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INTRODUCTION The designer should make the machine as reliable and as reasonable as possible to minimize the maintenance requirement and allow for long intervals between routine maintenance tasks. It is also important to design the machine and its control system so that the maintenance can be carried out safely. For example, hold- to- run controls can be installed that allow a machine to be run at a reduced speed, or a removable tool holder can be used so that sharp tools can be replaced on a work bench instead of in an difficult position inside a machine. In addition, operators and maintenance technicians must be discouraged from bypassing safety equipment. Safety components are often designed to interrupt processes in the event of a fault and will have an impact on the machine availability. In order to minimize this effect and the temptation to interfere with the safety circuits-high reliability safety components should be specified so as to keep the number of nuisance faults at minimum. Designing safety into a new machine is important, but it has to be remembered that the vast majority of machines do not remain unaltered with unchanged operating procedures for their entire lifetime. PRODUCTION OF COMPRESSED AIR Pneumatic systems operate on a supply of compressed air, which must be made available in sufficient quantity at a suitable pressure to meet the requirement of the system. When a pneumatic system is being adopted for the first time, it will be

necessary to deal with the question of compressed air supply. The key part of any facility for supply of compressed air is the compressor. A compressor is a machine that takes in air, gas or vapours at any certain pressure and delivers the air at a high pressure. Clean condition of the suction air is one of the factors, which decides the life of the compressors. Compressors may be classified into two types, namely: 1. Positive displacement compressors 2. Turbo compressors.

2 Positive displacement compressors are most frequently employed for

compressed air plants and have proved highly successful to supply air for pneumatic control application. The types of positive Compressors are, a. Reciprocating type compressors b. Rotary type compressors In this project a reciprocating type compressor will be utilized as they are built for stationary and portable services. The reciprocating compressor is by far the most common type used. Reciprocating compressors are made available in various sizes, starting from the smallest capacity of 6 bars up to largest capacity of 10 bars of pressure in a single stage mode, with a delivery volume capacity around 500 m3/min. PRESSES Press machine and tools are used in various operations like punching (hole), blanking, stamping, coining, drawing, deep drawing, etc. Base or bed is the lower part of the press frame. A thick plate called bolster plate is placed on the top of the bed. A die is fitted on the top of the bolster plate. The driving mechanism is mounted on the frame. The frame has got guide ways for the sliding movement of the ram. The driving mechanism is connected to the ram. The punch is fitted at the bottom of the ram. The die and punch are correctly aligned. The work piece is in the form of sheet metal. It is fed over the die. When the ram comes down, the punch presses the sheet metal. The required operation is carried out. The die and punch must be in perfect alignment for proper operation. Materials used for punch and die, 1. High speed steel 2. Cemented carbide A number of factors are to be taken into account in order to design the press namely weight and floor area, type of drive

3 MECHANICAL SYSTEMS In this mechanical system, the mechanical operations are used for the movement of the punch or die. The drive for the movements of the punch is obtained by various mechanical systems. In this project a pneumatic drive is implemented .This type of drive is a power operated drive. pressurized air. In this system, the drive is obtained with the use of

This system consists of a pneumatic cylinder, piston, piston rod,

direction control valve, pressure control valves, motor, pipelines and accessories. The pneumatic cylinder may be a single acting cylinder or double acting cylinder. The piston rod is connected to the piston. The piston along with the piston rod moves inside the cylinder to the rod. The suitable valves and other accessories are connected with the cylinder with the use of pipes. The pump sends the pressurized air into the cylinder. When the high pressure air is pumped through the top side of the cylinder, the ram moves downwards. At the end of the stroke, the air is pumped through the bottom side of the piston, the ram moves up. In pneumatic system filters are used to remove all foreign matters and moisture from the compressed air. Filters allow clean and dry air to flow to the system. The degree of filtration depends upon the size of the particles that are to be removed. The size of the particles varies from 5 min in the circuit point immediately after tapping from the main tank. SENSOR UNIT A sensor is a transducer used to make a measurement of a physical variable. Any sensor requires calibration in order to be useful as a measuring device. Calibration is the procedure by which the relationship between the measured variable and the converted output signal is established. Care should be taken in the choice of sensory devices for particular tasks. The operating characteristics of each device should be closely matched to the task for which it is being utilized. Different sensors can be used in different ways to sense same

conditions and the same sensors can be used in different ways to sense different conditions.

