A PROJECT REPORT

ON

PNEUMATIC FORCE ANALYSIS FOR

AN 5-AXIS ROBOT

Submitted by

Manikandan.A. BE(MECH) MBA(HR)

IssacSamuel.D. BE(MECH)

Manos Simson.T. BE(MECH)

PrakashRaj.V.S. BE(MECH)

ACKNOWLEDGEMENT

I would like to bring forth our sincere thanks to our beloved PRINCIPAL

Dr.S.NAGARAJAN M.E., Ph.D., for providing all the necessary facilities for the

completion of the project

I wish to express our sincere thanks to our Internal guide Mrs.

D.PRITIMAM.E., (Ph.D.,) for her guidance and suggestions throughout this project.

I would like to express our sincere thanks to our external guide CAPT.

WILLIAM for his valuable ideas, continuous encouragement and supervision during

this project.

I wish to express our sincere thanks to all of our All Mechanical staffs

&Nonteaching staffs for their valuable guidance and suggestions throughout this

project work.

Our sincere thanks to Parents & Friends

TABLE OF CONTENTS

CHAPTER TITLE PAGE NO.

NO.

ABSTRACT 7

LIST OF FIGURES 8

1. INTRODUCTION

1.1 HISTORY OF ROBOTS 9

1.2 LAW OF ROBOTICS 10

1.3 CLASSIFICATION OF ROBOTS 11

1.4 PICK AND PLACE ROBOTS 14

1.5 VARIOUS TASKS PERFORMED 17

BY PICK & PLACE ROBOTS

1.6 COMPONENTS OF ROBOT 20

1.7 ADVANTAGES OF PICK AND 24

PLACE ROBOTS

1.8 APPLICATION OF ROBOTS 25

2. PNEUMATIC CYLINDER REPLACEMENTS

2.1 REASON 27

2.2 PROBLEMS WE FACED 29

2.3 SOLUTION FOR EACH PROBLEM 29

2.3.1 PTC CREO 29

2.3.2 DESIGN 31

2.3.3 ANSYS 34

2.3.4 ACCURACY 36

2.3.4A FLUIDSIM 36

2.3.4B TECHNOLOGIES 39

2.3.4C FLUIDSIM HYDRAULICS 41

2.3.4D FLUIDSIM PNEUMATICS 42

2.3.4E TECHNICAL REQUIREMENT 42

2.3.4F PNEUMATIC COMPONENTS 44

2.3.4G SYMBOLS 52

2.3.4H WORKING 56

2.3.5 PNEUMATIC CYLINDERS 58

3. CONCLUSION

3.1 CONCLUDE OUR OPINION 60

3.2 TO FIND DIFFERENT IDEAS 60

4. REFERENCE

4.1 REFERENCES 61

ABSTRACT

Our project is to replace pneumatic cylinder instead of servo motors in pick & place

robot. We are going to analyse for 5-axis pick & place robot. Pick & Place robots are

used in industries for welding purposes, material handling palletizing etc., Main purpose

for replacing pneumatic cylinder is to avoid short circuit & fire accidents. Since, we

have very advanced servomotors and high level robotics, industries like producing fire

crackers, chemicals, petroleum won’t trust the servo motor robots. To overcome this

problem we are going to replace servo motors as pneumatic cylinders.

7

LIST OF FIGURES

S.NO FIGURES Pg.No

1. Pick and place robots loading 16

2. Pick and place robots unloading 17

3. Chemical and processing 27

4. Chemical industry 28

5. Project design 33

6. Simulate Results 35

7. Library(Symbols) 38

8. Advantages of compressed air 45

9. Pneumatic circuit 49

10. Sensor circuit 50

11. Electrical circuit 51

12. Structure and signal flow of pneumatic cylinder 57

8

Chapter 1

INTRODUCTION

There are lots of projects done in our engineering field. This is a big idea of a simple

project. A single idea may change our life. Also a mistake may change everything.

First of all, human need safety for their life. If a safety is not there in any institution,

people won’t prefer that institution. In the chemical and crakers industries the robots

were not used. Because of some short circuit problems. So we are going to solve this

problems and we discussed this below.

