FINAL-TERM ASSESMENT

MECHATRONICS

Written by

AYU MONICA D. D. S.

003201400003

PRESIDENT UNIVERSITY

2017
 Table of Contents

ABSTRACT ....................................................................................................................... 3
CHAPTER I INTRODUCTION ...................................................................................... 4
I.1. Background ......................................................................................................... 4
I.2. Objectives ............................................................................................................ 6
I.3. Problem Limitation ............................................................................................. 6
CHAPTER II STUDY LITERATURE ........................................................................... 7
II.1. Automation[1] ....................................................................................................... 7
II.2. Drilling[2] ............................................................................................................. 7
II.3. Chamfering[4] ....................................................................................................... 7
II.4. Pneumatic[6] ......................................................................................................... 8
II.5. FESTO FluidSIM 4 Pneumatics[8] ....................................................................... 9
II.6. Pneumatic Components[9] .................................................................................. 10
CHAPTER III DISCUSSION ........................................................................................ 17
CHAPTER IV CLOSING .............................................................................................. 24
REFERENCES ................................................................................................................ 25

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 ABSTRACT

With the increase in automation and use of computer control in machine tools, the
number of cutting tools per machining setup is on the increase. On one hand, such
multi-tool setups offer the advantages of reduced down-time and cost of
production and require less space and in-process inventory.

This paper discuss about making simulation of pneumatic automation of drilling

and chamfering. The simulation is done on FESTO FluidSIM 4 Pneumatics and
limited only for electric routing excluding cost efficiency and time efficiency
consideration.

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 CHAPTER I
INTRODUCTION

I.1. Background
With the technology and automation available to us today, the
opportunities to share information are unlimited. The industry realizes that
and is working together to figure out how to communicate electronically
with each other.
Industrial instrumentation and controls has always been a hotbed of
new products – improved sensors, amplifiers, displays, recorders, control
elements, valves, actuators and other widgets and gismos.
Automation or automatic control, is the use of various control
systems for operating equipment such as machinery, processes in factories,
boilers and heat treating ovens, switching in telephone networks, steering
and stabilization of ships, aircraft and other applications with minimal or
reduced human intervention. Some processes have been completely
automated. Automation has been achieved by various means including
mechanical, hydraulic, pneumatic, electrical, electronics and computers,
usually in combination.
Industrial automation in manufacturing is the use of “intelligent
machines in factories so that manufacturing processes can be carried out
with minimal human intervention. It involves the application of various
control systems to enable operating equipment to carry out on their own,
with little human intervention, tasks that require speed, endurance and
precision.
Industrial automation can be achieved by several different means,
including mechanical, electrical, electronic, hydraulic, pneumatic, and
computers. Usually, two or more of these means are used in combination.
The main benefits of manufacturing automation include leaner
operation processes that require less energy, less material, and reduced
labor waste. These can lead to improvements in quality, accuracy, and

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precision. The downsides include high costs of R&D and installation of
equipment.
Manufacturing has come a long way since its beginning, thanks to
automation. Automation is a complete range of products containing
examples of all of the common components used by pneumatics and
automation engineers in real industrial environments.
Students learn how each component operates, and how they can be
connected together to produce both manually operated and fully automated
pneumatic systems.
Automatics also integrates electrical components and even a USB
programmable microcontroller, so that students will gain familiarity with
the most modern of software controlled systems.
The technique of using gases for power transmission is called
pneumatics. The most used fluid in pneumatic systems is air. Pneumatic
systems to convert the existing conventional drilling machines into
automated drilling machines. The automation process involves various
pneumatic devices, pneumatic systems and also some electrical and
electronic devices.
The automation range contains examples of many commonly used
type of pneumatic and automation components such as:
 Cylinders – turn air pressure into motion.
 Mechanical valves – for user input or detecting the position
of the cylinders.
 Solenoid valves – route the air supply under electrical
control.
 Sensors and switches – provide feedback on the system’s
current state.
 Reservoir – to create time delays.
 Manifold – to distribute the air supply.
 Controllers – to add programmable control to pneumatic
circuits.

