Android App Controlled Pneumatic Bench Vice

ANDROID APP CONTROLLED PNEUMATIC BENCH VICE
Department of Mechanical Engineering Page 1
PDA College of Engineering, Kalaburagi
CHAPTER 1
INTRODUCTION
An incredible range of manufacturing systems use the force and power of fluids
such as water, oil and air. Powered clamps open and close with the force of pressurized
air or oil, large presses shape and form metal with hydraulic pressure, and assembly
torque tools fasten components with pressurized air. In each example, fluid power
provides the energy necessary to exert significant mechanical forces. Systems that use air
are called pneumatic systems while systems that use liquids like oil or water are called
hydraulic system. The pneumatic systems will be the subject of the first three sessions in
the course starting from this session. Pneumatics is all about using compressed air to
make a process happens. Compressed air is simply the air we breathe squeezed into a
small space under pressure. You might remember that air under pressure possesses
potential energy which can be released to do useful work. Their principle of operation is
similar to that of the hydraulic power systems. An air compressor converts the mechanical
energy of the prime mover into, mainly, pressure energy of the compressed air. This
transformation facilitates the transmission, storage, and control of energy. After
compression, the compressed air should be prepared for use. A pneumatic system consists
of a group of pneumatic components connected together so that a signal (compressed air)
is passed through the system to make something happen at the output. These groups of
components can be divided into five categories according to their function in the
pneumatic circuit as follows:
1. Supply elements: these elements are the sources of power that drives the system
which are the compressors.
2. Input elements: these elements are used to send signals to the final control elements
and come in two forms; either as components that is actuated by the operator like
push buttons or sensors that determine the status of the power elements such as limit
switches and proximity sensors.
3. Processing elements: these elements may perform operations on the input signals
before sending the signal to the final control elements such as non-return valves,
directional control valves and presser control valves.

4. Final control elements: to control the motion of actuators such as directional control
valves.
5. Power elements (actuators): these are the outputs of the pneumatic system which
use the stored potential energy to perform a certain task such as pneumatic cylinders
and motors.

CHAPTER 2
WORKING PRINCIPLE
 The compressed air from the compressor reaches the solenoid valve. The solenoid
valve changes the direction of flow according to the signals from the control unit.
 The compressed air pass through the solenoid valve and it is admitted into the
front end of the both the pneumatic cylinders. The air pushes the pistons of the
cylinders forward. At the end of the stroke air from the solenoid valve reaches the
rear end of the cylinder block. The pressure remains the same but the area is less
due to the presence of piston rod. This exerts greater pressure on the piston,
pushing it at a faster rate thus enabling faster return stroke.
 By the forward action of the pistons, the vice is moved front and the work piece
that is held in the vice is clamped rigidly. On the other hand, the jack is moved
upwards. The height of the jack is based on the stroke length of the piston.
 When the control unit sends signals to the solenoid valve, the solenoid valve
reverses the flow of the air in the pneumatic cylinder.
 Due to this, the piston of the cylinder moves backwards such that the vice is
released and the jack is lowered.
 Since the two pneumatic cylinders are controlled by a single solenoid valve,
individual controlling of components is impossible in our project

2.1 Block Diagram of the electrical Module

CHAPTER 3
MAIN PNEUMATIC COMPONENTS
Main Component of App Controlled Pneumatic Vice
1. Microcontroller
2. Bluetooth Module
3. Relay
4. Compressor
5. Pressure Regulating component
6. Solenoid operated Direction Control Valve
7. Double Acting Cylinder
8. Bench Vice
9. Pneumatic Pipe
10. Power Supply
11. Step down Transformer
Pneumatic components can be divided into two categories:
1. Components that produce and transport compressed air.
2. Components that consume compressed air.
All main pneumatic components can be represented by simple pneumatic
symbols. Each symbol shows only the function of the component it represents, but not its
structure. Pneumatic symbols can be combined to form pneumatic diagrams. A pneumatic
diagram describes the relations between each pneumatic component, that is, the design of
the system.
(a) Compressor
A compressor can compress air to the required pressures. It can convert the
mechanical energy from motors and engines into the potential energy in compressed air
(Fig. 2). A single central compressor can supply various pneumatic components with
compressed air, which is transported through pipes from the cylinder to the pneumatic
components. Compressors can be divided into two classes: reciprocator and rotary.

