FAB Gearshift NEW 09

7/23/2019 FAB Gearshift NEW 09

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FABRICATION OF AUTOMATIC GEAR

SHIFTING SYSTEM

Submitted in the partial fulfillment of the requirement for the award of

DIPLOMA IN MECHANICAL ENGINEERING

SUBMITTED BY:

1. S. MANIVANNAN 4. B. RAJKUMAR

2. G. PUGAZHENDHI 5. S. YUVARAJ

3. S. RAJASEKAR 6. V. GOPU

Under guidance of

Mr. S. JAGADEESAN

MA!" #$$%&

DEPARTMENT OF MECHANICAL ENGINEERING.

CENTRAL POLYTECHNIC COLLEGE

TARAMANI


2/47

CENTRAL POLYTECHNIC COLLEGE

TARAMANI

BONAFIDE CERTIFICATE

Thi' i' to certif( that thi' )ro*ect wor+ on

FABRICATION OF AUTOMATIC GEAR SHIFTING SYSTEM

'ubmitted b( ,,,,,,,, ,,,,,& eg& -o& ,,,,,

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Thi' i' the bonafide record of wor+ carried out b( him under our 'uper.i'ion

during the (ear #$$%

Submitted for the /i.a0.oce e1am held on ,,,,,&&

)23E!T 4UIDE

I-TE-A5 E6AMI-E E6TE-A5 E6AMI-E


3/47

ACKNOWLEDGEMENT


4/47

ACKNOWLEDGEMENT

At the out'et7 we would li+e to empha'i8e our 'incere than+' to the

)rincipal Mr. -------------------------------encouragement and .aluable ad.ice&

we than+ our E'quired "ead of Department Mr .--------------------for

pre'enting hi' felicitation' on u'&

9e are grateful on our Entourage' Mr. ---------------------for guiding

in .ariou' a'pect' of the pro*ect ma+ing it a grand 'ucce''&

9e al'o owe our 'incere than+' to all 'taff member' of the

Mechanical Department&

Ultimatel(7 we e1tend our than+' to all who had rendered their co0

operation for the 'ucce'' of the pro*ect&


5/47

CONTENT


6/47

CONTENT

& I-T2DU!TI2-

#& SY-2)SIS

;& !2-STU!TI2- DETAI5S

& )-EUMATI! !2M)2-E-TS DETAI5S

?& S)AE )ATS DA9I-4

@& A))5I!ATI2-

& AD/A-TA4ES A-D DISAD/A-TA4ES

%& EATUES 2 T"IS )23E!T

$& SATY7!AE A-D MAI-TE-A-!E

& )AI-TI-4 A-D I-IS"I-4

#& !2ST ESTIMATI2-

;& !2-!5USI2-


7/47

INTRODUCTION


8/47

INTRODUCTION

Thi' i' a 'elf C a''e''ment te't on the part of the 'tudent' to a''e'' hi'

competenc( in creati.it(&

During the cour'e of 'tud(7 the 'tudent i' put on a 'ound theoretical

foundation of .ariou' mechanical engineering 'ub*ect' and of cour'e7 to a

'ati'factor( e1tent& 2pportunitie' are made a.ailable to him to wor+ on

different +ind' of machine'7 'o that he i' e1po'ed to .ariou' +ind' of

manufacturing proce''&

A' a 'tudent' learn more and more hi' hold on production technolog(

become' 'tronger& "e attain' a 'tage of perfection7 when he him'elf i' able

to de'ign and fabricate a de.ice&

Thi' i' the pro*ect wor+& That i' the te'timon( for the 'trenuou'

training7 which the 'tudent had in the in'titute& Thi' a''ure' that he i' no

more a 'tudent7 he i' an engineer&

Thi' report di'cu'e' the nece''it( of the pro*ect and .ariou' a'pect' of

planning 7de'ign7 'election of material'7 fabrication7 erection7 e'timation and

te'ting&


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YNOP I


10/47

YNOP I

To increa'e the producti.it( and to o.ercome '+illed labor 'hortage&Mo't of the manufacturing indu'trie' are going for automation& The main

arm for u' to 'elect the pro*ect wor+ i' to acquire practical +nowledge in the

field of .ehicle automation u'ing )-EUMATI! SYSTEM&

9e 'elected AUT2MATI! )-EUMATI! 4EA !"A-4E a'

our pro*ect wor+ and we u'ed principle' of Mechatronic' in de.eloping thi'