1.1 HISTORY OF ROBOTS :

Robot is a word that is both a coinage by an individual person and a borrowing. It has

been in English since 1923 when the Czech writer Karel Capek's play R.U.R. was

translated into English and presented in London and New York. R.U.R., published in

1921, is an abbreviation of Rossum's Universal Robots, robot itself comes from Czech

robota, "servitude, forced labor," from rab, "slave." The Slavic root behind robota is orb-

, from the Indo-European root orbh, referring to separation from one's group or passing

out of one sphere of ownership into another. Czech robota is also similar to another

German derivative of this root, namely Arbeit, "work”. Arbeit may be descended from a

word that meant "slave labor," and later generalized to just "labor."

9

1.2 LAW OF ROBOTICS:

Isaac Asimov conceived the robots as humanoids, devoid of feelings, and used

them in a number of stories. His robots were well-designed, fail-safe machines, whose

brains were programmed by human beings. Anticipating the dangers and havoc such a

device could cause, he postulated rules for their ethical conduct.

Robots were required to perform according to three principles known as “Three

laws of Robotics”’ which are as valid for real robots as they were for Asimov’s robots

and they are:

1. A robot should not injure a human being or, through inaction, allow a human to be

harmed.

2. A robot must obey orders given by humans except when that conflicts with the First

Law.

3. A robot must protect its own existence unless that conflicts with the First or Second

law.

These are very general laws and apply even to other machines and appliances. They are

always taken care of in any robot design.

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1.3 CLASSIFICATION OF ROBOTS

Industrial robots are found in a variety of locations including the automobile and

manufacturing industries. Robots cut and shape fabricated parts, assemble machinery

and inspect manufactured parts. Some types of jobs robots do: load bricks, die cast, drill,

fasten, forge, make glass, grind, heat treat, load/unload machines, machine parts, handle

parts, measure, monitor radiation, run nuts, sort parts, clean parts, profile objects,

perform quality control, rivet, sand blast, change tools and weld. Outside the

manufacturing world robots perform other important jobs. They can be found in

hazardous duty service, CAD/CAM design and prototyping, maintenance jobs, fighting

fires, medical applications military warfare and on the farm.

Industrial robots: Robots today are being utilized in a wide variety of industrial

applications. Any job that involves repetitiveness, accuracy, endurance, speed, and

reliability can be done much better by robots, which is why many industrial jobs that

used to be done by humans are increasingly being done by robots.

Mobile robots: Also known as Automated Guided Vehicles, or AGVs, these are used

for transporting material over large sized places like hospitals, container ports, and

warehouses, using wires or markers placed in the floor, or lasers, or vision, to sense the

environment they operate in.

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An advanced form of the AGV is the SGV, or the Self Guided Vehicle, like PatrolBot

Gofer, Tug, and Speci-Minder, which can be taught to autonomously navigate within a

space.

Agriculturerobots: Although the idea of robots planting seeds, ploughing fields, and

gathering the harvest may seem straight out of a futuristic science fiction book,

nevertheless there are several robots in the experimental stages of being used for

agricultural purposes, such as robots that can pick apples.

Telerobots: These robots are used in places that are hazardous to humans, or are

inaccessible or far away. A human operator located at a distance from a telerobot

controls its action, which was accomplished with the arm of the space shuttle. Telerobots

are also useful in nuclear power plants where they, instead of humans, can handle

hazardous material or undertake operations potentially harmful for humans.

Service Robots: The Japanese are in the forefront in these types of robots. Essentially,

this category comprises of any robot that is used outside an industrial facility, although

they can be sub-divided into two main types of robots: one, robots used for professional

jobs, and the second, robots used for personal use.

12

Amongst the former type are the above mentioned robots used for military use, and then

there are robots that are used for underwater jobs, or robots used for cleaning hazardous

waste, and the like.

Cartesian robot /Gantry robot: Used for pick and place work, application of sealant,

assembly operations, handling machine tools and arc welding. It's a robot whose arm has

three prismatic joints, whose axes are coincident with a Cartesian coordinator.

Cylindrical robot: Used for assembly operations, handling at machine tools, spot

welding, and handling at die-casting machines. It's a robot whose axes form a cylindrical

coordinate system.

Spherical/Polar robot: Used for handling at machine tools, spot welding, die-casting,

fettling machines, gas welding and arc welding. It's a robot whose axes form a polar

coordinate system.

SCARA robot: Used for pick and place work, application of sealant, assembly

operations and handling machine tools. It's a robot which has two parallel rotary joints to

provide compliance in a plane.