(a) Compressor used in laboratories (b) Pneumatic symbol of the air compressor

(b) Pressure regulating component
Pressure regulating components are formed by various components, each of which
has its own pneumatic symbol:
i. Filter – can remove impurities from compressed air before it is fed to the
pneumatic components.
ii. Pressure regulator – to stabilize the pressure and regulate the operation of
pneumatic components
iii. Lubricator – To provide lubrication for pneumatic components.

(c) Pneumatic symbols of the pneumatic components within a pressure regulating
component
The consumption of compressed air Examples of components that consume
compressed air include execution components (cylinders), directional control valves and
assistant valves.
(a) Execution component Pneumatic execution components provide rectilinear or
rotary movement. Examples of pneumatic execution components include cylinder
pistons, pneumatic motors, etc. Rectilinear motion is produced by cylinder
pistons, while pneumatic motors provide continuous rotations. There are many
kinds of cylinders, such as single acting cylinders and double acting cylinders.
(i) Single acting cylinder
Therefore, it can only produce thrust in one direction (Fig. 4). The piston rod is
propelled in the opposite direction by an internal spring, or by the external force provided
by mechanical movement or weight of a load.

(b) Symbol for Single acting Pneumatic Cylinder
The thrust from the piston rod is greatly lowered because it has to overcome the
force from the spring. Therefore, in order to provide the driving force for machines, the
diameter of the cylinder should be increased. In order to match the length of the spring,
the length of the cylinder should also be increased, thus limiting the length of the path.
Single acting cylinders are used in stamping, printing, moving materials, etc.
(ii) Double acting cylinder
In a double acting cylinder, air pressure is applied alternately to the relative
surface of the piston, producing a propelling force and a retracting force (Fig. 6). As the
effective area of the piston is small, the thrust produced during retraction is relatively
weak. The impeccable tubes of double acting cylinders are usually made of steel. The
working surfaces are also polished and coated with chromium to reduce friction.

(b) Pneumatic symbol of a double
Double acting cylinder acting cylinder
(c) Directional control valve
Directional control valves ensure the flow of air between air ports by opening,
closing and switching their internal connections. Their classification is determined by the
number of ports, the number of switching positions, the normal position of the valve and
its method of operation. Common types of directional control valves include 2/2, 3/2, 5/2,
etc. The first number represents the number of ports; the second number represents the
number of positions. A directional control valve that has two ports and five positions can
be represented by the drawing in Fig. 8, as well as its own unique pneumatic symbol.
Describing a 5/2 directional control valve

(i) 2/2 Directional control valve
The structure of a 2/2 directional control valve is very simple. It uses the thrust
from the spring to open and close the valve, stopping compressed air from flowing
towards working tube ‘A’ from air inlet ‘P’. When a force is applied to the control axis,
the valve will be pushed open, connecting ‘P’ with ‘A’ (Fig. 9). The force applied to the
control axis has to overcome both air pressure and the repulsive force of the spring. The
control valve can be driven manually or mechanically, and restored to its original position
by the spring.
The above figure shows the 2/2 DCV Here is the Pneumatic symbol for
the DCV
(ii) 3/2 Directional control valve :
A 3/2 directional control valve can be used to control a single acting cylinder (Fig.
10). The open valves in the middle will close until ‘P’ and ‘A’ are connected together.
Then another valve will open the sealed base between ‘A’ and ‘R’ (exhaust). The valves
can be driven manually, mechanically, electrically or pneumatically. 3/2 directional
control valves can further be divided into two classes: Normally open type (N.O.) and
normally closed type (N.C.) (Fig. 11).

3/2 directional control valve
The Cross Section of the above DCV

(iii) 5/2 Directional control valve
When a pressure pulse is input into the pressure control port ‘P’, the spool will
move to the left, connecting inlet ‘P’ and work passage ‘B’. Work passage ‘A’ will then
make a release of air through ‘R1’ and ‘R2’. The directional valves will remain in this
operational position until signals of the contrary are received. Therefore, this type of
directional control valves is said to have the function of ‘memory’.
(a) Cross section
The above figure is the pneumatic symbol
(b) Control valve:
A control valve is a valve that controls the flow of air. Examples include no return
valves, flow control valves, shuttle valves, etc.
(i) Non-return valve
A non-return valve allows air to flow in one direction only. When air flows in the
opposite direction, the valve will close. Another name for non-return valve is poppet
valve (Fig. 13).

