PNEUMATIC GRINDING MACHINE SYNOPSIS

The grinding machine is a machine tool designed to grind metal by applying pneumatic pressure.

The machine is exclusively intended for mass production and they represent fasten and more efficient way to grind a metal.

Grinding is used to grind thin and soft metals. The operation of the unit is simplified to a few simple operations involving a cylinder block and piston arrangement.

There are numerous types of cutting machines in Engineering field, which are used to fulfill the requirements. We are interested to introduce pneumatic system in slotting machine. The main function of Pneumatic grinding is to grind thin and soft metals by pneumatic power.

INTRODUCTION

NEED FOR AUTOMATION

Nowadays almost all the manufacturing process is being automated in order to deliver the products at a faster rate. operation is being automated for the following reasons. The manufacturing

To achieve mass production To reduce man power To increase the efficiency of the plant To reduce the work load To reduce the production cost To reduce the production time To reduce the material handling To reduce the fatigue of workers To achieve good product quality
Less Maintenance

PNEUMATIC SYSTEMS

How Pneumatic Systems Works

Filtered Air is pulled through system by vacuum pump Evacuated air passes through instrument case causes gyro to spin Spinning gyros provide rigidity in space for instrument references Air exhausts through Gyro Pressure Gauge exhaust port Gauge measures system pressure Failure Warning System

Pneumatics in review

Pneumatics has long since played an important role as a technology in the performance of mechanical work. It is also used in the development of automation solutions. In the majority of applications compressed air is used for one or more of the following functions:

_ To determine the status of processors (sensors) _ Information processing (processors) _ Switching of actuators by means of final control elements _ Carrying out work (actuators)

To be able to control machinery and installations necessitates the construction of a generally complex logic interconnection of statuses and switching conditions. This occurs as a result of the interaction of sensors, processors, control elements and actuators in pneumatic or partly pneumatic systems.

The technological progress made in material, design and production

processes has further improved the quality and diversity of pneumatic components and thereby contributed to their widely spread use in automation.

The pneumatic cylinder has a significant role as a linear drive unit, due to its

_ relatively low cost, _ ease of installation, _ simple and robust construction and _ ready availability in various sizes and stroke lengths.

The pneumatic cylinder has the following general characteristics: _ Diameters 2.5 to 320 mm _ Stroke lengths 1 to 2000 mm _ Available forces 2 to 45000 N at 6 bar _ Piston speed 0.1 to 1.5 m/s

Elements of a Basic Compressed Air Pneumatic System

A. Air Compressor B.Check Valve C.Accumulator D.Directional Valve E.Actuator

Elements of a Basic Compressed Air Pneumatic System

Advantages of Pneumatic Systems

Light weight Safe Reliable Eco-friendly Small (can be) Unaffected by atmospheric changes Inexpensive components Pressure seals are usually problem free Forces transmitted are easy to manage (within acceptable PSI limits)

The Advantages of Using Pneumatics

Fluid power technology encompasses both hydraulics and pneumatics. Hydraulic applications use pressurized fluids, mostly oil, while pneumatic applications use pressurized gases, mostly air. Mobile construction equipment uses a hydraulic pump mounted on the engine.

The outlet of the pump is plumbed to a set of valves. Each valve is then plumbed to a cylinder. This allows you to distribute power from the engine all around the equipment. The same is true for a FIRST robot.

Once you install the compressor and are operating one valve and cylinder combination, youve done most of the work. To add an additional valve and cylinder combination, you just tee into The pressure line and add in the additional circuit

Why use pneumatics in your FRC application? Here are some design considerations for your review:

Weight

Compare the weight of several valves and cylinders to that of the motors, gears, belts, and chains used on some lift mechanisms and you will find the weight comparable, if not much lighter.

Simple to Design Using pneumatics is much easier than building a motor; gear, chain and sprocket lift mechanism. Once you have reviewed the layout on page 15, you will find it very easy to build a circuit.

Adjustable Force To adjust the force of the cylinder, all you have to do is adjust the regulator in front of it. The force is equal to the area of the cylinder piston times the pressure. Remember that the valves need at a minimum of 1530psi to work properly.