Articulated robot: Used for assembly operations, die-casting, fettling machines, gas

welding, arc welding and spray painting. It's a robot whose arm has at least three rotary

joints.

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Parallel robot: One use is a mobile platform handling cockpit flight simulators. It's a

robot whose arms have concurrent prismatic or rotary joints.

There are lots of robots used in industries among them we took the pick and place robots

for our project

1.4 PICK AND PLACE ROBOT:

Automation as a technology is concerned with the use of mechanical, electrical,

electronic and computer-based control systems to replace human beings with machines,

not only for physical work but also for the intelligent information processing.

Industrial automation, which started in the eighteenth century as fixed automation has

transformed into flexible and programmable automation in the last 15 or 20 years.

Computer numerically controlled machine tools, transfer and assembly lines are some

examples in this category.

Common people are easily influenced by science fiction and thus imagine a robot

as a humanoid that can walk, see, hear, speak, and do the desired work. But the scientific

interpretation of science fiction scenario propounds a robot as an automatic machine that

is able to interact with and modify the environment in which it operates. Therefore, it is

essentialto define what constitutes a robot.

14

Different definitions from diverse sources are available for a robot.Industrial robots are

found in a variety of locations including the automobile and manufacturing industries.

Robots cut and shape fabricated parts, assemble machinery and inspect manufactured

parts.

Some types of jobs robots do: load bricks, die cast, drill, fasten, forge, make glass,

grind, heat treat, load/unload machines, machine parts, handle parts, measure, monitor

radiation, run nuts, sort parts, clean parts, profile objects, perform quality control, rivet,

sand blast, change tools and weld.

Outside the manufacturing world robots perform other important jobs. They can be

found in hazardous duty service, CAD/CAM design and prototyping, maintenance jobs,

fighting fires, medical applications, military warfare and on the farm.

15

Fig. 1

16

1.5VARIOUS TASKS PERFORMED BY PICK & PLACE ROBOT:

1.) The use of robots for placing products in cartons and transfer of cartons and

products between different stations in the packaging lines is very common in all

industries. High speed pick-and-place robots for placing small items like candy

and cookies in packages are often combined with a visual observation system for

identifying products.

Fig.2

17

2.) Flexible packaging material is the generic term for soft packages made of film,

foil or paper sheeting. Popular forms are stand-up pouches, bags, sachets and

envelopes.These packages are often formed, filled and sealed in a vertical or

horizontal form-fill-seal machine. The package is then finally put into a case by

top loading.

3.) Cartooning machines erect boxes from flat sheets of corrugated material. The

erected boxes are then filled with products or individual cartons and are then

prepared for the palletizing process. As with most packaging machines, vacuum

cups, vacuum pumps and other pneumatic components are an essential part of the

cartooning

4.) Rotary cartoner is one of the most popular types of cartooning machines. These

machines use a series of vacuum bars equipped with suction cups that move in a

continuous rotary motion. Rotary cartoners utilize a "pick-and-carry" motion to

move cartons.

5.) Palletizing is the process of placing packages on a pallet alternatively removing

them from a pallet (depalletizing). Palletizing machines use vacuum pumps,

suction cups and other pneumatic components. These machines typically pick up

multiple boxes at a time and place them on a stack (or remove them from a stack).

18

6.) The use of specialized machines for high speed pick-and-place of small items with

suction cups is very common in the electronics and consumer industries. This

application is typically characterized by short cycle times, high acceleration forces

and large variations on the parts to be handled.

7.) During the pouch/bag forming phase vacuum is often applied to transport belts

that help provide a grip on both sides of the pouch/bag material. The vacuum belt

moves the pouch material from a web roll into position to receive the product

from the filler. Holes in the belt allow vacuum to hold the pouch while the belt is

rotating and the pouch is been removed.

8.) Vacuum and suction cups are used to pick and open paper and plastic bags.

Suction cups with stiffer bellows and a soft sealing lip are preferred in these quite

often high-speed applications.

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1.6COMPONENTS OF ROBOT:-

1. STRUCTURE

The structure of a robot is usually mostly mechanical and can be called a

kinematic chain. The chain is formed of links, actuators, and joints which can

allow one or more degrees of freedom. Most contemporary robots use open serial

chains in which each link connects the one before to the one after it. These robots

are called serial robots and often resemble the human arm. Robots used as

manipulators have an end effector mounted on the last link. This end effector can

be anything from a welding device to a mechanical hand used to manipulate the

environment.

