Pneumatic TMT Rod Bending Machine
Pneumatic TMT Rod Bending Machine
Pneumatic TMT Rod Bending Machine
Now in this world the use of bending machine is increased. The construction sites are the most
basic type of example is for bending machine. The main objective of this project is to
implement the Pneumatic rod bending machine in the construction sites with less cost
compared to the existing bending machines, and increasing the productivity of the stirrups. The
bending machine is one of the most important machine tool in sheet metal work shop. It is
primarily designed for bending. The bend has been made with the help of punch which exerts
large force on the work clamped on the die. The bending machine is designed in such a way that,
it works automatically. The automation strategy, when implemented is believed to result in
reduced cycle time, costs and improved product quality. Other possible advantages are
repeatability, increased productivity, reduced labor and integration of business systems.
Automation is achieved with the help of Electro pneumatic system.
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INDEX
1 Introduction 8
1.1 Problem Summary 8
1.2 Objectives of the Project 8
1.3 AIM Of Project 8
1.4 Project Details 9
2 Literature Survey 9
2.1 Prior Concept 11
3 Materials / Tools Required 12
3.1 Hardware Modules 12
3.2 Components 12
3.3 Description Of Components 12
3.3.1 Pneumatic Cylinder 12
3.3.2 Solenoid Valve 13
3.3.3 Air Compressor 13
3.3.4 Air Pipe 14
3.3.5 TMT Rod 14
3.3.6 Pressure Gauge 15
3.3.7 Pneumatic Fittings 15
4 Cylinder 16
4.1 Design Calculations Of Cylinder 16
4.1.1 Force 16
4.1.2 Pneumatic Cylinder Design 17
6 Working Principal 19
7 List Of Components 20
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10 Applications Of Pneumatic TMT Rod Bending Machine 21
12 Future Scope 22
13 References 23
14 Canvases 24
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INTRODUCTION
Pneumatic TMT rod bending machine will reduce the manual efforts of the user. Pneumatic
TMT rod bending machine will be useful to the user to manage and generate accurate results for
TMT rod at the time of bending. It will reduce the time compare to manually doing.
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1.4 Project Details:
Where your project or innovation will use?
Our project/innovation is going to be used in construction sites. Because we are seeing that the
labours who are working at construction places have to do the rod bending by there own hands. It
is creating physically problems for the workers.
2. Literature Survey
I Muhammed, S. Ravivishwnath, P. Sureshkumar , N.Sarvanan Design and fabrication
of hydraulic rod bending machine, April 2014. Worked on design and fabrication of rod bending
machine and they concluded that Each and every work of human is reduced by a machine, but
few are as like construction the usage of machines for bending rods for stirrups which are used to
withstand loads in beams and columns are not done by machine because the cost of machine is
high and need skilled labours to operate it. So this project is aimed to do bending operation for stirrups
using hydraulics and named as hydraulic rod bending machine. The main objective of our project
is to implement the hydraulic rod bending machine in the construction sites with less cost compared to the
existing bending machines, and increasing the productivity of the stirrups.2.Vilas Shinde,
Darshan Adhav, Suraj Jadhav, Afsar Attar, Sandip Gorde. Design and fabrication of hydraulic
stirrup making machine, May 2016.They worked on Design and Fabrication of Hydraulic
Stirrups Making Machine and they concluded that Since testing the stirrup making machine it is
observed that how much time is required to make single piece of stirrup by effective working.
The detail description is given as below: Loading and unloading combining clamping the bar to
fixture it almost takes only 5 to 6seconds. Time required to forward and backward stroke is about
10 to 11 seconds during which stirrup is made. Considering machine ergonomics that is
interaction of human operator with machine, it is very easy to operate it because operating switch
is provided at suitable place of machine. Again loading and unloading is not complicated since
not very specialized tooling is used it is very simple structure. Most of the earlier pneumatic
control systems were used in the process control industries, where the low pressure air of the
order 7-bar was easily obtainable and give sufficiently fast response. Pneumatic systems are
extensively used in the automation of production machinery and in the field of automatic
controllers. For instance, pneumatic circuits that convert the energy of compressed air into
mechanical energy enjoy wide usage, and various types of pneumatic controllers are found in
industry. Certain performance characteristics such as fuel consumption, dynamic response and
output stiffness can be compared for general types of pneumatic actuators, such as piston-
cylinder and rotary types. Figure (a) and (b) show the two types of pneumatic actuators (Sorli et
al., 1999). The final decision on the best type and design configuration for pneumatic actuator
can be made only in relation to the requirements of a particular application. The pneumatic
actuator has most often been of the piston cylinder type because of its low cost and simplicity
(Tablin et al., 1963) The pneumatic power is converted to straight line reciprocating and rotary
motions by pneumatic cylinders and pneumatic motors. The pneumatic power is converted to
straight line reciprocating and rotary motions by pneumatic cylinders and pneumatic motors. The
pneumatic position servo systems are used in numerous applications because of their ability to
position loads with high dynamic response and to augment the force required moving the loads.