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 There are some applications that provide pneumatic circuit simulations
such as FESTO FluidSIM 4, Matrix, Easy5 and etc.

I.2. Objectives
This paper is written for some purposes such as:
 Learning to understand automatic pneumatic circuit in FESTO
FluidSIM 4 Pneumatics.
 Understand the application of latching.
 Arranging automation system of drilling and chamfer machining.

I.3. Problem Limitation

This paper’s discussion is limited to some topics, there are:
 Vice is already available.
 This discussion does not discuss about cost efficient.
 This discussion does not discuss about time efficient.
 The discussion does not cover about electricity routing.
 This paper only limits to automation system of drilling and
chamfering with raw data as written.
 The simulation is done on FESTO FluidSIM 4 Pneumatics.

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 CHAPTER II
STUDY LITERATURE

II.1. Automation[1]
Automation (industrial automation) is the use of control systems,
such as computers or robots, and information technologies for handling
different processes and machineries in an industry to replace a human
being. It is the second step beyond mechanization in the scope of
industrialization.

II.2. Drilling[2]
Drilling is the process of producing round holes in a solid material or
enlarging existing holes with the use of multi-tooth cutting tools called
drills or drill bits. There are various type of cutting tools available for
drilling, but the most common is the twist drill. The spindle speed is
constant for any one operation, while the cutting speed varies all along the
cutting edge.

Figure 2.1. Automatic Drilling.[3]

II.3. Chamfering[4]
Chamfering is the operation of beveling the extreme end of a
workpiece. This is done to remove the burrs, to protect the end of the
workpiece from being damaged and to have a better look. The operation

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 may be performed after knurling, rough turning, boring, and drilling.
Chamfering is an essential operation before thread cutting so that the nut
may pass freely on the threaded workpiece.

Figure 2.2. Automated chamfer.[5]

II.4. Pneumatic[6]
Pneumatic transmits power using a gas instead of a liquid.
Compressed air is usually used, but nitrogen or other inert gases can be
used for special applications. With pneumatics, air is usually pumped into
a receiver using a compressor. The receiver holds a large volume of
compressed air to be used by the pneumatic system as needed.
Atmospheric air contains airborne dirt, water vapor, and other
contaminants, so filters and air dryers are often used in pneumatic systems
to keep compressed air clean and dry, which improve reliability and
service life of the components and system. Pneumatic systems also use a
variety of valves for controlling direction, pressure, and speed of actuators.
Most pneumatic systems operate at pressures of about 100 psi or less.
Because of the lower pressure, cylinders and other actuators must be sized
larger than their hydraulic counterparts to apply an equivalent force. For
example, a hydraulic cylinder with a 2 in. diameter piston (3.14 sq. in.
area) and fluid pressure of 1,000 psi can push with 3140 lbs. of force. A
pneumatic cylinder using 100 psi air would need a bore of almost 6½ in.
(33 sq. in.) to develop the same force.
Pneumatic systems usually operate at much lower pressure than
hydraulic systems do.

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 Figure 2.3. Pneumatic system.[7]

II.5. FESTO FluidSIM 4 Pneumatics[8]

FESTO FluidSIM 4 Pneumatics is a teaching tool for simulating
pneumatics basics and runs using Microsoft Windows. FluidSIM supports
learning, educating, and visualizing pneumatic knowledge. Pneumatic
components are explained with textual descriptions, figure, and animations
that illustrate underlying working principles; exercises and educational
films mediate knowledge about both important circuits and the usage of
pneumatic components.

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 Figure 2.4. FESTO FluidSIM 4.

II.6. Pneumatic Components[9]

Here below the list of components used in pneumatic circuit for drilling
and chamfer machining.
 Compressor
Compressor provides the necessary compressed air. The pressure is
restricted to the preset operating pressure.

Figure 2.5. Compressor.

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 Double Acting Cylinder
Double acting cylinder (DAC) is the piston rod 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.

Figure 2.6. Double acting cylinder.

Figure 2.7. DAC icon in FluidSIM.

 Air Motor
Air motor is motor that transforms pneumatic energy into mechanical
energy.

