
3.2 Proposed System:
The
proposed system aims to overcome the limitations of the existing systems by
developing a fully automated pneumatic paper plate making machine. This machine
will utilize pneumatic actuators and sensors to automate the feeding, folding,
sealing, and ejecting processes. It will incorporate intelligent control
mechanisms to ensure accurate plate dimensions and high production efficiency.
CHAPTER-4
OBJECTIVES
- Design
and fabricate a pneumatic paper plate making machine capable of producing plates
of various sizes.
- Develop
an automated feeding mechanism for continuous paper feeding.
- Implement
a folding mechanism to fold the paper into plate shapes.
- Integrate
a sealing mechanism to securely seal the plates.
- Incorporate
an ejection system to release the finished plates.
- Design
an intelligent control system for precise plate dimensions and production
speed control.
- Ensure
the machine's safety and reliability during operation.
CHAPTER-5
METHODOLOGY
The project will follow these steps:
We
followed a series of steps that will guide us to solve the problems and fulfill
the project objectives.
- Firstly
we concentrated on designing the dimensions of the various components such
as the punch, die and the frame.
- We
further analysed the loading conditions required for the manufacturing of
paper (leaf) plate using the pneumatic system as the main operating
- We
also tried to find out the different ways in which the pneumatic plates
are made in today’s industry.
- By
taking a survey on the internet we found that the plate making industries
have equipments which are much more expensive and are not affordable to
the small scale industries and thus they are not able to make profit.
- We
further took a look at the die manufacturers as well as the frame
manufacturers and the pneumatic cylinder supplying dealers.
- We
then further collected all the components and we went on towards the
assembling of the components.
- We
faced many difficulties while assembling, as there were many issues
regarding the fittings of the components.
- After
facing many difficulties, we finally were able to complete our project
successfully with the help of our guide Prof. Mr. Vishwas Palve sir
CHAPTER-6
WORKING
PRINCIPLE AND BLOCK DIAGRAM
In this paper plate 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. A 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.
At
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 fixed on
the base of the machine by screw rods.
The height of the base can be adjusted by rotating the screw rod. The
whole unit is fixed on the column. When 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 ocplatey.
When
it ocplateies part A 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. Next, direction control valves
are actuated which makes the air to flow in part B of cylinder. Due to air in
part A is released to the atmosphere by a valve. This makes the punch to move
upwards. The plate can be taken out and the next paper can be placed over the
die for the next cycle.
ARDUINO UNO POWER SUPPLY DC VALVE RELAY CONTROL ON OFF BUTTON AIR TANK PNUMATIC
CYLINDER
PNEUMATICS
Pneumatic Cylinder
The
word ‘pneumatic’ 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) Pı Vı = P2 V2
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. Pneumatics 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
both 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 advantages of an all-pneumatic 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
Air Compressor
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.
Positive displacement compressor
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
Reciprocating type compressor
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.
AIR PIPE
Air Pipe
A
pipe is a tubular section or hollow cylinder, usually but not necessarily of
circularcross section, used mainly to convey substances which can flow liquids
and gases (fluids), slurries, powders, masses of small solids. It can also be
used for structural applications; hollow pipe is far stiffer per unit weight
than solid members. A pipe is a tubular section or hollow cylinder, usually but
not necessarily of circularcross section, used mainly to convey substances
which can flow liquids and gases (fluids), slurries, powders, masses of small
solids. It can also be used for structural applications; hollow pipe is far
stiffer per unit weight than solid members.
PNEUMATIC CIRCUIT:
PNEUMATIC
CONTROL SYSTEMS can be designed in the form of pneumatic circuits. A pneumatic
circuit is formed by various pneumatic components, such as cylinders,
directional control valves, flow control valves, etc. Pneumatic circuits have
the following functions:
- To
control the injection and release of compressed air in the cylinders.
- To
use one valve to control another valve
PNEUMATIC CIRCUIT DIAGRAM:
A
pneumatic circuit diagram uses pneumatic symbols to describe its design. Some
basic rules must be followed when drawing pneumatic diagrams. i) A pneumatic
circuit diagram represents the circuit in static form and assumes there is no
supply of pressure. The placement of the pneumatic components on the circuit
also follows this assumption. ii) The pneumatic symbol of a directional control
valve is formed by one or more squares. The inlet and exhaust are drawn
underneath the square, while the outlet is drawn on the top. Each function of
the valve (the position of the valve) shall be represented by a square. If
there are two or more functions, the squares should be arranged horizontally
Fig: 1
CONSTRUCTION AND DESIGN
For
this model we are used pneumatic cylinder which have 100mm internal diameter
and 50 mm stroke. For body we used mild steel material.