Pneumatic systems are also very reliable (Clements and Len, 1985).
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Fig: (a). Double Acting Linear Pneumatic actuator
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The open literature surveyed showed a wide spectrum of new applications of pneumatic servos
such as milling machines, robotics, and advanced train suspension. Therefore, the surveyed
literature reported is subdivided into three main groups. The first group is concerned with
various applications of pneumatic actuators. The second group includes the theoretical,
experimental approaches for modeling the pneumatic actuator. The third group is related with the
control strategies applied to pneumatic actuators. Pneumatic servos have advantages over
hydraulics in high temperature and nuclear environments. The actuator, rather than the servo
valve, generally limits system response and stiffness. Where simplicity and cost are paramount,
the piston cylinder is probably the best choice. But if minimum fuel consumption is desired
rotary type of motor is indicated. (Taplin et al., 1963) also have been shown the rotary servo has
nearly twice the band pass of the piston cylinder servo. This result is typical for many
applications. In short duration missile applications, the weight of a self-contained solid
propellant pneumatic servo may be half that of an equivalent self-contained hydraulic system.
Where a pneumatic system is to replace a heavier hydraulic system, maximum dynamic response
and output stiffness are essential. The outstanding difference between pneumatic and hydraulic
systems arises from the low bulk modulus of the pneumatic working medium. The bulk modulus
of a gas is p, where hh is the ratio of specific heats for the gas and p is the instantaneous
pressure. This is the major obstacle in achieving a high response pneumatic system. Several
countries have been investigating and developing active suspension technologies in order to
improve both vertical and lateral ride quality of fast train passenger cars. (Cho et al., (1985).
investigated the use of actively controlled pneumatic actuators in parallel with conventional
passive suspension to improve vehicle dynamics. The use of pneumatic actuators for vehicle
active suspension reduced the rms car body lateral suspension stroke by 34 percent with a power
requirement of 5.7 KW per car. The advantages and limitations of the conventional pneumatic
cylinder were discussed by (Bird et al., 1985). Recent developments in the design of pneumatic
linear actuators have resulted in the production of more compact and better- guided actuators.
The author worked on the development of special servo control system and its integration into
complete control system. (Vincent et al., 1989) investigated an alternative approach to the design
of controllers for positioning damping. To avoid conflicting requirements problem associated
with traditional state variable feedback design, the design is based on energy methods and is not
a full state variable feedback design. The method is illustrated using a low order spring mass
example, and the results are compared with a linear quadratic design. Electro hydraulic and
electro pneumatic servo drives can provide precise position control for a multitude of industries
from textile manufacture to machine tools. A significant application of the latter type was in a
universal rotary machining center where the primary requirement was for an increase in both
productivity and flexibility.
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Pneumatic devices are used in many industrial applications. Generally appropriate for
applications involving less force than hydraulic applications, and typically less expensive than
electric applications, most pneumatic devices are designed to use clean dry air as an
energy source. The actuator then converts that compressed air into mechanical motion. The type
of motion produced depends on the design of the actuator.
Pneumatic devices are also used where electric motors cannot be used for safety
reasons, such as mining applications where rock drills are powered by air motors to preclude the
need for electric motors deep in the mine where explosive gases may be present.
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Materials / Tools Required
3.2 Components:
Pneumatic Cylinder
Solenoid Valve
Air Compressor
Air Pipe
Rods
Pressure Gauge
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When tank pressure reaches its lower limit, the air compressor turns on again and re-pressurizes
the tank. The most common types of air compressors are: electric or gas/diesel powered
compressors. The power of a compressor is measured in HP (Horsepower) and CFM (cubic
feet of air per minute). The gallon size of the tank tells you how much compressed air "in
reserve" is available.
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3.3.6 Pressure Gauge:
Pressure regulators, commonly called pressure- reducing valves, maintain constant output
pressure in compressed-air systems regardless of variations in input pressure or output flow.
Regulators are a special class of valve containing integral loading, sensing, actuating, and control
components. Available in many configurations, they can be broadly classified as general purpose,
special purpose, or precision.
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4. Cylinder:
Cylinders are linear actuators which convert fluid power into mechanical power. They are
also known as JACKS or RAMS. Hydraulic cylinders are used at high pressures and
produce large forces and precise movement. For this reason they are constructed of strong
materials such as steel and designed to withstand large forces. Because gas is an
expansive substance, it is dangerous to use pneumatic cylinders at high pressures so they
are limited to about 10 bar pressure. Consequently they are constructed from lighter
materials such as aluminum and brass. Because gas is a compressible substance, the
motion of a pneumatic cylinder is hard to control precisely. The basic theory for
hydraulic and pneumatic cylinders is otherwise the same.
4.1.1 Force:
The fluid pushes against the face of the piston and produces a force. The force
produced is given by the formula:
F = p.A
p is the pressure in N/m2 and A is the area the pressure acts on in m2.