A non-return valve
Pneumatic Symbol of a non – returning valve

(ii) Flow control valve
A flow control valve is formed by a non-return valve and a variable throttle (Fig. 14).
(a) Flow control valve
Cross section of the flow control valve
The Pneumatic symbol for the control valve

Pneumatic Systems Diagram

Relay:
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such as solid-
state relays. Relays are used where it is necessary to control a circuit by a separate low-
power signal we use a relay of 9Volts, as shown below.
A simple electromagnetic relay consists of a coil of wire wrapped around a soft
iron core (a solenoid), an iron yoke which provides a low reluctance path for magnetic
flux, a movable iron armature, and one or more sets of contacts (there are two contacts in
the relay pictured). The armature is hinged to the yoke and mechanically linked to one or
more sets of moving contacts. The armature is held in place by a spring so that when the
relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of
the two sets of contacts in the relay pictured is closed, and the other set is open. Other
relays may have more or fewer sets of contacts depending on their function. The relay in
the picture also has a wire connecting the armature to the yoke. This ensures continuity of
the circuit between the moving contacts on the armature, and the circuit track on
the printed circuit board (PCB) via the yoke, which is soldered to the PCB.
When an electric current is passed through the coil it generates a magnetic
field that activates the armature, and the consequent movement of the movable contact(s)
either makes or breaks (depending upon construction) a connection with a fixed contact.
If the set of contacts was closed when the relay was de-energized, then the movement
opens the contacts and breaks the connection, and vice versa if the contacts were open.

When the current to the coil is switched off, the armature is returned by a force,
approximately half as strong as the magnetic force, to its relaxed position. Usually this
force is provided by a spring, but gravity is also used commonly in industrial motor
starters. Most relays are manufactured to operate quickly. In a low-voltage application
this reduces noise; in a high voltage or current application it reduces arcing.
When the coil is energized with direct current, a diode is often placed across the
coil to dissipate the energy from the collapsing magnetic field at deactivation, which
would otherwise generate a voltage spike dangerous to semiconductor circuit
components. Such diodes were not widely used before the application of transistors as
relay drivers, but soon became ubiquitous as early germanium transistors were easily
destroyed by this surge. Some automotive relays include a diode inside the relay case.
If the relay is driving a large, or especially a reactive load, there may be a similar
problem of surge currents around the relay output contacts. In this case a snubber circuit
(a capacitor and resistor in series) across the contacts may absorb the surge. Suitably rated
capacitors and the associated resistor are sold as a single packaged component for this
commonplace use.
If the coil is designed to be energized with alternating current (AC), some method
is used to split the flux into two out-of-phase components which add together, increasing
the minimum pull on the armature during the AC cycle. Typically this is done with a
small copper "shading ring" crimped around a portion of the core that creates the delayed,
out-of-phase component, which holds the contacts during the zero crossings of the control
voltage.

Pneumatic Pipes:
The Pipes are basically high-pressure pipes which are used to transfer pressurized air.
The technology is still used on a smaller scale. While its use for communicating
information has been superseded, pneumatic tubes are widely used for transporting small
objects, where convenience and speed in a local environment are important.
In the United States, drive-up banks often use pneumatic tubes to transport cash
and documents between cars and tellers. Some U.S. hospitals have a computer-controlled
pneumatic tube system to deliver drugs, documents and specimens to and from
laboratories and nurses' stations. Many factories use them to deliver parts quickly across
large campuses. Many larger stores use systems to securely transport excess cash from
checkout stands to back offices, and to send change back to cashiers. NASA's
original Mission Control Center had pneumatic tubes connecting controller consoles with
staff support rooms. Denver International Airport uses many pneumatic tube systems,
including a 25 cm diameter system for moving aircraft parts to remote concourses, a
10 cm system for United Airlines ticketing, and a robust system in the parking toll
collection system with an outlet at every booth.