2. POWER SOURCE

At present mostly (lead-acid) batteries are used, but potential power sources could

be:

• Pneumatic (compressed gases)

• Hydraulics (compressed liquids)

• Flywheel energy storage

• Organic garbage (through anaerobic digestion)

20

3. ACTUATION

Actuators are like the "muscles" of a robot, the parts which convert stored energy

into movement. By far the most popular actuators are electric motors that spin a

wheel or gear, and linear actuators that control industrial robots in factors. But

there are some recent advances in alternative types of actuators, powered by

electricity, chemicals, or compressed air.

4. TOUCH

Current robotic and prosthetic hands receive far less tactile information than the

human hand. Recent researchhas developed a tactile sensor array that mimics the

mechanical properties and touch receptors of human fingertips. The sensor array is

constructed as a rigid core surrounded by conductive fluid contained by an

elastomeric skin. Electrodes are mounted on the surface of the rigid core and are

connected to an impedance-measuring device within the core. When the artificial

skin touches an object the fluid path around the electrodes is deformed, producing

impedance changes that map the forces received from the object.

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5. VISION

Computer vision is the science and technology of machines that see. As a

scientific discipline, computer vision is concerned with the theory behind artificial

systems that extract information from images.

The image data can take many forms, such as video sequences and views from

cameras. In most practical computer vision applications, the computers are pre-

programmed to solve a particular task, but methods based on learning are now

becoming increasingly common.

Computer vision systems rely on image sensors which detect electromagnetic

radiation which is typically in the form of either visible light or infra-red light.

The sensors are designed using solid-state physics.

The process by which light propagates and reflects off surfaces is explained using

optics. Sophisticated image sensors even require quantum mechanics to provide a

complete understanding of the image formation process.

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6. MANIPULATION

Robots which must work in the real world require some way to manipulate

objects; pick up, modify, destroy, or otherwise have an effect. Thus the 'hands' of

a robot are often referred to as end effectors, while the arm is referred to as a

manipulator. Most robot arms have replaceable effectors, each allowing them to

perform some small range of tasks. Some have a fixed manipulator which cannot

be replaced, while a few have one very general purpose manipulator, for example

a humanoid hand.

1.) Mechanical Grippers: One of the most common effectors is the gripper. In its

simplest manifestation it consists of just two fingers which can open and close

to pick up and let go of a range of small objects.

2.) Vacuum Grippers: Pick and place robots for electronic components and for

large objects like car windscreens, will often use very simple vacuum grippers.

These are very simple astrictive devices, but can hold very large loads

provided the pretension surface is smooth enough to ensure suction.

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1.7 ADVANTAGES OF PICK AND PLACE ROBOTS:

1.)Accuracy and Pick and Place Robots: Robots are outfitted with wide reaches

and slim arms, steady repeatability and precise tooling - all of which allows them

to be extremely accurate. This high precision capability makes them a good match

for applications.

2.)Flexible Pick and Place: One of the main advantages of is flexibility. robots

are easily programmable. They are able to accommodate multiple changes in

product shape and type. In addition, robots provide a high level of movement

flexibility.

3.)Increase Consistency with Pick and Place: robot systems have the ability to

improve product quality and cycle time. Robotic movements are regulated, so the

results are always the same.

4.)Robots are Space-Efficient: Because they are designed with compact bases,

pick and place robots are ideal if you are looking to conserve floor space. Robots

can be programmed to move within strictlimits- leading to even better use of

space.

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5.)Robots Maximize Safety: Pick and place applications can be physically

demanding. They are labor-intensive, repetitive, and monotonous. Depending on

the weight and size of a part, moving it from one place to another can be very

demanding work. Pick and place robots are unaffected by the stresses of the

application. They are able to work without taking breaks or making mistakes.

6.)Save with Pick and Place Robots:

Incorporating pick and place robots can effectively cut your costs. Robotic

precision and reliability allow for less wasted material and more efficient use of

time. Plus, the initial investment in robots is quickly recouped - making pick and

place robots an extremely cost-effective solution.

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1.8 APPLICATION:

1. Material handling

2. packaging

3. Raping

4. As a welder/ curter

and many more application

26

Chapter 2

PNEUMATIC CYLINDER REPLACEMENT:

Our aim is to replace pneumatic cylinders instead of servo motors in a pick and

place robot to avoid the short circuit problems in the chemical and crackers industries.