4 TYPES OF SENSORS Passive sensors detect the reflected or emitted electro-magnetic radiation from natural sources, while active sensors detect reflected responses from objects which are irradiated from artificially generated energy sources, such as radar. Each is divided further in to non-scanning and scanning systems. The IR transmitter and IR receiver circuit is used to sense obstacles crossing the sensor. It is fixed to the frame stand with a suitable arrangement. The pneumatic cylinder is fixed to the frame stand by right angles to the bottom frame stand. This cylinder arrangement is used to punch the material. The pneumatic cylinder is controlled by the flow control valve, double acting solenoid valve and control unit. IR SENSORS AT NORMAL CONDITION The IR transmitter sensor is transmitting the infrared rays with the help of 555 IC timer circuit. These infrared rays are received by the IR receiver sensor. The Transistor T1, T2 and T3 are used as an amplifier section. At normal condition Transistor T5 is OFF condition. At that time relay is OFF, so that the punching machine operates continuously. IR SENSORS AT OBNORMAL CONDITION At abnormal conditions the IR transmitter and IR receiver, the resistance across the Transmitter and receiver is high due to the non-conductivity of the IR waves. So the output of transistor T5 goes from OFF condition to ON stage. In that time the relay is ON position. In that time, the punching machine will stop, so that the accident will be prevented.

Figure 1: IR RECEIVER CIRCUIT

Figure 2: IC 555 TIMER CIRCUIT

Figure 3: Layout of Accident Avoiding System.

7 DESIGN CALCULATIONS WORKING PRESSURE: 4 bar to 6 bars OPERATING FORCE = Pressure x Cylinder area F Where, D is the diameter of the cylinder in mm. Operating force = = CUTTING FORCE Cutting Force = Yield stress x Shearing area 6 x 105 x 0.785 x 0.057 x 0.057 1532.96 N = P x (3.14/4) (D * D)

Yield Stress of the work material from data book for asthetic fibre (y) = 40 N/mm2 Shearing area = (3.14 x d x t)

Factor of safety is to be decided based upon the operating force and cutting force. Cutting force for aesthetic fibre MECHANICAL ADVANTAGE W x L1 = P x L2 = 40 x 117.74 = 1256 N

W/p = MECHANICAL ADVANTAGE = L2 / L1 = LEVERAGE L2 / L1 is 2:1 Hence applied force is doubled due to the leverage. Operating force is greater than cutting force, hence the design is safe and the material is cut.

8 WORKING PRINCIPLE Compressed air from a compressor is used to do the work by means of the pressing the piston rod in the piston cylinder through a solenoid valve. The pressurized airs force is transmitted to a punch by means of a valve by its mechanical advantage. The upper die (eg: punch) is forced downward on the work material. This is the main principle of the unit. WORKING The compressed air from the compressor at the pressure of 2 to 7 bar is passed through a pipe connected to the Solenoid Valve with one input when the IR sensor unit in normal condition. The DC valve (Solenoid Valve) is actuated with input power. The 5/2 Solenoid Valve has one input port, two output ports and two exhaust port. This solenoid valve is controlled by the electronic control timing unit. When the solenoid valve is in the ON position; the compressed air pushes the pneumatic cylinder piston downwards to punch the work piece forcefully. When the solenoid valve is in the OFF position, the compressed air pushes the pneumatic cylinder piston upwards due to the high air pressure at the bottom of the piston. This solenoid valve ON/OFF signal is controlled by the control unit. The upper die is guided by a guide to precisely meet the lower die. The materials are in between the upper die and lower die. The upper die (punch) shears the material to the required profile and the blank is moved downwards through the die clearance. When the piston is at the extreme point of the stock length, the exhaust valve is opened and the air is exhausted through it and the pressurized air come in at the top of the piston and it pushes the piston downwards. Now the piston reaches the bottom point of the required stroke length. Now the material is fed and the next stroke of the piston is made ready. When the material is correctly positioned then the switch button is again actuated and the actuated and the process repeat itself. ADVANTAGES AND APPLICATIONS The advantages of the press operation with the accident avoiding system are listed below:

9 1. The outstanding advantage of pneumatic system is the control valve which consistently applies a specified load with minimum effort. 2. 3. 4. 5. 6. To prevent the accident by using sensor unit From thin foils to metal sheets can be pierced according to desirable shapes. It can be modified to any extend to bring out the required effort. Its outcome can be utilized properly in the extensive mechanical field. Multiple cylinder systems can be put into action according to the need of pressing effort. 7. In modern payer plants this pneumatic system can be used for loading press roll. 8. 9. Simple construction than the mechanical and hydraulic presses. Compared to hydraulic and mechanical presses pneumatic press is economical. 10. 11. 12. It does not require current carrying cables. No extra skill is required for operating this system. Operation is very smooth and in this system we can get more output by applying less effort. 13. This system can be effectively used for punch mark in industrial materials such as industries name, address or number of product.

10 REFERENCE 1. Blackburn, J. (1960). Fluid power control. Cambridge: The MIT press. 2. Campbell, S. (2005). Sensor systems and technologies. San diego: City Press. 3. Fisher, J. (1998). Handbook of Valves. Control valves Inc: Midlithion. 4. Campbell, J. (2005). Sensor systems. Chicago: Blackie academic and professional. 5. Jon.S.Wilson. (2004). Sensor technology handbook. San diego: Newness.