Power supply:
A power supply is a component that supplies power to at least one electric load.
Typically, it converts one type of electrical power to another, but it may also convert a a
different form of energy.
The step Down transformer is connected to the main power supply socket and as
the relay needs a continuous DC supply of 12V which can only be supplied through the
battery .
Battery used here is a Lead Acid Battery:
In the discharged state both the positive and negative plates become lead (II)
sulfate (PbSO
4), and the electrolyte loses much of its dissolved sulfuric acid and becomes primarily
water. The discharge process is driven by the conduction of electrons from the negative
plate back into the cell at the positive plate in the external circuit.
The sum of the molecular masses of the reactants is 642.6 g/mol, so theoretically a
cell can produce two faradays of charge (192,971 coulombs) from 642.6 g of reactants, or
83.4 ampere-hours per kilogram (or 13.9 ampere-hours per kilogram for a 12-volt
battery). For a 2 volts cell, this comes to 167 watt-hours per kilogram of reactants, but a
lead–acid cell in practice gives only 30–40 watt-hours per kilogram of battery, due to the
mass of the water and other constituent parts.
Charging:
In the fully charged state, the negative plate consists of lead, and the positive
plate lead dioxide, with the electrolyte of concentrated sulfuric acid.
Overcharging with high charging voltages generates oxygen and hydrogen gas
by electrolysis of water, which is lost to the cell. The design of some types of lead-acid
battery allow the electrolyte level to be inspected and topped up with any water that has
been lost.
Due to the freezing-point depression of the electrolyte, as the battery discharges
and the concentration of sulfuric acid decreases, the electrolyte is more likely to freeze
during winter weather when discharged.

Step Down Transformer:
The transformer is static electrical equipment which transforms electrical energy
(from primary side windings) to the magnetic energy (in transformer magnetic core) and
again to the electrical energy (on these secondary transformer side). The operating
frequency and nominal power are approximately equal on primary and secondary
transformer side because the transformer is a very efficient equipment, while the voltage
and current values are usually different. Essentially, that is the main task of the
transformer, converting high voltage (HV) and low current from the primary side to the
low voltage (LV) and high current on the secondary side and vice versa. Also, a
transformer with its operation principle provides galvanic isolation in the electrical
system. With those features, the transformer is the most important part of the electrical
system and provides economical and reliable transmission and distribution of electrical
energy.
The step down transformer is used to provide this low voltage value which is
suitable for electronics supplying. It transforms home voltage (230/120 V) from primary
to a low voltage on the secondary side which is used for the electronic supplying. If
electronic devices are designed to have higher nominal power, transformers with high
operating frequency are used (kHz-s). The transformers with higher nominal power value
and 50/60 Hz nominal frequency would be too large and heavy. Also, the daily used
battery chargers use the step-down transformer in its design.

The step-down transformers have a very important function in power system.
They lower the voltage level and adapt it for energy consumers. It is performed in several
steps described below:
 A long distance energy transmission system should have voltage level as high as
possible. With high voltage and low current, the transmission power loss
Will be significantly decreased. A power grid is designed that has to be connected
with the transmission system with the different voltage levels. Step-down transformers
are used in interconnection of transmission systems with different voltage level. They
decrease voltage level from high to lower value (e.g. 765/220 kV, 410/220 kV, 220/ 110
kV). These transformers are huge and have very high nominal power (even 1000 MVA).
In this case, when the transformer turns ratio is not high the auto transformers are usually
installed.
 The next voltage level transformation step is adapting transmission voltage to the
distribution level. The characteristic voltage ratios in this case are 220/20 kV,
110/20 kV (also the LV secondary voltages 35 kV and 10 kV can be found). The
nominal power of those transformers is up to 60 MVA (usually 20 MVA). The on-
load tap changer is almost always installed in these transformers. A voltage
regulation is the main function of tap changer. In USA the tap changer is based on
LV side, and in rest of the world mostly on the HV transformer side.
 The final voltage transformation step is adapting the voltage to the home voltage
level
 These transformers are known as small distribution transformers with nominal
power up to 5 MVA (mostly below of 1 MVA) and with nominal voltage values
35, 20, 10 kV on HV side and 400/200 V on LV side. It is noticeable that those
transformers have high turns ratio. They usually have de-energized tap changer
with 5 tap position (+/- 2 tap position) and do not have on load tap changer.