2.1 Reasons:

Because of short circuits happening in chemical industries, considering human safety,

we are replacing pneumatic cylinders instead of servo motors in a pick & place robot.

Fig.3

Also, it may affect using in fire industries.

27

Also, for the less consumption of electricity

Fig.4

These are the reasons, it may cause damage to human, while working. That’s why we are

developing this project.

28

2.2 PROBLEMS WE FACED:

• Grip Force in first cylinder

• Pneumatic cylinders analysis

• Circuits for pneumatic cylinders(FESTO FLUID SIM)

• Force analysis

2.3 SOLUTIONS FOR EACH PROBLEM:

2.3.1 PTC CREO

For this design we have used the PTC CREO. Creo is a family or suite of design

software supporting product design for discrete manufacturers and is developed by PTC.

The suite consists of apps, ach delivering a distinct set of capabilities for a user role

within product development. Creo runs on Microsoft Windows and provides apps for

3D CAD parametric feature solid modeling, 3D direct modeling, 2Dorthographic views,

Finite Element Analysis and simulation, schematic design, technical illustrations,

and viewing and visualization.Creo Elements pro and CreoParametric compete

directly with CATIA, Siemens NX/Solidedge, and Solidworks.

29

The Creosuite of apps replace and supersede PTC’s products formerly known

as Pro/ENGINEER, CoCreate, and ProductView. PTC began developing Creo in 2009,

and announced it using the code name Project Lightning at Planet PTC Live, in Las

Vegas, in June 2010. In October 2010, PTC unveiled the product name for Project

Lightning to be Creo. PTC released Creo 1.0 in June 2011.

PTC Creo, formerly known as Pro/ENGINEER, is a

3D CAD/CAM/CAE feature-based, associative solid modeling software. It is one of a

suite of 10 collaborative applications that provide solid modeling, assembly

modelling, 2D orthographic views, finite element analysis, sub divisional

and NURBS surfacing, and NC and tooling functionality for mechanical designers .

Creo Elements/Parametric complete directly with Solidworks, CATIA, and

NX/Solid Edges. It was created by Parametric Technology Corporation(PTC) and was

the first of its kind to market.

The application runs on Microsoft Windows. The UNIX version was discontinued

after 4.0, except x86-64 UNIX on Solaris. The name changed to Creo 1.0 after

Pro/ENGINEER Wildfire 5.0 (rebranded PTC Creo Elements/Pro), took place on

October 28, 2010, which coincided with PTC’s announcement of Creo, a new design

software application suite. Creo Elements/Pro will be discontinued after version 2 in

favor of the Creo design suite.

30

2.3.2 DESIGN:

We designed using PTC Creo. Our project consists of several component

and they are:

1. Four pneumatic cylinder

2. One rotating cylinder

3. Grippers

4. Base

5. Bearing

6. Handle

7. Link rod etc…

In our design we have used 5 pneumatic cylinder, so that it is an 5 axis robot. Using this

5 pneumatic cylinder we can able to do many operation like loading and unloading,

moving some objects etc...

In that five pneumatic cylinder one rotating cylinder were placed for the rotating

movement of the object.

In this robot we have placed Grippers to hold the objects. There are two types of

grippers were used in the pick and place robots, they are mechanical gripper and vaccum

gripper, but we are used only mechanical gripper.

31

Link rod is to connect one cylinder to another cylinder in this robot. Base is used to

place this robot in any place with the help some bolts.

The bearing is placed along with the rotating cylinder to rotate the object and place it.

To Rotate the arm the rotating cylinder is used.

We used creo software for making 3d design and force analysis. And fLUIDSIM

software for pneumatic circuit and pneumatic accuracy.

32

Fig.5

33

2.3.3 ANALYSIS:

For analysis we used this software. By using this software we have solved the the

force in the cylinders in the design.Ansys, Inc. is an American Computer Aided

engineering software developer headquartered south of Pittsburgh in Cecil Township,

Pennsylvania. United States. Ansys publishes engineering analysis software across a

range of disciplines including finite element analysis, structural analysis, computational

fluid dynamics, explicit and implicit methods, and heat transfer.