Further information given as follow:
Dimension of Model:
Fig. Front View and Side View
of C Frame body
Top view and Front View of Ram
Machine Die
CALCULATION RELATED TO PNEUMATIC CYLINDER:
DIMENSION
- Cylinder
type – double acting
- Internal
diameter; D – 100 mm
- Stroke
– 50 mm
- Piston
rod diameter; d – 20 mm
- Maximum
working pressure; P – 100 psi ( 7bar )
SPECIFICATION OF PNEUMATIC CYLINDER
- Cylinder
thrust in forward stroke F = F = F = 549.77 550 kg
- Cylinder
thrust in return stroke F = F = F = 351.85 kg
- Theoretical
air consumption calculation
Free air consumption in liters for forward
stroke
C
= 3.141 liters
Free air consumption in liters for forward
stroke; C
C = C =
C = 2.0106 liters
Hence
for one complete one cycle of operation for this cylinder, the free air
consumption will be (3.141 + 2.106 = 5.1516 liters)
MOUNTING TYPES
- Front
plate mounting
- Rear
plate mounting
- Double
trunion mounting
- Centretrunion
mounting
- Neck
mounting
- Leg
mounting
- Hinge
mounting
But
we are select “Front type mounting” because it‟s suitable for our project
construction
SAFETY MEASURES WHEN USING PNEUMATIC CONTROL
SYSTEMS
- Compressed
air can cause serious damage to the human body if they enter the body
through ducts like the oral cavity or ears.
- Never
spray compressed air onto anyone.
- Under
high temperature, compressed air can pass through human skin.
- Compressed
air released from the exhaust contains particles and oil droplets, which
can cause damage to eyes.
- Even
though the pressure of compressed air in pipes and reservoirs is
relatively low, when the container loses its entirety, fierce explosions
may still occur.
- Before
switching on a compressed air supply unit, one should thoroughly inspect
the whole circuit to see if there are any loose parts, abnormal pressure
or damaged pipes.
- A
loose pipe may shake violently due to the high pressure built up inside
it. Therefore, each time before the system pressure is increased; thorough
inspection of the entire circuit is required to prevent accidents.
- As
the force produced by pneumatic cylinders is relatively large, and the
action is usually very fast, you may suffer serious injuries if you get
hit by a cylinder.
- Switches
should be installed on the compressed air supply unit to allow easy and
speedy control of air flow.
- In
case of a leakage, the compressed air supply unit should be turned off
immediately.
- The
compressed air supply unit must be turned off before changes can be made
to the system.
- Stay
clear of the moving parts of the system. Never try to move the driving
parts in the mechanical operation valve with your hand.
INTRODUCTION TO WELDING
PROCESS
INTRODUCTION
Welding
is a process in which two or more parts are joined permanently at their
touching surfaces by a suitable application of heat and/or pressure. Often a
filler material is added to facilitate coalescence. The assembled parts that
are joined by welding are called a weldment. Welding is primarily used in metal
parts and their alloys.
WELDING PROCESSES ARE CLASSIFIED INTO TWO MAJOR
GROUPS:
- Fusion
welding: In this process, base metal is melted by means of heat. Often, in
fusion welding operations, a filler metal is added to the molten pool to
facilitate the process and provide bulk and strength to the joint.
Commonly used fusion welding processes are: arc welding, resistance
welding, oxy fuel welding, electron beam welding and laser beam welding.
- Solid-state
welding: In this process, joining of parts takes place by application of
pressure alone or a combination of heat and pressure. No filler metal is
used. Commonly used solid-state welding processes are: diffusion welding,
friction welding, ultrasonic welding.
Arc
welding and similar processes Arc welding is a method of permanently joining
two or more metal parts. It consists of combination of different welding
processes wherein coalescence is produced by heating with an electric arc,
(mostly without the application of pressure) and with or without the use of
filler metals depending upon the base plate thickness. A homogeneous joint is
achieved by melting and fusing the adjacent portions of the separate parts. The
final welded joint has unit strength approximately equal to that of the base
material. The arc temperature is maintained approximately 4400°C. A flux
material is used to prevent oxidation, which decomposes under the heat of
welding and releases a gas that shields the arc and the hot metal. The second
basic method employs an inert or nearly inert gas to form a protective envelope
around the arc and the weld. Helium, argon, and carbon dioxide are the most
commonly used gases.
SHIELDED-METAL ARC (SMAW) OR STICK WELDING
This
is an arc welding process wherein coalescence is produced by heating the work piece
with an electric arc setup between a flux-coated electrode and the work piece.
The electrode is in a rod form coated with flux. Figure M6.1.1 illustrates the
process.
Shielded-Metal Arc (SMAW)
SUBMERGED ARC WELDING (SAW)
This
is another type of arc welding process, in which coalescence is produced by
heating the work piece with an electric arc setup between the bare electrode
and the work piece. Molten pool remains completely hidden under a blanket of
granular material called flux. The electrode is in a wire form and is
continuously fed from a reel. Movement of the weld gun, dispensing of the flux
and picking up of surplus flux granules behind the gun are usually automatic.