CHAPTER 4
PROCEDURE OF THE PROJECT
Step 1:
We have taken a 10 bar double acting cylinder, which looks like this, one end it is
screwed with a flat plate which acts as movable jaw.
Step 2:
This cylinder which has a plate screwed to the rod is fixed on a small table:

Step 3:
Electronic components:
Microcontroller:
A microcontroller is a compact integrated circuit designed to govern a specific
operation in an embedded system. A typical microcontroller includes a processor,
memory and input/output (I/O) peripherals on a single chip. We use 8051 Microcontroller
unit.
Technically called as Intel MCS-51 Architecture, the 8051 microcontroller series
was developed by Intel in the year 1980 and were very popular in the 80’s (still are
popular).
8051 Microcontroller has many features like Serial Communication, Timers,
Interrupts, etc. and hence many students and beginners start their work on the concept of
Microcontrollers with 8051 Microcontroller (although this trend seems to be changed
with the introduction of Arduino).

Even though 8051 Microcontroller might seem a little bit out of fashion, we feel
that it is one of the best platforms to get started with Microcontrollers, Embedded
Systems and Programming (both C and Assembly).
So, in this post, you’ll be given an introduction to 8051 microcontroller and some
of the basics of 8051 Microcontroller.
But before going in to the Introduction and Basics of 8051 Microcontroller, we
need to a little bit about what a Microcontroller is and Difference between
Microprocessor and Microcontroller.

What is a Microcontroller?
A Microcontroller is a VLSI IC that contains a CPU (Processor) along with some
other peripherals like Memory (RAM and ROM), I/O Ports, Timers/Counters,
Communication Interface, ADC, etc.
On the contrary, a Microprocessor (which was developed before Microcontroller)
is just a Processor (CPU) and doesn’t have the above mentioned peripherals. In order to
make it work or build a system around it, we need to interface the peripherals separately.

Until the development of Microcontrollers, almost all process and control tasks
were implemented using Microprocessors. As Microprocessor need the additional
peripherals to work as a system, the overall cost of the control system was high.
But with the development of Microcontroller, the situation has changed
completely including the world of Embedded Systems.
Applications of 8051 Microcontroller
Even with the development of many advanced and superior Microcontrollers,
8051 Microcontroller is still being used in many embedded system and applications.
Some of the applications of 8051 Microcontroller are mentioned below:
 Consumer Appliances (TV Tuners, Remote controls, Computers, Sewing
Machines, etc.)
 Home Applications (TVs, VCR, Video Games, Camcorder, Music Instruments,
Home Security Systems, Garage Door Openers, etc.)
 Communication Systems (Mobile Phones, Intercoms, Answering Machines, Paging
Devices, etc.)
 Office (Fax Machines, Printers, Copiers, Laser Printers, etc.)
 Automobiles (Air Bags, ABS, Engine Control, Transmission Control, Temperature
Control, Keyless Entry, etc)
 Aeronautical and Space
 Medical Equipment
 Defense Systems
 Robotics

Bluetooth Module:
HC‐05 module is an easy to use Bluetooth SPP (Serial Port Protocol) module,
designed for transparent wireless serial connection setup. The HC-05 Bluetooth Module
can be used in a Master or Slave configuration, making it a great solution for wireless
communication. This serial port Bluetooth module is fully qualified Bluetooth V2.0+EDR
(Enhanced Data Rate) 3Mbps Modulation with complete 2.4GHz radio transceiver and
baseband. It uses CSR Blue core 04‐External single chip Bluetooth system with CMOS
technology and with AFH (Adaptive Frequency Hopping Feature).
Hardware Features
 Typical ‐80dBm sensitivity.
 Up to +4dBm RF transmit power.
 3.3 to 5 V I/O.
 PIO (Programmable Input/Output) control.
 UART interface with programmable baud rate.
 With integrated antenna.
 With edge connector.
Program for HC-05 Bluetooth Module:
The program given below is the HC-05 Bluetooth module program. This process
is quite different from others since we are going to use android mobile to control and
communicate with Arduino. Here the Bluetooth module acts as an interface between our
mobile and Arduino board. Before getting into the execution process, follow the given
procedure:

 First of all, the user should install an application called BLUETOOTH SSP PRO from
the play store which is a free application.
 After installation, pair the Bluetooth module to your mobile as like connecting one
device to other using Bluetooth. The default pairing code is 1234.
 Upload the given program to the Arduino Uno board. After uploading the code,
unplug the USB from the Arduino.
 Now use external power adapter to power the Uno board.
 The Bluetooth SPP PRO has three types of communication mode. Here Byte stream
mode is used to communicate. So select that mode and give the input as 1, as soon as
the input has given the led will turn on and for 0 led will turn off.
The above shown is the procedure to connect an android phone to the Bluetooth Arduino.

