INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY, ERODE.

DES IGN OF PC

CONTROLLED SEMIAUTOMATIC PRINTING OPERATION

M.DINESH BABU

Presented by

&

K.SATHEESHWARAN

THIRD YEAR

(B.E.MECHANICAL ENGINEERING)
E-mail:babusatheeshirtt@gmail.com Contact no: 9500290298, 9566988285. 9500290298, CONTACT ADDRESS: THE PROFESSOR AND HEAD, DEPARTMENT OF MECHANICAL, INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY,

ERODE - 638316

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.

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

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.

7. TRAVERSE STEP DIAGRAM: A1 D C B A 8. UNMINIMIZED EQUATIONS: A1 = a0 b0 c0 d0 A1 = a0 b1 c0 d0 C1 = a0 b0 c0 d0 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 b0 c0 d0 c1 b1 b1 b0 b0 c1 d1 c0 b1 b1 b0 a0 a1 a1 a0 a0 a1 a1 a0 a0 a1 a1 a0 a0 a1 a1 a0 Y A1 Y1 Y B1 A0 X1 A1 Y C1 A0 B0 X Y X0 A0 = a1 b0 c0 d0 A0 = a1 b1 c0 d0 D1 = a0 b0 c1 d0 B1 = a0 b0 c0 d0 B0 = a0 b1 c0 d0 C0 = a0 b0 c1 d1 A0 B1 A1 A0 B0 C1 D1 C0 D0

D1 D0

Y0

C0

10. MINIMISED EQUATION: __ __ __ A1 = Y X + a0b1 X A0 = Y b0 + b1 X __ B1 = Y X a0 b0 B0 = X a0 b0 C1 = Y X b0 __ C0 = Y

D1 = Y __ D0 = Y Y1 = a1 Y0 = d1 X1 = a1 b1 __ X0 = Y d0

11. AUTOMATION STUDIO:

A0

A1

B0

B1

24V
START Y X A1

0V

A0

B1

B0

A0

A1

A0

B1

B0

X A0 Y X A0 B1 A1 B0 B1

Fig 1. Circuit diagram in AUTOMATION STUDIO

B0 A0 A1 B0 B1

A0

12. ELECTRO PNEUMATICS DIAGRAM:

Y C0

B0

C1

C0

C1

D0

D1

C1

D1

C0

D0 C1 C0 D1 D0

A1 X

B1

D0 Y

C0 A1 Y C0 C1 D1 Y

C1

D0

D1

8
D0 D1

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.

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

10

14. EXPERIMENTAL SETUP:

Cylinder A

Cylinder D

Cylinder B

Cylinder C

Fig 4. Experimental setup 15. MODEL SETUP:

Fig.5 Model setup (Designed using Pro/E software) 16. SIZING:

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

17. COST CALCULATION: The cost was calculated using FESTO manual and listed below: Cylinders 5/2 Double acting solenoid valves Air filter regulator unit PLC : Rs. 13,250 : Rs.3, 330 : Rs.2, 365 : 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 8th edition, Elsevier Advanced Technology, Oxford, UK. [2] FESTO Manual [3] Croser. P, (1989), Pneumatics-Basic level FESTO Didactic KG, D-7300, Esslingen.