Durable

All of us have problems burning up motors from time to time. You can stall an air cylinder against a load indefinitely and turn off the compressor. These are industrial grade products.

Power

If you look at the force table on page 12, you have the option of using a small 3/4 bore cylinder at 20psi, which will produce a force of around 9 pounds. If you use a 2 bore cylinder at 60psi, you can get 180 pounds of force. As you can see, your options are wide open.

Custom Cylinders and a Rotary Actuator

You may order the exact cylinder or rotary actuator you need for the job from Bimba again this year, and get them in a few days via regular UPS.

Last Minute Additions

At the last minute, you can add a cylinder and valve very quickly.

Air Pump

Air Pump Heart of pneumatic system is pressure or vacuum air pump (Usually engine driven)

Two basic types:

Wet air pumps use engine oil to lubricate pump internally

Dry air pumps-more common have graphite vanes inside pump casing -selflubricate as pump rotates

A Compressor
Pump that compresses air, raising air pressure to above ambient pressure for use in pneumatic systems

B Check valve
One-way valve - allows pressurized air to enter the pneumatic system, but prevents backflow of air toward the Compressor when Compressor is stopped (prevent loss of pressure

C Accumulator
Stores compressed air, Prevents surges in pressure Prevents constant Compressor operation (duty cycles of Compressor

D Directional valve
Controls pressurized air flow from Accumulator (source to user equipment via selected port

Some valves are one way shut tight

Some valves are two way, allowing free exhaust from the port not selected Valves can be actuated manually or electrically

l Valve Type: 3-Port/2-Position, 5-Port/2-Position, and Modular Fixed Length Manifold 2 x 3/2

l Low Power Consumption

l Manifold System with Easy Assembly Available

l High Flow Rate

l Manual Overrides

l Operates Under Pressure of up to 8 Bar (116 psi)

SPECIFICATIONS Valves V60-V62: Air/spring or 5/3 (with APB) Manual Override: Push type

Voltage: 24 Vdc Port Size: 18, 14, and 38" available All models shown smaller than actual size. OM-AIR-V60P4D7A-XP0900, $44. OM-AIR-V61R417A-A313JH, $78. OM-AIR-V61RA11A-A313JH, $140. Valve assemblies ready to install with all accessories available

l Requires Air Filtration of 50 Microns or Better

l 24 Vdc Operation

l DIN Connector Type C

l Through Hole Wall Mounting Manifold

l Temperature Range of -10 to 50C (14 to 122F

Technical Principles of Valves

Symbol to DIN-ISO 1219

The circuit function illustrations are defined to the DIN-ISO 1219 Standard. These can be used to show other switching processes.

The respective valve ports are specified by letters in the standard where P defines the pressure port, A and B service ports while R and S are vent or exhaust ports. The new illustration of pneumatics is specified with numbers.

Circuit Function

The circuit function of a valve indicates the functions which can be achieved.

The circuit function defines whether a valve shuts-off or allows the fluid flow, whether all the ports are shut-off in the de-energized position, or whether some ports are closed and others left Open.

Flow-Rate Values

The size of valve required for a particular application is generally established by the Kv rating to VDI/VDE 2173. This figure is evolved for standardized units and conditions, i.e. flow rate in m3/h. Kv ratings for each valve are quoted in the catalog. For valves which are also used for pneumatics, the air flow is also indicated in QNn.

Kv-Value: measured with water at inlet port with free outlet at 14.5 PSI
and 68 F. Indicated in m3/h Cv-Value: Cv in USG/min=1.165 Kv in m3/h QNn-Value: (for gases) Indicated in liter per minute (l/min) measured with air at 68F and 87 PSI and a pressure drop of 14.5 PSI across the valve.

Technical Principles of Valves

The Burkert coils are available in all the popular used AC and DC voltages. Thelow power consumption, in particular with the smaller solenoid systems, means that the control via solid state circuitry is possible. The magnetic force available, increases as the air gap between stopper and armature decreases, irrespective whether AC or DC is involved.