pro*ect wor+7 the 'tanding mechani'm i' achie.ed b( reciprocating the

double acting c(linder' which controlled b( 'ingle 'olenoid operated >F#

wa( Directional control .al.e& Thi' i' actuated through the da'hboard panel

in front of the dri.er&

The operating pre''ure required for thi' '('tem i' > to ? bar& The

maintenance required for thi' '('tem i' le'' than the other '('tem'& It i' u'edto reducing the gear 'hifting time without lo'ing the brea+ power and the

efficienc( i' impro.ed7 the main ad.antage' of our pro*ect are elimination of

wear and tear7 'imple in operation7 fa't mo.ement in control and le'' 'pace

b( elimination of lin+age'&


11/47

CON TRUCTION


12/47

CON TRUCTION

Thi' unit con'i't' of

G 4ear bo1 unit

#G )neumatic control '('tem

GEAR BOX UNITH

in thi' pro*ect the gear dri.e' are arranged in a M&S& 'heet fabricated 'quare

'haped bo1& The gear' are arranged in three 'tep' &the gear changer unit i'

+ept in middle and it i' 'hifted b( the control of pneumatic c(linder& The

pneumatic c(linder i' actuated through the >F#wa( le.er operated directional

control .al.e&

PNEUMATIC CONTROL SYSTEM;

The 'liding gear unit i' 'hifted b( the pneumatic c(linder of #$ mm dia and

@$mm 'tro+e length& Thi' pneumatic c(linder i' actuated through the >F#

wa( le.er operated directional control .al.e& The .al.e i' actuated through a

le.er b( hand&


13/47


14/47

ORKING

PRINCIPLE

ORKING PRINCIPLE


15/47

The gear 'hifting operation i' 'tart when le.er i' turned in the control.al.e&

9hen the hand le.er i' turned7 the >F# wa( directional controlled

'olenoid .al.e 'upplie' pre''uri'ed air to the air c(linder in the

pneumatic c(linder unit&& the pneumatic circuit i' 'hown in below

figure&


16/47

The pi'ton rod pu'he' the (o+e in the gear changer &thu' gear dri.e change'

to ne1t 'peed& The c(linder in A0 JMI-USG po'ition the middle gear

conncect' the bottom 'haft gear' and in AK po'ition the middle gear

connect' the top 'haft gear'&


17/47

DESCRIPTION OF

PNEUMATIC

COMPONENTS


18/47

DESCRIPTION OF PNEUMATIC

COMPONENTS

& Double acting air c(linder with pi'ton arrangement&

#& Spool .al.e J# po'ition > port' .al.eG

;& )neumatic fitting'

a& Bul+ head union

b& le1ible ho'e'

c& Air compre''or'

DOUBLE ACTING AIR CYLINDER WITH PISTON

ARRANGEMENT:

It con'i't' of a pi'ton in'ide a c(lindrical hou'ing called a barrel&

Attached to one end of the pi'ton i' a rod which the rod end ha' one port&

Thi' rod end port i' u'ed for entrance of air and e1tend' out'ide one end of

the c(linder& At another end i' a port for e1it of air&

Double acting c(linder can be e1tended and retracted pneumaticall(&

The 'malle't bore 'i8e of a double acting c(linder i' F inch& The pi'ton7

which i' made of ductile Iron7 contain' u0cup pac+ing to 'eal again't lea+age


19/47

between the pi'ton and barrel& The port' are located in the end cap'7 which

are 'ecured to the barrel b( bolt' and nut'&

SPOOL VALVE:

The 'pool i' rod in >F# .alue'7 'o that >F# .al.e i' called 'pool

.al.e& It u'ed to change the path of flow of air&

DIRECTING CONTROL VALVES:

A direction control .al.e i' u'ed to change the direction of airflow a'

and when required b( the '('tem for re.er'ing the machine tool de.ice'& A

direction control .al.e ma( be cla''ified7 according to the con'truction of

the internal mo.ing part'7 a'

& otar( 'pool T(pe&

#& Sliding Spool T(pe&

;& Solenoid operated .al.e'

SOLENOID OPERATED VALVES:


20/47

Solenoid .al.e' are electromechanical de.ice' li+e rela(' and

contractor'& A 'olenoid .al.e i' u'ed to obtain mechanical mo.ement in

machiner( b( utili8ing fluid or air pre''ure& The fluid or air pre''ure i'

applied to the c(linder pi'ton through a .al.e operated b( a c(lindrical

electrical coil& The electrical coil along with it' frame and plunger i' +nown

a' the 'olenoid and the a''embl( of 'olenoid and mechanical .al.e i' +nown

a' 'olenoid .al.e& The 'olenoid .al.e i' thu' another important

electromechanical de.ice u'ed in control of machine'& Solenoid .al.e' are

of two t(pe'7

& Single 'olenoid 'pring return operating .al.e7J>F#G

#& Double 'olenoid operating .al.e&

In fig i' 'hown a 'ingle 'olenoid 'pring return .al.e in it' de0energi8ed

condition& The '(mbol for the 'olenoid and the return are al'o 'hown& The

'olenoid .al.e i' 'hown connected to the c(linder to help reader' under'tand

the 'olenoid .al.e action& In the de energi8ed condition7 the plunger and the

.al.e 'pool po'ition a' 'hown in figure &

>F# 9AY /A5/E


21/47

In thi' po'ition of 'pool7 port ) i' connected to port A and port B i'

connected to tan+ or e1hau't Ji&e& atmo'phereG if air i' u'ed& Spring pre''ure

JSG +eep' the 'pool in thi' condition a' long a' the coil i' de energi8ed&

luid pre''ure from port ) through port A i' applied to the left 'ide of the

c(linder pi'ton& Thu' the c(linder pi'ton mo.e' in the right direction& -ow


22/47

when the 'olenoid coil i' energi8ed7 plunger i' attracted and it pu'he' the

'pool again't 'pring pre''ure&

The new po'ition of plunger and 'pool are 'hown in fig #&

In thi' po'ition of 'pool7 port A get' connected to tan+ and port ) get'

connected to port B& Thu' pre''ure i' applied to the c(linder pi'ton from

right and mo.e' the pi'ton rod to the left& At the 'ame time fluid in the other

'ide i' drained out to the tan+& 9hen the 'olenoid coil i' again de energi8ed7

the 'pring JSG will mo.e the 'pool to it' original po'ition a' 'hown in figure

& Thu'7 normall( when the 'olenoid coil i' de energi8ed the pi'ton rod

remain' e1tended&


23/47

PNEUMATIC

!ITTING


24/47

PNEUMATIC FITTINGS:

There are no nut' to tighten the tube to the fitting' a' in the

con.entional t(pe of metallic fitting'& The tube i' connected to the fitting b(

a 'imple pu'h en'uring lea+ proof connection and can be relea'ed b(

pre''ing the cap and doe' not require an( 'pecial tooling li+e 'panner to

connect JorG di'connect the tube from the fitting&

SPECIFICATION OF THE FITTING:

Bod( Material 0 )la'tic

!ollectFThread -ipple 0 Bra''

Seal 0 -itrate ubber

luid U'ed 0 Air

Ma1& 2perating )re''ure 0 @ Bar

Tolerance on 2D of the tube' 0 mm

Min& 9all thic+ne'' of tube' 0 mm&


25/47

FLEXIBLE HOSES:

The )neumatic ho'e'7 which i' u'ed when pneumatic component'

'uch a' actuator' are 'ub*ected to mo.ement& "o'e i' fabricated in la(er of

Ela'tomer or '(nthetic rubber7 which permit' operation at high pre''ure&

The 'tandard out'ide diameter of tubing i' F? inch& If the ho'e i' 'ub*ected

to rubbing7 it 'hould be enca'ed in a protecti.e 'lee.e&


26/47

ADVANTAGES AND LIMITATIONS

ADVANTAGES:

The )neumatic arm i' more efficient in the technical field

Luic+ re'pon'e i' achie.ed

Simple in con'truction'

Ea'( to maintain and repair

!o't of the unit i' le'' when compared to other robotic'

-o fire ha8ard problem due to o.er loading

!omparati.el( the operation co't i' le''

The operation of arm i' fa'ter becau'e the media to operate i' air

!ontinuou' operation i' po''ible without 'topping.

LIMITATIONS:

"igh torque cannot be obtained&

5oad !arr(ing capacit( of thi' unit i' not .er( high J; C > +gF'G

Silencer ma( be u'ed7 to reduce the noi'e of compre''ed air


27/47

A))5I!ATI2-

! DISCHARGE OF WORKPIECE:

The arm fed ha' wide application in low co't automation& It can be

u'ed in automated a''embl( line' to pic+0up the fini'hed product from

wor+'tation and place them in the bin'& It can al'o be u'ed to pic+0up the

raw material and place them on the con.e(or belt' and .ice .er'a&

"! #OB CLAMPING:

Thi' unit can al'o be u'ed in clamping operation' in certain area' of

ma'' production' where clamping and unclamping ha.e to be done at high'peed'& The application of thi' unit i' limited to operation'7 which in.ol.e'

moderate clamping force'&

$! TRANSFER OF #OBS BETWEEN WORK STATIONS:

The gripping method u'ed in a low co't automation to mo.e the wor+

piece from one wor+'tation to another& The combination of an angular

rotar( motion i' the principle behind thi' method& The gripper hold' the

wor+ rigidl(& The to and fro motion i' achie.ed b( mean' of the actuating

c(linder&


28/47

%! TOOL CHANGING APPLICATION:

9hen the pneumatic arm' are made 'maller in 'i8e the( can be u'ed

in automatic tool changer in !-! turning and drilling machine'7 b(

attaching 'uitable tool holding de.ice to the rotar( c(linder&


29/47

PARE PART AND

A EMBLY DRAING


30/47

ADVANTAGE


31/47

ADVANTAGES

It require' 'imple maintenance care'&

The mo.ing part' of thi' '('tem are cooled b( the oil it'elf u'ed&

Thu' thi' pro*ect doe' not require an( cooling arrangement'&

The 'afet( '('tem for automobile&

!hec+ing and cleaning are ea'( becau'e of the main part' are 'crewed

Ea'( to "andle&


32/47

DI ADVANTAGE


33/47

DI ADVANTAGE

Initial co't i' high

"igh maintenance co't


34/47

APPLICATION


35/47

APPLICATIONS

It i' .er( much u'eful for care 2wner' Auto0garage'& Thi' automatic

gear 'hifting'('tem i' u'ed for 'mooth engagement of gear 'electing for the

.ehicle'&

Thu' it can be u'edful for the following t(pe of .ehicle'&

G MAUT"I

#G AMBASSAD2

;G IAT


36/47

PAINTING AND

!INI HING


37/47

FINISHING AND PAINTING

32B )E)AATI2-

Before welding7 remo.e an( bend in the 5 angle with the 'ludge

hammer on the an.il bloc+& Then it i' cut to the required length with the

hac+'aw blade and fabricated to required dimen'ional 'hape with arc

welding&

I-IS"I-4 2)EATI2- BE2E )AI-TI-4

After welding7 an( 'lag on the welded area i' remo.ed with the

chipping hammer and cleaned with the metal wire bru'h& Then all the

'urface' are rubbed with the emer( 'heet&

Metalprimer i' applied on the 'urface' with the bru'h& After dr(ing the

metal primer7 the 'econd coating i' applied with the paint&


38/47

SA!ETY"CARE ANDMAINTENANCE


39/47

SA!ETY"CARE AND MAINTENANCE

Before 'tarting the operation7 'ome of the point' to be noted for 'afet(

purpo'e7

& Before 'tarting the operation7 chec+ the following item'

JG !hec+ the pre''urecondition for proper operation &

J#G !hec+ the alignment of gear engagele.er in the '('tem

J;G DonNt in'ert the an( material or ob*ect between the during

operation

J


40/47

FEATURES OF THIS PRO#ECT

It can in'talled ea'il(

529 electrical power con'umption

It can be utili8ed

It i' 'imple in con'truction

5ow co't

5e'' weight and ea'( to handle

5ife of '('tem increa'ed

It i' 'imple in operation&&


41/47

CO T E TIMATION


42/47

CO T E TIMATION

&>F# wa( 'olenoid operated D! /al.e ?$$7$$

#& Double acting c(linder #$$&$$

;& /al.e connector' >no' #$$&$$

%$$&$$


43/47

CONCLU ION


44/47

CONCLU ION

9e ma+e thi' pro*ect entirel( different from other pro*ect'& Since

concept' in.ol.ed in our pro*ect i' entirel( different that a 'ingle unit i' u'ed

to .ariou' purpo'e'7 which i' not de.eloped b( an( of other team member'&

B( doing thi' pro*ect we gained the +nowledge of fabrication wor+

and how the welding i' doing and material 'election for particular

component' etc&7

It i' concluded that an( fabrication wor+ can be done with the help of

welding&

9e ha.e 'ucce''full( completed the pro*ect wor+ on u'ing welding

wor+ at our In'titute&

2nce again we e1pre'' our 'incere than+' to our 'taff member'&


45/47

BIBLIOGRAPHY


46/47

BIBLIOGRAPHY

& 92=S"2) TE!"-2524Y 0"A3A !"29DY

#& )2DU!TI2- TE!"-2524Y 0&S& ="UMI

;& MA!"I-E S"2) TE!"-2524Y 0S&S&MA-IA-

&5UID )29E BY 0E&SU-DAM22T"Y


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