ANSYS Autodyn is computer simulation tool for simulating the response of

materials to short duration severe loadings from impact, high pressure or

explosions.ANSYS Mechanical is a finite element analysis tool for structural analysis,

including linear, nonlinear and dynamic studies. This computer simulation product

provides finite elements to model behavior, and supports material models and equation

solvers for a wide range of mechanical design problems. ANSYS Mechanical also

includes thermal analysis and coupled-physics capabilities

involving acoustics, piezoelectric, thermal–structural and thermo-electric analysis.

ANSYS HFSS is a Finite Element Analysis tool for simulating full-wave

electromagnetic fields. HFSS incorporates finite element, integral equation, and hybrid

methods to solve a wide range of microwave, RF and high-speed digital applications

34

Fig 6

35

2.3.4 ACCURACY:

For accuracy we have used the FLUIDSIM PNEMATICS software we discussed

about the accuracy below

2.3.4A FLUIDSIM:

FluidSIM 5 is a comprehensive software for the creation, simulation, instruction

and study of electropneumatic, electrohydraulic, digital and electronic circuits. All of the

program functions interact smoothly, combining different media forms and sources of

knowledge in an easily accessible fashion.

FluidSIM unites an intuitive circuit diagram editor with detailed descriptions of all

components, component photos, sectional view animations and video sequences. As a

result FluidSIM is perfect not only for use in lessons but also for the preparation thereof

and as a self-study program.

FluidSIM allows both the convenient creation of circuits as well as their interactive

simulation. Not only state changes and component switches, which result from the

system, are calculated. Moreover, the user can interactively operate and activate

switches or change-over valves. Also, signals from connected hardware or via an

interface from other programs can be transferred. FluidSIM immediately reacts to such

events and simulates seamlessly the altered system.

36

Extensive library:

You build your circuit diagram from a library of hundreds of pneumatic, hydraulic and

electronical components. But the component library is not static. It is constantly

improved and enriched with new components.

Intuitive user interface:

With FluidSIM you create your first circuit diagram in only a few minutes. With the

intelligent chosen default parameters for all components you can observe physical

phenomena in no time.

Lightning fast simulations:

The simulation core of FluidSIM has been consistently designed for speed, without

compromising the accuracy of the results. As a result, electrical signals up to a frequency

of 100 kHz can be simulated in FluidSIM.

37

Fig.7

38

Complete didactic materials:

The easy intuitive user interface, extensive component library and robust simulation core

are complemented with a large collection of didactic materials. Starting point is the

integrated tutorial 'Simulating with FluidSIM' which teaches the basics of pneumatics,

hydraulics and electrical engineering. Educational films and presentations provide the

opportunity to go further and get a deeper understanding of the components.

2.3.4B TECHNOLOGIES:

Components and learning materials of FluidSIM are divided in three separate

technologies. A separate license can be purchased for each technology. The individual

technologies cover the following subjects:

Pneumatics:

• Pneumatics/Electropneumatics

• Closed-loop pneumatics

• Vacuum technique

• Electrical controls

• Digital technology

• GRAFCET (EN 60848)

39

Hydraulics:

• Hydraulics/Electrohydraulics

• Closed-loop hydraulics/Proportional hydraulics

• Mobile hydraulics

• Electrical controls

• Digital technology

• GRAFCET (EN 60848)

Electrical engineering:

• Electrical engineering (AC/DC)

• Electrical controls

• Electrical machines

• Electronics

• Closed-loop control

• Extended digital technology

• GRAFCET (EN60848)

40

2.3.4C FLUIDSIM HYDRAULICS:

FLUIDSIM Hydraulics is a teaching tool for simulating hydraulics basics

and runs using Microsoft Windows. It can be used in combination with the Festro

Didactic GmbH & Co.KG,and art systems software GmbH,Paderborn.

A major feature ofFluidSIM is its close connection with CAD functionality

and simulation. FluidSIM allows DIN-compliant drawing of electro-hydraulic circuit

diagrams and can perform realistic simulations of the drawing based on physical models

of the components. Simply stated, this eliminates the gap between the drawing of a

circuit diagram and the simulation of the related hydraulic system.

The CAD functionality of a FulidSIM has been specially tailored for

fluidics. For example- while drawing, the program will check whether or not certain

connection between components are permissible.

Another feature of FluidSIM results from its well thought-out didactic

concept: FluidSIM supports learning, education, and visualizing hydraulic knowledge.

Hydraulic components are explained with textual descriptions, figures, and animations

thatillustrate underlying working principles; excercises and education films mediate

knowledge about both important circuits and the usage of hydraulics components.