Figure 2.8. Air motor icon in FluidSIM.

 The Semi-Rotary Actuator

The semi-rotary actuator is controlled by a reciprocal input of compressed
air. In the end positions the semi-rotary actuator can activate switches or
valves via labels.

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 Figure 2.9. Semi-rotary actuator.

Figure 2.10. Semi-rotary actuator icon in FluidSIM.

 Time Delay
Time delay is made up of a pneumatically operated 3/2-way valve, a one-
way flow control valve, and small air accumulator. When the necessary
pressure is reached at the control connection 12 of the unit, the 3/2-way
valve switches and the flow passes freely from 1 to 2.

Formatted: Indent: Left: 0.5"

Figure 2.11. Time delay. Formatted: Centered, Indent: Left: 0.5"

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 Formatted: Indent: Left: 0.5"

Figure 2.12. Time delay icon in FluidSIM. Formatted: Centered, Indent: Left: 0.5"

 Pressure Sequence Valve

Pressure sequence valve is valve when operated need to move spring
inside to let air flows with certain pressure as designed spring required
pressure. This valve will operate if connection 12 has been reached. The
flow passes freely from 1 to 2. Removing the signal allows the valve to
return to is starting position through the use of a return spring. Connection
1 will be shut. The pressure of the control signal is infinitely adjustable via
a pressure setting screw.

Formatted: Indent: Left: 0.5"

Figure 2.13. Pressure sequence. Formatted: Centered, Indent: Left: 0.5"

Formatted: Indent: Left: 0.5"

Figure 2.14. Pressure sequence icon in FluidSIM. Formatted: Centered, Indent: Left: 0.5"

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 3/2-Way Valve with Pushbutton (Normally Closed)
3/2-way valve with pushbutton (normally closed) is valve operated with
pushbutton. The flow passes freely from 1 to 2. Releasing the pushbutton
allows the valve to return its starting position through the use of a return
spring. Connection 1 will be shut.

Formatted: Indent: Left: 0.5"

Figure 2.15. 3/2-way valve with pushbutton (normally closed). Formatted: Centered, Indent: Left: 0.5"

Formatted: Indent: Left: 0.5"

Figure 2.16. 3/2-way valve with pushbutton (normally closed) icon in Formatted: Centered, Indent: Left: 0.5"

FluidSIM.

 3/2-Way Roller Lever Valve (Normally Closed)

3/2-way roller lever valve (normally closed) is valve operated with roller
by pressing on the lever, for example through the use of a switching cam
of a cylinder. The flow passes through from 1 to 2. After releasing the
lever, the valve returns to its initial position through the use of a return
spring. Connection 1 will be shut.

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 Formatted: Indent: Left: 0.5"

Figure 2.17. 3/2-way roller lever valve (normally closed). Formatted: Centered, Indent: Left: 0.5"

Formatted: Indent: Left: 0.5"

Figure 2.18. 3/2-way roller lever valve (normally closed) icon in Formatted: Centered, Indent: Left: 0.5"

FluidSIM.

 5/2-Way Impulsive Valve (Pneumatically Operated)

5/2-way impulsive valve (pneumatically operated) is valve controlled by
applying reciprocal pilot pressures at connection 14 (flow passes from 1 to
4) and connection 12 (flow passes from 1 to 2). The valve’s operating
position remains until an opposite signal is received by the valve.

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 Figure 2.19. 5/2-way impulsive valve (pneumatically operated).

Figure 2.20. 5/2-way impulsive valve (pneumatically operated) icon in

FluidSIM.

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 CHAPTER III
DISCUSSION

The block diagram of drilling and chamfer machining is shown in Figure 3.1.

Figure 3.1. Block diagram of drilling and chamfer machining.

Notes:
A : Vice cylinder
B : Drilling cylinder
C : Chamfer cylinder
D : Semi-rotary actuator
WP : Workpiece
The schematic step diagram is shown in Figure 3.2.

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 Figure 3.2. Schematic step diagram.