This assumes that the pressure on the other side of the piston is negligible. The diagram
shows a double acting cylinder. In this case the pressure on the other side is usually
atmospheric so if p is a gauge pressure we need not worry about the atmospheric
pressure.
Let “A” be the full area of the piston and “a” be the cross sectional area of the rod. If the
pressure is acting on the road side, then the area on which the pressure acts is (A - a).
This force acting on the load is often less because of friction between the seals and both
the piston and piston rod.
Diameter of rod= 10 mm
π π
F= 4 * ( ∗D2) = 4 * ( ∗102)
4 4
π
= 4 * ( ∗100) = 314 N
4
F = 314 N
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4.1.2 Pneumatic Cylinder Design:
We know pressure is given by,
F
P=
A
π 2
A= D So,
4
314
P= π
( ∗D2)
4
D2 = 0.001m
D = 0.0317m
D = 31.62mm
= 60 + 20 = 80 mm
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5. Components Specification:
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6. Working Principal:
The bending machine works with the help of pneumatic single acting cylinder. The piston is
connected to the moving bending tool. It is used to bend the small size of the TMT Rod. The
machine is portable in size, so easy transportable. The compressed air from the compressor is
used as the force medium for this operation. There are pneumatic Single acting cylinders
solenoid valves, flow control valve and the timer unit is used. The arm from the compressor
enters to the flow control valve. The controlled air from the flow control valve enters to the
solenoid valve. The function of solenoid valves all of air correct time interval. The 3/2 solenoid
valve is used. In one position air enters to the cylinder and pushes the piston so that the bending
stroke is obtained. The next position air enters to the other side of cylinder and pusses the piston
return back, so that the releasing stroke is obtained. The speed of the bending and releasing
stroke is varied by the timer control unit circuit.
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Block Diagrams
Front View
Top View
3d View
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7. List Of Components:
SR. NO. Component Name Quantity
1. Hinges 1
2. Single Acting Cylinder 1
3. Pneumatic Pipes 1 (8mm X 5mm)
4. Pneumatic Fittings 1
5. Pneumatic Valves 1
6. Solenoid Valve 1
7. Pressure Gauge 1
8. TMT Rod 2-3
9. Air Compressor 1
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10. Applications Of Pneumatic TMT Rod Bending Machine:
Angle bending
Metal bending
In construction field
In production
This machine is very useful for small scale industries
All industrial application
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12. Future Scope:
Operation for making rod bend is tedious and required continuous manual work to perform the
bending operation. This will minimize human efforts for less physical exertion of the operator.
Adverse effect of repetitive work on human health is inimizing. Reduce the wastage of stirrup
and this will reduce the cost of stirrup making activity. There is a scope to design the stirrup
with safety standards and with ergonomic considerations which will help to avoid the
incidents during manually stirrup making. There is a scope to improve the stirrup making
efficiency and production capacity of stirrup by using human powered flywheel motor of
stirrup making. The currently available machines are motor power (electrical supply)
operation machines and hydraulic type machine which cannot work where non availability
of electricity. This research presents a new urge as method to bend the given rod of 10, 12 mm
diameter with the help of human power as a energy source for performing the job. Since old age
man is always trying to gain more and more luxurious. Man is always trying to develop more
and more modified technique with increasing the aesthetic look and economic consideration.
Hence there is always more and more scope. But due to some time constraints, and also due to
lack of funds, we only have thought and put in the report the following future modifications.
1. It can be made rack and pinion operated or spring and lever operated, by replacing the
pneumatic circuit by rack and the pinion arrangement by the square threaded screw and nut
arrangement. 2. The place where there is scarcity of the electricity the electric motor operate
compressor is replaced by an I.C. Engine installed compressor. 3. In this machine, compressed
air is used to move the cutting tool for carrying out cutting operation. After the completion of the
cycle the air moves out through the out port of Solenoid valve. This air is released to the
atmosphere. In future the mechanism can be developed to use this air again for the working of
cylinder. Thus in future there are so many modifications, which we can make to survive the huge
global world of competition.
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13. References:
1) www.ijirset.com/upload/2014/special/tapsa/41_TAPSAMECH003.pdf
2) www.mdpi.com/2076-0825/5/1/3/pdf
3) Oil, Hydraulic & Pneumatics Book published by Tech Max
4) https://images.google.com/
5) https://en.wikipedia.org/wiki/Searching
6) www.ijirset.com/upload/2014/special/ta psa/41_TAPSAMECH003.pdf
7) seminarprojects.org/c/working-of-hydraulic- sheet-bending-machine-pdf
8) Manufacturing Process II published by Books India
9) http://www.paperpublications.org/
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Canvases:
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14.3 Empathy Mapping Canvas:
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14.4 Product Development Canvas:
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Periodic Progress Report:
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15.2 Second PPR:
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15.3 Third PPR:
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15.4 Forth PPR:
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Patent Search and Analysis Report
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16.2 PSAR -2:
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16.3 PSAR -3:
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16.4 PSAR-4:
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16.5 PSAR-5:
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Thank You
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