41

The development of FluidSIM included special emphasis on both an intuitive and

easy-to-learn user interface. The user will quickly learn to draw and simulate electro-

hydraulics circuit diagrams.

2.3.4D FLUIDSIM PNEUMATICS:

FLUIDSIM Pneumatics is a teaching tool for simulating pneumatics basics

and runs using Microsoft Windows. It can be used in combination with the Festro

Didactic GmbH & Co. KG training hardware, but also independently. FluidSIM was

developed as a joint venture between the university of Paderborn, Festro Didactic GmbH

& Co.KG, and Art Systems Software GmbH, Paderborn.

A major feature of FluidSIM is its close connection with CAD functionality and

simulation. FluidSIM allows DIN-compliant drawing of electro-pneumatic circuit

diagrams and can perform realistic simulations of the drawing based on physical models

of the components. Simply stated, this eliminates the gap between the drawing of a

circuit diagram and the simulation of the related pneumatics system.

The CAD functionality of a FulidSIM has been specially tailored for fluidics. For

example- while drawing, the program will check whether or not certain connection

between components are permissible.

42

Another feature of FluidSIM results from its well thought-out didactic

concept: FluidSIM supports learning, education, and visualizing pneumatic knowledge.

Pneumatic components are explained with textual descriptions, figures, and animations

that illustrate underlying working principles; excercises and education films mediate

knowledge about both important circuits and the usage of pneumatic components.

The development of FluidSIM included special emphasis on both an

intuitive and easy-to-learn user interface. The user will quickly learn to draw and

simulate electro-pneumatics circuit diagrams.

2.3.4E TECHNICAL REQUIREMENTS:

You need a computer with a Pentium Processor or higher that runs using

Microsoft Windows9X, Microsoft WindowsME, Microsoft WindowsNT,

MicrosoftWindowsXP.

If you intend to draw simple circuit diagrams or to simulate the existing

circuit diagrams, 64 MB RAM is adequate. However, minimum 128 MB RAM is

recommended to simulate complex circuit diagrams.

In order to play the educational films, you will need a CD-ROM drive that

runs at double speed along with hardware for sound.

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2.3.4F PNEUMATIC COMPONENTS:

Some of the pneumatic componenets used in the FluidSIM are given below

Compessed air supply: The compressed air supply provides the needed

compressed air. It contains a pressure control valve that can be adjusted to output the

desired operating pressure.

Air Service unit, simplified representation: The service unit is made up of a

compressed air filter with water separator and a pressure control valve.

Air Service unit: The service unit is made up of a compressed air filter with

water separator and a pressure control valve.

Configurable 2/n way valve: The configurable 2/n way valve is a way valve with

two connections, where both its body elements and its operating modes are user-

definable.

Configurable 3/n way valve: The configurable 4/n way valve is a way valve with three

connections, where both its body elements and its operating modes are user-definable.

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Fig 8

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Configurable 4/n way valve: The configurable 4/n way valve is a way valve with

four connections, where both its body elements and its operating modes are user-

definable.

Configurable 5/n way valve: The configurable 4/n way valve is a way valve with

five connections, where both its body elements and its operating modes are user-

definable.

Pneumatic proximity switch,solenoid operated: A permanent solenoid found on

the piston of a cylinder drives this 3/2 pneumatic directional valve and triggers the

control signal. The flow passes freely from 1 to 2.

Low pressure amplifier unit, 2 compartments: Each of the two double-level

low pressure amplifier units has the function of a 3/2 directional valve that is normally

closed.

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Shuttle valve: The shuttle valve is switched based on the compressed air entering

into either input connection 1 and leaving via an output connection 2.

Quick exhaust: The compressed air passes from connection 1 to connection 2. If

the pressure should decrease at connection 1, then the compressed air from connection 1

will escapes to the outside via the installed silencer.

Two pressure valve: The two pressure valve is switched based on the compressed

air entering into both input connections 1 and leaving via an output connections 2.

Pneumatic counter: The counter register pneumatics signals starting at a

predetermined number and counting backwards. If zero is reached, then the counter

releases an output signal.

Single acting cylinder: The pistin rod of a single acting cylinder is operated by

the input of compressed air at the front end position. When the compressed air is shut

off, the piston returns to its starting positions via a return spring. The piston of the

cylinder contains a permanent solenoid which can be used to operate a proximity switch.