In this system, before starting the machining, A must move to the left to hold
workpiece. After some time, then the machining process will be started soon after
A finish its position. The B motor will be turned on, and start to move down and
drill the workpiece. After finishing drilling, B must go up and motor B is turned
off. Then, we move to chamfer as motor D is activated to change from drilling
tool become chamfer tool. As the cutting tool is changed, then motor C will be
turned on and move down to cut chamfer on workpiece. As chamfer is done, then
C will go up and motor C is turned down. Then motor D is once again activated to
change to drilling tool as its initial position. Then A will be back to its position.
This is the end of machining process.

Component part list:

Item Qty Component

1. 3 Double acting cylinder
2. 3 Manometer
3. 3 One-way flow control valve
4. 6 5/2-way valve, pneumatically operated
5. 2 3/2-way valve, pneumatically operated
6. 6 3/2-way valve, mechanically roller operated,
spring returned
7. 1 3/2-way valve, pushbutton, spring returned

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 8. 8 Time delay
9. 1 Pressure sequence valve
10. 2 Air motor
11. 1 Semi rotary actuator
12. 5(*) Compressor
( )
Note: * Can be reduced to 1 compressor, but only for better visualization in circuit we use 5
compressors.

Table 1. Part list with quantity.

Methodology of steps in system:

No. Step Equipment

1. Putting workpiece in the vice Vice
manually
2. Clamping the workpiece DAC 1, 3/2 DCV NC, flow control at inlet,
pressure sequence S1 & S2, manometer
3. Drilling pneumatic motor is running Sensor (S2 and PS1) from clamping
process, air motor
4. Drilling moves downward to DAC 2, flow control at outlet, S3 and S4
workpiece
5. Drilling at max position then moves Sensor max at DAC 2 (S4), time delay
upward
6. Drilling at min or ori position then Sensor min at DAC 2 (S3), time delay
pneumatic motor stop
7. Drilling part moves from drilling to Semi motor and time delay
chamfer
8. Chamfering pneumatic motor is Time delay, air motor
running
9. Chamfering moves downward to Time delay, DAC 3, flow control at outlet,
workpiece S5 & S6
10. After chamfer reach max stroke Sensor max at DAC 3 (S6)
then move upward
11. Chamfering at min stroke then Sensor min at DAX 3 (S5), time delay
pneumatic motor stop
12. Chamfer change place with drilling Time delay, semi motor
13. Vice goes back to min or ori Time delay
position

Table 2. Steps with each equipment.

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The pneumatic circuit is shown in Figure 3.3. How the system works:
1) When the valve button is pushed, air will flow through S1 valve as S1 is the
minimum stroke of cylinder A and this is initial condition where cylinder A
hits S1 and the air will push the first 5/2 valve (A). Thus air will flow through
Line A.
2) From Line A, the air will push 5/2 valve (C) to allow air from compressor
enter cylinder A. Inlet of cylinder A is equipped with one-way flow control
valve which makes the cylinder A moves slowly with constant pressure
contained. Cylinder A reaches S2 which is at 100 mm (CYLINDER A+)
3) As cylinder A stroke reaches the maximum pressure at 5 bar, then the air
from Line A will flow through pressure sequence valve (PS1) as connection 1
is connected to Line A and connection 12 is connected to inlet air pneumatic
line of Cylinder A.
4) Then from PS1, air will flow through S2 valve (S2 valve is opened as
Cylinder A reach S2). The air will flow to actuate air motor (MB+) through
3/2 valve (E) and also will open 5/2 valve before air flow to cylinder (D).
Then go through time delay (TD1) with opening level of 3% and the air will
open connection 4 to let air flow through. The air from compressor will flow
through 5/2 valve and enters cylinder B. Cylinder B will move slowly as the
outlet is equipped with one-way flow control valve and the stroke will reach
320 mm (CYLINDER B+).
5) Before Cylinder B goes back to minimal position, as it reaches S4, then valve
S4 will operate and actuate and the air from main compressor will move to
Line B as the valve actuate 5/2 valve (A) to move air to connection 2 and 5/2
valve (B) to let air flow through connection 4.
6) Then the air will flow through time delay (TD2) with opening level of 4%.
This time delay is to help drilling to stay for a while on workpiece for the
chips would stay away from drill way. Then drilling will go back to its
position after air flow through connection 2 of TD2 and direct 5/2 valve (D)
to flow air through connection 2 (Cylinder B-).