CHAPTER 5
ADVANTAGE OF PNEUMATIC VICE
 Quick operation.
 Stable and rigid design.
 Extremely high clamping force.
 High accuracy and repeatability.
 Reduces production costs.
 Design is compact and very simple to operate requiring almost no maintenance.
 Can be mounted horizontally or vertically.
The Advantages of Pneumatic Systems
Pneumatic control systems are widely used in our society, especially in the
industrial sectors for the driving of automatic machines. Pneumatic systems have a lot of
advantages.
 High effectiveness
Many factors have equipped their production lines with compressed air supplies
and movable compressors. There is an unlimited supply of air in our atmosphere to
produce compressed air. Moreover, the use of compressed air is not restricted by distance,
as it can easily be transported through pipes. After use, compressed air can be released
directly into the atmosphere without the need of processing.
 High durability and reliability
Pneumatic components are extremely durable and cannot be damaged easily.
Compared to electromotive components, pneumatic components are more durable and
reliable.
 Simple design
The designs of pneumatic components are relatively simple. They are thus more
suitable for use in simple automatic control systems.

 High adaptability to harsh environment
Compared to the elements of other systems, compressed air is less affected by
high Temperature, dust, corrosion, etc.
 Safety
Pneumatic systems are safer than electromotive systems because they can work in
inflammable environment without causing fire or explosion. Apart from that, overloading
in pneumatic system will only lead to sliding or cessation of operation. Unlike
electromotive components, pneumatic components do not burn or get overheated when
overloaded.
 Easy selection of speed and pressure
The speeds of rectilinear and oscillating movement of pneumatic systems are easy
to adjust and subject to few limitations. The pressure and the volume of air can easily be
adjusted by a pressure regulator.
 Environmental friendly
Environmental friendly the operation of pneumatic systems does not produce
pollutants. The air released is also processed in special ways. Therefore, pneumatic
systems can work in environments that demand high level of cleanliness. One example is
the production lines of integrated circuits.
 Economical
As pneumatic components are not expensive, the costs of pneumatic systems are
quite low. Moreover, as pneumatic systems are very durable, the cost of repair is
significantly lower than that of other systems.

Disadvantage of Pneumatic Systems
Although pneumatic systems possess a lot of advantages, they are also subject to
many limitations.
 Relatively low accuracy As pneumatic systems are powered by the force provided
by compressed air, their operation is subject to the volume of the compressed air.
As the volume of air may change when compressed or heated, the supply of air to
the system may not be accurate, causing a decrease in the overall accuracy of the
system.
 Low loading As the cylinders of pneumatic components are not very large, a
pneumatic system cannot drive loads that are too heavy.
 Processing required before use Compressed air must be processed before use to
ensure the absence of water vapour or dust. Otherwise, the moving parts of the
pneumatic components may wear out quickly due to friction.
 Uneven moving speed As air can easily be compressed, the moving speeds of the
pistons are relatively uneven.
 Noise will be produced when compressed air is released from the pneumatic
components.

CHAPTER 6
THE APPLICATION OF PNEUMATIC SYSTEMS
The application of pneumatic systems is very extensive. The following are some
examples.
(a) Transport system:
Figure shows a simplified industrial transport system. When the button switch is
pushed, the cylinder will push one of the goods from the shelf onto the transfer belt.
When the button switch is released, the cylinder will retract automatically. Fig. 34b shows
the circuit diagram of the transport system.
(a) Operation of a pneumatic transport system
(b) Pneumatic circuit diagram of a pneumatic transport system

(b) Vehicle door operation system
Pneumatic systems can be used to operate the doors of public vehicles. Assuming
that the opening and closing of the doors are controlled by two button switches ON and
OFF. When the button switch ON is pressed, the doors will open. When the button switch
OFF is pushed, the doors will close. Figure shows a pneumatic system that can be used to
operate the doors of vehicles.
(a) Operation of a pneumatic system that
(b) Pneumatic circuit diagram controls the movement of vehicle doors.

