CHAPTER 1

INTRODUCTION

1.1 GENERAL

What is the difference between a standard elevator and a 5 horsepower,

chain driven, cantilevered lift system with programmable operations and additional
pneumatic safety? In a general way, they are both conveyance systems capable of
vertical transportation of people or goods between levels of a building or structure.
They are also similar in that both require a massive amount of research and
development to operate successfully and without harm to those who ride inside
them. In a more precise way however, they differ greatly in that I have never
designed and fabricated an elevator yet have successfully done just that with a lift
system. In the world of theatre, creative ideas run rampant.

Even in the technical side of this artistic field, imagination can’t be kept
from spilling over into everyday tasks. While this usually makes for an incredibly
enjoyable workplace, there can also be an unfortunate lack of accountability where
safety is concerned. Many theatre technicians are gifted with inspired minds for
creation, but as an arts education is more often than not devoid of any formalized
training in engineering, severe danger can be much closer than expected. Given the
current trend of engineering and technology in theatre, productions are only going
to get bigger and more complex.

The demand for technicians with working knowledge in more advanced

arenas is rising exponentially. Pushing one’s intellectual bounds is always a great
opportunity for learning. It is when this foray into the unknown involves the ability
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to harm one’s self and others, however, that caution is required and steps taken to
prevent accidents from occurring. I am reminded of the old adage “A little
knowledge is a dangerous thing”. One must be very honest with one’s self to know
one’s limitations and take head not to overstep one’s own ability without first
ensuring a safe work space.

It is when you reach the extent of your own experiences and by pushing
further that scholarship can be attained. These are rules that I clung to tightly as I
delved into regions of design and fabrication previously unknown to me. Why a lift
system? What makes this project so significant that it merits a volume to document
it? To answer this question context is key. It may not be so remarkable to see such
a project originate from say, a mechanical engineering or even automotive
department where such intricate examples of work may be more commonplace but
in the theatre, projects of this caliber are anything but common. Multifaceted
systems created specifically for flexible use in a theatrical environment are produce
by a very small list of specialized companies, making such systems very expensive
and quite rare outside of major city theatres.

By comparison, the notion that such a system could be designed and

manufactured at a fraction of the cost, and by students no less, out of a state
college arts department, would seem farfetched. This text documents the
monumental effort made by a small team of students who wanted to challenge their
capabilities. Assisted by a handful of advisors who desired little more than to help
us succeed, my partners and I successfully brought to life an automated system far
exceeding our combined capabilities. This was achieved by immersing ourselves
completely in the topics necessary to become proficient in all aspects of the
system.
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 Learning at an accelerated rate was required by all to ensure that the maiden
voyage of the lift was accomplished before a scheduled deadline and nothing less
than excellence would be acceptable. Directing us every step of the way was a
stern standard for safety and a ticking clock. It is this trial by fire, from conception
through completion, which is described in the chapters that follow.

A pneumatics jack uses air as fluid, which is compressible, that is forced

into a cylinder by a pump plunger. Since it is stable. When the plunger pulls back,
it draws atmospheric air comes through a suction check valve into the pump
chamber. When the plunger moves forward, it pushes the air through a discharge
check valve into the cylinder. The suction valve ball is within the chamber and
opens with each draw of the plunger. The discharge valve ball is outside the
chamber and opens when the air is pushed into the cylinder. At this point the
suction ball within the chamber is forced shut and compressed air pressure builds
in the cylinder.

1.2 AIR COMPRESSOR

An air compressor is a device that converts power (using an electric motor,
diesel or gasoline engine etc...) in to potential energy stored in pressurized air. By
one of several methods, an air compressor forces more and more air into a
storage tank, increasing the pressure. When tank pressure reaches its upper limit
the air compressor shuts off. The compressed air, then, is held in the tank until
called into use. The energy contained in the compressed air can be used for a

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variety of applications, utilizing the kinetic energy of air as it is released and the
tank depressurizes.

When tank pressure reaches its lower limit, the air compressor turn on again
and re-pressurize the tank. According to design and principle of operation they can
be classified as positive displacement compressors and negative displacement
compressors. Air compressors are used in industries for variety of applications and
they consume large amount of power from a manufacturing plant. In present
scenario the demand of energy efficiency is increasing day by day. Improved
energy efficiency can earn significant to the plant. This motivated me to do the
analysis of compressors in the manufacturing plant. Twelve compressors were
analyzed.

Least efficient compressor is replaced with energy efficient one. For other
compressors preventive maintenance practices are suggested to improve efficiency.
In manufacturing plant, compressors are running in a corrosive and high
temperature conditions. So upgrading the design of the compressor unit can
increase the reliability, safety and overall efficiency of the screw compressor. As a
solution, modification in air compressor system was suggested to improve energy
efficiency.

1.3 PNEUMATICS ACTUATORS

Pneumatic actuators are the devices used for converting pressure energy of
compressed air into the mechanical energy to perform useful work. In other words,
Actuators are used to perform the task of exerting the required force at the end of
the stroke or used to create displacement by the movement of the piston. The
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pressurised air from the compressor is supplied to reservoir. The pressurised air
from storage is supplied to pneumatic actuator to do work.
The air cylinder is a simple and efficient device for providing linear thrust or
straight line motions with a rapid speed of response. Friction losses are low,
seldom exceeds 5 % with a cylinder in good condition, and cylinders are
particularly suitable for single purpose applications and /or where rapid movement
is required. They are also suitable for use under conditions which preclude the
employment of hydraulic cylinders that is at high ambient temperature of up to 200
to 250.

Their chief limitation is that the elastic nature of the compressed air makes
them unsuitable for powering movement where absolutely steady forces or motions
are required applied against a fluctuating load, or where extreme accuracy of feed
is necessary. The air cylinder is also inherently limited in thrust output by the
relatively low supply pressure so that production of high output forces can only be
achieved by a large size of the cylinders.

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 CHAPTER 2
LITERATURE REVIEW
2.1 GENERAL
Review of literature used in earlier studies provides a link with present
approaches and it helps to adapt, modify and improve the conceptual framework
with the view of to analyze the new techniques for this study. Farming the
methodology is an essential part in any kind of research work, which leads a lot of
literature review.

2.2 STUDY OF LITERATURE

Name of PERFORMANCE ANALYSIS AND MODIFICATION OF AIR

the COMPRESSOR SYSTEM

Literature International Research Journal of Engineering and Technology

Name of (IRJET) ISSN: 2395-0056 Volume: 02 Issue: 05 Aug-2003
the Journal Dr.Vishnu , Prof. Deepika Vasanthakumar

Name of When tank pressure reaches its upper limit the air compressor
the Author shuts off. The compressed air, then, is held in the tank until called
Frame into use.The energy contained in the compressed air can be used
for a variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes.

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