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7) As cylinder B reaching its minimum stroke, S3, then S3 valve is opened and
air from Line B will flow through S3 valve and go to close pneumatically 3/2
valve (E) to shut down motor B (MB-). Air through S3 valve also will flow to
time delay valve (TD3) with opening level of 2% and will actuate to 5/2 valve
(F) and actuate motor D (MD+).
8) At the same time, air also flow going to time delay (TD4) opening level of
5%, this allows to give time delay after motor D is actuated and then motor C
will actuate 3/2 valve (G) thus air from compressor will go to Cylinder C
(MC+). At the same time, air flow going to time delay (TD5) with opening
level of 6% and will actuate 5/2 valve (H) and let air from compressor to go
to Cylinder C. As the air slowly enters cylinder C from compressor as we also
set one-way flow control valve on the outlet of cylinder C, the cylinder C
slowly reach its maximum stroke, S6, which is 202 mm (C+).
9) As cylinder C reaches S6, then S6 valve is opened. As S6 valve is opened, it
allows air from line B flow through and actuate 5/2 valve (B) and thus the air
from the main compressor flow through the outlet 2 to Line C.
10) As the air flow through Line C, then the air will go to time delay (TD7) with
opening level of 5% and will actuate 5/2 valve (H). This is to change the
direction of air from compressor to the outlet 2 and cause cylinder C to be
back (C-) reaching its minimum stroke (S5).
11) As cylinder C reaches its minimum stroke, S5, then S5 valve will be opened
and let the air from Line C to flow through. The air will direct 3/2 valve
before motor C (G) to block air from compressor to actuate motor C (MC-).
After that, the air also flow through the same line going time delay (TD6)
with opening level of 5% and actuate 5/2 valve (F) to actuate motor D
become its initial position to change chamfer to drilling (MD-).
12) As we set time-delay valve on cylinder A area (TD8) with opening level of
2%, as the air flow through Line C, then the air will flow through time-delay
valve and actuate 5/2 valve (C) to allow air flow from compressor to cylinder
A and it will move to its minimum stroke, S1 (A-). Therefore S1 valve will be
opened. This cycle will be repeated as the pushbutton is pressed.

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Notes: Any opening level of one-way flow control valve and time delay valve can
be configured in any level suitable to system requirements.

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Figure 3.3. Pneumatic circuit for drilling and chamfer machining

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 CHAPTER IV
CONCLUSION

The manual controlled machine is controlled into automatic machine by

using various pneumatic devices as discussed in the paper.

Since this paper does not concern about time efficiency, thus there is no
information about the process time. For any time delay valve, we can set the
opening level according to required and based on system required so that the
processing time would have fitted and efficient. The amount of time delay valve
as represented in this paper is the minimal required amount. The amount of
compressor as represented is 5 compressors, but actually the compressor amount
can be reduced to 1 compressor, it is for good visualization so the pneumatic lines
are not interfered.

By utilizing automatic machining, it would reduce cost for operators and

operating time is saved to a greater extent. The automatic drilling and chamfer
machining by pneumatic power utilization, would be advantageous more than
manually operated drilling and chamfer machining.

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2017 http://www.surecontrols.com/what-is-industrial-automation/
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http://www.americanmachinist.com/machining-cutting/cutting-tool-applications-
chapter-8-drills-and-drilling-operations
3. Restosan RM 30 NC – Automatic Drilling Machine – Cited on 19 November
2017 http://retosan.com/en/portfolio-item/rm-30-nc-invertorlu-matkap-tezgahi/
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machine-operations-chamfering-parting-off/
5. Production Machining – Cited on 19 November 2017
https://www.productionmachining.com/products/fully-automated-chamfering-
machine
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November 2017 http://www.nfpa.com/fluidpower/whatispneumatics.aspx
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