Single acting cylinder with return spring: The piston of the single acting

cylinder is extended to its back position by the input of compressed air. When the

compressed air is switched off, a return spring moves the piston back to its front

position.

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Double acting cylinder: The piston rod of a double acting cylinder is operated by

the reciprocal input of compressed air at the front and back of the cylinder. The end

position damping is adjustable via two regular screws. The piston of the cylinder

contains a permanent solenoid which can be used to operate a proximity switch.

Double acting cylinder with in and out piston rod: The in and out piston rod of

the double acting cylinder is controlled by alternating the compressed air input. The

cushioning can be adapted with two adjustment screws.

This FLUIDSIM pneumatics were used for the circuit flow with greater accuracy.

We have used this software for the greater accuracy in this replacements in this robots.

Because of using the pneumatic cylinder it need higher accuracy. If the greater accuracy

were not there it cause some damage so we need greater accuracy for operations.

We have done 3 analysis using fluidsim software. There are 3 circuits as output. They

are as follows:-

• Pneumatic circuit

• Sensor circuit

• Electrical circuit

From these circuit we can able to get greater accuracy in this pneumatics cylinder.

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Pneumatic circuit:-

Fig 9

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Sensor circuit:

Fig 10

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Electrical circuit:

Fig.11

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2.3.4G SYMBOLS:

- Double acting cylinder

This cylinder has 2 input and 2 output poles, it is controlled by electric circuit in this

project. We have 4 double acting cylinders.

- Rotary cylinder

This cylinder used to rotate the object to 180 degree, because it is a semi rotary

cylinder. We have 1 rotary cylinder in our project.

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- solenoid valve

Solenoid valve gives constant current at both ends. We are using 5/2 solenoid valve

- push button

Here we are using 3 push buttons. This transfers electric current to pneumatic cylinder

valves

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-Air service unit

This service unit has one lubricating system to maintain the temperature of compressed

air and sends to double acting cylinder.

-Valve solenoid

This will activate the current in the solenoid valves in the double acting cylinders

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- Relay

This is connected to the electric circuit. It has 2 switches. They are Make switch &

Brake switch. This will control the current supply.

- make switch & brake switch

Make switch gives current to the cylinder. Brake switch brakes the current.

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2.3.4HWORKING :-

Cylinder 1-Double acting (left bottom)

Cylinder 2-Double acting( left top)

Cylinder 3-double acting( right top)

Cylinder 4- double acting (right down)-Gripper cylinder

Rotating cylinder- Semi Rotary cylinder

Initially, the cylinder 4 (Gripper cylinder) will be acting first, it is

connected to S9 valve. Then the sensor senses the current and passes the signal to

the cylinder 1. Then to the cylinder 2 and then to cylinder 3. Next to rotary

cylinder.etc vice versa.

Flow rate = 750m/s

Condition max=5000 m/s

Pressure = 4bar

Condition max=20 bar

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Fig 12

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2.3.5 PNEUMAITC CYLINDERS:

Signification of pneumatic cylinders:

1. Relatively low cost

2. Easy of installation

3. Simple and Robust construction

4. Ready availability in various size and stroke length

General characters of pneumatic cylinders:

Diameter - 2.5 to 320mm

Stroke length - 1 to 2000mm

Aavilable force - 2 to 45000N at 6 bar

Piston speed - 0.1 to 1.5 m/s

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Pneumatic component can be performed by following types of motion

• Linear

• Swivel

• Rotary

Pneumatics used in working operatins

• Drilling

• Turning

• Milling

• Sawing

• Finishing

• Foarming

• Quality control

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Chapter 3

CONCLUSION:-

3.1 concluding our opinion:-

We have successfully replaced the pneumatic cylinders instead of servo

motors in pick and place robotics in 5 axis robots. This project will be very useful

for human safety in future.

3.2 To get different ideas:-

Although robotics is famous recent 10 years, many are less courage enough

to do research in robotics. We are taking this project for our clear idea of human

safety enough. Based on this project many people will bring about projects based

on safety and in big budget projects.

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Chapter 4

REFERENCE:-

1. Pick and place robot book by Patel Charmin Rajendrakumar, India

2. FLUIDSIM book by Festro

3. Pneumatic cylinder advantages from internet

4. Referred analysis and accuracy with capt. William(external guide)

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