CHAPTER 7
SAFETY MEASURES WHEN USING PNEUMATIC
CONTROL SYSTEMS
1. Compressed air can cause serious damage to the human body if they enter the
body through ducts like the oral cavity or ears.
2. Never spray compressed air onto anyone.
3. Under high temperature, compressed air can pass through human skin.
4. Compressed air released from the exhaust contains particles and oil droplets,
which can cause damage to eyes.
5. Even though the pressure of compressed air in pipes and reservoirs is relatively
low, when the container loses its entirety, fierce explosions may still occur.
6. Before switching on a compressed air supply unit, one should thoroughly inspect
the whole circuit to see if there are any loose parts, abnormal pressure or damaged
pipes.
7. A loose pipe may shake violently due to the high pressure built up inside it.
Therefore, each time before the system pressure is increased, thorough inspection
of the entire circuit is required to prevent accidents.
8. As the force produced by pneumatic cylinders is relatively large, and the action is
usually very fast, you may suffer serious injuries if you get hit by a cylinder.
9. Switches should be installed on the compressed air supply unit to allow easy and
speedy control of air flow.
10. In case of a leakage, the compressed air supply unit should be turned off
immediately.
11. The compressed air supply unit must be turned off before changes can be made to
the system.
12. Stay clear of the moving parts of the system. Never try to move the driving parts
in the mechanical operation valve with your hand.

CHAPTER 8
CALCULATION

 COSTING
• There are three elements of any products are:
Material (2) Labor (3) Expenses
 Material:
• Direct material:
Material which is processed for final product but it is a part of the product is direct
material cost is this material is called direct from market.
• In – direct material:
Material which does not forms part of the final product but it is a must be for processing
direct material is called in-direct material e.g. – Cotton waste, oil, etc.
 Labor:
• Direct labor:
The worker who actually performed the work on the directly material rather mechanically
of by machine is called direct labor.
• In-direct labor: It supervised the activity of the direct labor.
 Expenses:
• Direct Expenses:
The expenses, which can be directly changed on the particular product, are called
expenses.
• In – Direct Expenses:
The expenses that cannot be directly or confidently changed on particular products are
called in-direct expenses.

CHAPTER 9
COST ESTIMATION
Sl. No. Name Of the Component Cost
1. Metallic Frame 800/-
2. Pneumatic Cylinder 2000/-
3. Pneumatic Inlet Port Manifold 500/-
4. Pneumatic Pipes 300/-
5. Battery 900/-
6. Battery connector 250/-
7. Bluetooth Module 480/-
8. Step Down Transformer 350/-
9. 8051 Microcontroller 400/-
10. Power supply Board with capacitors 100/-
11. Wiring 180/-
12. 5/2 Direction control valve 1,091/-
13. Led Indicators 180/-
14. Relay for 8051 MCU 100/-
15. Other (Welding , Painting ) 500/-

CONCLUSION
The project thus gives a system that can easily fix the workpiece & work on it.
The pneumatic vice provides extremely high clamping force & High accuracy and
repeatability. Pneumatic system can get high production rate. The operation of pneumatic
systems does not produce pollutants.
In addition to the pneumatic system this android app which works on Bluetooth
basis helps to operate the vice in long range distance also.
After studying this report we have known that how the pneumatic bench vice will
work, and knowing the construction and how the mechanism works. We learnt how the
theoretical design is possible in practical. Other bench vice require operator to manually
perform the process but this proposed arrangement does it automatically, this bench vice
has lighter weight compared to other vices. The cost of bench vice is less and easy to
operate so it is affordable for all industries and institutions.

REFERENCES
[1] “Pneumatic system” by S.R. Mujumdar
[2] “Fluid Power with Applications” by Anthony Esposito
[3] “Microcontroller 8051” by Mazidi
[4] Bentzley, Craig (2011). "Installing a Bench Vise"
[5] Haan, E. R. (October 1954), "Selecting and using a bench vise", Popular
Mechanics, 102 (4): 233–235, ISSN 0032-4558.
[6] http://www.reliableplant.com/Read/1625/tool-misuse
[7] http://www.homedepot.com/catalog/pdfImages/85/85db41ac-3902-450b-b875-
d0a1ebff68a9.pdf

Android App Controlled Pneumatic Bench Vice

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