Flux-Cored Arc Welding (FCAW)
FLUX-CORED ARC WELDING (FCAW)
This
process is similar to the shielded-arc stick welding process with the main
difference being the flux is inside the welding rod. Tubular, coiled and
continuously fed electrode containing flux inside the electrode is used,
thereby, saving the cost of changing the welding. Sometimes, externally
supplied gas is used to assist in shielding the arc.
GAS-METAL ARC WELDING (GMAW)
In
this process an inert gas such as argon, helium, carbon dioxide or a mixture of
them are used to prevent atmospheric contamination of the weld. The shielding
gas is allowed to flow through the weld gun. The electrode used here is in a wire
form, fed continuously at a fixed rate. The wire is consumed during the process
and thereby provides filler metal. This process is illustrated in Figure M6.1.2
Gas-Metal Arc Welding
GAS-TUNGSTEN ARC
WELDING (GTAW)
This
process is also known as tungsten–inert gas (TIG) welding. This is similar to
the Gas Metal Arc Welding process. Difference being the electrode is non
consumable and does not provide filler metal in this case. A gas shield
(usually inert gas) is used as in the GMAW process. If the filler metal is
required, an auxiliary rod is used
Plasma Arc Welding (PAW)
PLASMA ARC WELDING (PAW)
This
process is similar to TIG. A non-consumable electrode is used in this process.
Arc plasma is a temporary state of gas. The gas gets ionized after the passage
of electric current and becomes a conductor of electricity. The plasma consists
of free electrons, positive ions, and neutral particles. Plasma arc welding
differs from GTAW welding in the amount ofionized gas which is greatly
increased in plasma arc welding, and it is this ionized gas that provides the
heat of welding. This process has been illustrated in Figure M6.1.3.
OXYFUEL GAS WELDING (OFW)
This
process is also known as oxy-acetylene welding. Heat is supplied by the
combustion of acetylene in a stream of oxygen. Both gases are supplied to the
torch through flexible hoses. Heat from this torch is lower and far less
concentrated than that from an electric arc.
RESISTANCE WELDING
Resistance
welding is a group of welding process in which coalescence is produced by the
heat obtained from the resistance of the work to the flow of electric current
in a circuit of which the work is a part and by the application of pressure. No
filler metal is needed in this process.
ELECTRON-BEAM WELDING
(EBW)
Electron beam welding is defined as a fusion welding process wherein
coalescence is produced by the heat obtained from a concentrated beam of high
velocity electron. When high velocity electrons strike the workpiece, kinetic
energy is transformed into thermal energy causing localized heating and melting
of the weld metal. The electron beam generation takes place in a vacuum, and
the process works best whenthe entire operation and the workpiece are also in a
high vacuum of 10-4torr or lower. However, radiations nameray, infrared and
ultraviolet radiation generates and the welding operator must be protected
LASER BEAM WELDING (LBW)
Laser
beam welding is defined as a fusion welding process and coalescence is achieved
by utilizing the heat obtained from a concentrated coherent light beam and
impinging upon the surface to be joined. This process uses the energy in an
extremely concentrated beam of coherent, mono-chromatic light to melt the weld
metal. This process is illustrated in Figure M6.1.4
Laser Beam Welding
CHAPTER-7
APPLICATIONS
- This
product is an alternative for plastic plates and plates.
- Easily
decomposing product.
- Cheaper
and easily available material is used.
- Eco
friendly product.
- The
pneumatic arm is more efficient in the technical field.
- Quick
response is achieved
- Simple
in construction.
- Easy
to maintain and repair.
- Cost
of the unit is less.
- No
fire hazard problem due to over loading.
- Comparatively
the operation cost is less.
- Continuous
operation is possible without stopping.
- It
reduces the manual work.
- It
reduces the production time.
- Ocplateies
less floor space.
- Less
skilled operator is sufficient.
CHAPTER-8
CONCLUSION
This paper plate and dish making
machine gives desire shapes of plate and dish as approximate efficiency of 80%.
It is clearly seen that the project is economically possible in all aspect, and
paper recycling unit has a potential to generate employment for many worker and
can also act as an environment friendly initiative for the world.
We specialize in the production and distribution of Paper Plate Making Machine in Varanasi. For inquiries, feel free to reach out to us at 9263451822 or 9555823309. Your satisfaction is our priority, and we are dedicated to providing top-quality products to meet your needs. Whether you’re interested in aromatic Agarbattis, eco-friendly paper plates, well-crafted notebooks, or efficient detergent powder making machines, we have a wide range of offerings to cater to your requirements. Connect with us for more information and let us assist you in finding the perfect solutions for your business or personal use.
ReplyDeletePaper Plate Making Machine