DESIGN AND DEVELOPMENT OF PNEUMATIC RAMMING MACHINE

Abstract

Moulding is one of the important metals forming process in manufacturing components for various applications in industry, Casting of any size and shape can be made accurately. Automation in this field helps to improve the foundry environment and accuracy of the cast parts, Efficiency of moulding is affected by various parameters like permeability, collapsibility, adhesiveness ele. So it is a must to avoid defects in casting. The defects occur in sand castings post a great problem in foundry. On account of defects more than 10% castings are rejected. Even though skilled labor is employed for ramming operation, the packing of molding sand will not be even throughout the molding box. So we have selected the idea of fabricating "PNEUMATIC RAMMER". This rammer is operated pneumatically. By using this rammer moulding sand will be packed evenly throughout the box..

Specification

The pneumatic rammer is used for ramming the sand uniformly around the pattern. It can be used even in small scale industries. To operate this rammer an air compressor is needed. A butt which is attached to the bottom of the piston rod does the operation of ramming. The pressure developed inside the cylinder reciprocates the piston and hence the butt. This rammer is handled by an operator just by moving it over the moulding sand. The butt rams the sand at places moved and the sand is uniformly rammed.
This rammer reduces the ramming time and labor. Due to this the cost is reduced considerably. So this machine finds application in foundries


INDUSTRIAL APPLICATION
The rammer can be handled by an operator without feeling uneasiness. No separate skill is required to operate this rammer.
The operation is quick and hence it is a time saving one. The operation is easy and consumes less cost. Due to the above reasons it finds its extensive application in manufacturing industries, It has an extensive application in both large scale and small scale industries because of its economy and easy handling.
1.1. NEED FOR AUTOMATION
■ Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of these sources, pneumatics form an attractive medium for low cost automation. The main advantages of all pneumatic systems are economy, and simplicity. Automation plays an important role in mass production. Nowadays almost all the manufacturing process is being atomized in order to deliver the products at a faster rate.


The piston rod is circular in cross section. It connects piston with piston of other cylinder. The piston rod is made of mild steel ground and polished. A high finish is essential on the outer rod surface to minimize wear on the rod seals. The piston rod is connected to the piston by mechanical fastening.
The piston and the piston rod can be separated if necessary.
One end of the piston rod is connected to the hottom of the piston. The other end of the piston rod is connected to the other piston rod by means of coupling. The piston transmits the working force to the oil cylinder through the piston rod.
The piston rod is designed to withstand the high compressive force. It should avoid bending and withstand shock loads caused by the cutting force.
The piston moves inside the rod seal fixed in the bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air from the bottom of the cylinder while the rod reciprocates through it.

The cylinder should be enclosed to get the applied pressure from the compressor and act on the pinion.
The cylinder is thus closed by the cover plates on both the ends such that there is no leakage of air.
An inlet port is provided on the top cover plate and an outlet ports on the bottom cover plate. There is also a hole drilled for the movement of the piston.
The cylinder cover plate protects the cylinder from dust and other particle and maintains the same pressure that is taken from the compressor.The flange has to hold the piston in both of its extreme positions.
The piston hits the top plat during the return stroke and hits the bottom plate during end of forward stroke. So. the cover plates must be strong enough to withstand the load.


It is attached to the cylinder cover plates and also to the carriage with the help of'L' bends and bolts straight line motion and force.
These are also used to operate a mechanical operation which in turn operates the valve mechanism. Solenoids may be push type or pull type. The push type solenoid is one in which the plunger is pushed when the solenoid is energized electrically. The pull type solenoid is one is which the plunger is pulled when the solenoid is energized.
The name of the parts of the solenoid should be learned so that they can be recognized when called upon to make repairs, to do service work or to install them.


W ECLAIM •
Claim I: Combines the affordability o f the ESP32 microcontroller with pneumatic components to deliver a budget-friendly solution for automated ramming processes.
Claim 2: An innovative design o f the circuit includes a relay module connected to the Pneumatic solenoid valve that can control the direction o f the air flow to the cyclinder based on the microcontroller's signals.
Claim 3: The system leverages pneumatics and optimized control algorithms, minimizing energy consumption while maintaining high performance.
Claim 4: The electrical transmission system is efficiently organized to manage wires and connections, reducing interference and ensuring seamless operation of the ramming machine.
Claim 5: The machine is designed to be adaptable for various ramming tasks and can be scaled or customized for specific industrial needs.
Claim 6: By reducing energy waste and utilizing environmentally friendly pneumatic technology, the machine aligns with sustainable manufacturing practices.

Documents