An AC solenoid system has a larger magnetic force available at a greater stroke, than a comparable DC solenoid system. The characteristic stroke - force graph indicated in Figure 1 clarifies this relation. At the moment of being energized, i.e. when the air gap is at its maximum, AC solenoid valves draw much higher currents than when the armature is in

TG

the energized position, i.e. air gap is closed. This results in a higher output and increased pressure range. In DC systems, after switching on the current, flow increases relatively slowly until a constant holding current is reached. These valves are therefore only able to control low pressures, unless they are provided with smaller orifices.

A timebased comparison of the energization characteristics for AC and DC solenoids is shown in Figure 2. As well as the Burkert solenoid valves with standard coils, we also have valves available with high voltage, impulse and explosion-proof coil systems.

Advantages and distinguishing characteristics of compressed air:

Availability Air is available practically everywhere in unlimited quantities.

Transport Air can be easily transported in pipelines, even over large distances.

Storage Compressed air can be stored in a reservoir and removed as required. In addition, the reservoir can be transportable.

Temperature Compressed air is relatively insensitive to temperature fluctuations. This ensures reliable operation, even under extreme conditions. Explosion proof Compressed air offers no risk of explosion or fire. Cleanliness Unduplicated exhaust air is clean. Any unduplicated air which escapes Through leaking pipes or components does not cause contamination. Components The operating components are of simple construction and therefore relatively inexpensive. Speed Compressed air is a very fast working medium. This enables high working speeds to be attained. Overload safe Pneumatic tools and operating components can be loaded to the point of stopping and are therefore overload safe.

A grinding machine, often shortened to grinder, is a machine tool used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear deformation. Grinding is used to finish workpieces that must show high surface quality (e.g., low surface roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some roughing applications in which grinding removes high volumes of metal quite rapidly. Thus, grinding is a diverse field.

Introduction
The grinding machine consists of a power-driven grinding wheel spinning at the required speed (which is determined by the wheels diameter and manufacturers rating, usually by a formula) and a bed with a fixture to guide and hold the work-piece. The grinding head can be controlled to travel across a fixed work piece or the workpiece can be moved while the grind head stays in a fixed position. Very fine control of the grinding head or tables position is possible using a vernier calibrated hand wheel, or using the features of numerical controls. Grinding machines remove material from the workpiece by abrasion, which can generate substantial amounts of heat; they therefore incorporate a coolant to cool the workpiece so that it does not overheat and go outside its tolerance. The coolant also benefits the machinist as the heat generated may cause burns in some cases. In very high-precision grinding machines (most cylindrical and surface grinders) the final grinding stages are usually set up so that they remove about 200 nm (less than 1/100000 in) per pass - this generates so little heat that even with no coolant, the temperature rise is negligible.

Types
These machines include the: Belt grinder, which is usually used as a machining method to process metals and other materials, with the aid of coated abrasives. Sanding is the machining of wood; grinding is the common name for machining metals. Belt grinding is a versatile process suitable for all kind of applications like finishing, deburring, andstock removal. Bench grinder, which usually has two wheels of different grain sizes for roughing and finishing operations and is secured to a workbench or floor stand. Its uses include shaping tool bits or various tools that need to be made or repaired. Bench grinders are manually operated. Cylindrical grinder, which includes both the types that use centers and the centerless types. A cylindrical grinder may have multiple grinding wheels. The workpiece is rotated and fed past the wheel(s) to form a cylinder. It is used to make precision rods, tubes, bearing races, bushings, and many other parts. Surface grinder which includes the wash grinder. A surface grinder has a "head" which is lowered, and the workpiece is moved back and forth past the grinding wheel on a table that has a permanent magnet for use with magnetic stock. Surface grinders can be manually operated or have CNC controls. Tool and cutter grinder and the D-bit grinder. These usually can perform the minor function of the drill bit grinder, or other specialist toolroom grinding operations.

Jig grinder, which as the name implies, has a variety of uses when finishing jigs, dies, and fixtures. Its primary function is in the realm of grinding holes and pins. It can also be used for complex surface grinding to finish work started on a mill. Gear grinder, which is usually employed as the final machining process when manufacturing a highprecision gear. The primary function of these machines is to remove the remaining few thousandths of an inch of material left by other manufacturing methods (such as gashing or hobbing).