This document describes an automatic pneumatic controlled door and closing system using a programmable logic controller (PLC). A group of six students submitted the project to fulfill their diploma requirements. The system uses a double acting cylinder and 5/2 way solenoid valve controlled by an infrared sensor to automatically open and close a door. When an object is detected by the infrared sensor, it activates the solenoid valve which operates the cylinder to open the door.

1. B.E.PROJECTS
CONTACT 9444863248
chock1963@gmail.com

2. AUTOMATIC PNEUMATIC CONTROLLED DOOR AND
CLOSING SYSTEM USING PLC

3. AUTOMATIC PNEUMATIC CONTROLLED DOOR AND
CLOSING SYSTEM USING PLC
Submitted in the partial fulfillment of the requirement for the award of
“DIPLOMA IN MECHANCIAL ENGINEERING (MTMR)”
SUBMITTED BY:
1. A.MANIKANDAN 4. S.NANDAKUMAR
2. M.ARUNKUMAR 5.S.RAMESH KUMAR
3. N.JEEVAKUMAR 6. S.MUTHUKUMAR
Under guidance of
Mr. A.CHOCKALINGAM, M.E.,
OCTOBER 2014.
DEPARTMENT OF MECHANICAL ENGINEERING (MTMR)
A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

4. CHEM BARAMBAKKAM, CHENNAI – 602 103
A M K TECHNOLOGICAL POLYTECHNIC COLLEGE
CHEM BARAMBAKKAM, CHENNAI – 602 103
BONAFIDE CERTIFICATE
This is to certify that this Project work on
“ AUTOMATIC PNEUMATIC CONTROLLED DOOR
AND CLOSING SYSTEM USING PLC ”
submitted by …………………… ……………. Reg. No. ……………
in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING (MTMR)
This is the bonafide record of work carried out by him under our supervision
during the year 2014
Submitted for the Viva-voce exam held on ……………..
H.O.D PROJECT GUIDE

5. INTERNAL EXAMINER EXTERNAL EXAMINER
ACKNOWLEDGEMENT

6. ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the
Principal Mr.A. VIJAY KISHORE, M.TECH., MISTE.., encouragement
and valuable advice.
we thank our Esquired Head of Department Mr R. RAJKUMAR,
A.M.I.E, M.E., for presenting his felicitations on us.
We are grateful on our Entourages Mr. A.CHOCKALINGAM,
M.E., for guiding in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the
Mechanical Engineering (MTMR) Department.
Ultimately, we extend our thanks to all who had rendered their co-operation
for the success of the project.

7. CONTENTS

8. CONTENTS
Chapter No. TITLE
1. SYNOPSIS
2. CONSTRUCTION
3. WORKING PRINCIPLE
4. MECHANICAL ASSEMBLY DIAGRAM
5. PNEUMATIC CIRCUIT DIAGRAM
6. INTRODUCTION TO PLC
7. PNEUMATIC COMPONENT DETAILS
8. FINISHING AND PAINTING
9. COST ESTIMATION
10. CONCLUSION
11. BIBLIOGRAPHY
12. PHOTO VIEW

9. SYNOPSIS

10. SYNOPSIS
To increase the productivity and to overcome skilled labour shortage,
most of the manufacturing industries are going for automation. The main
aim for us to select this project work is to acquire practical knowledge in the
field of automation using Pneumatic system.
We selected “AUTOMATIC DOOR OPENING AND CLOSING USING
PENUMATIC SYSTEM USING PLC ” as our project work and the gate is
automatically opened by the double acting cylinder which is actuated
through the 5/2 way double solenoid directional control valve . The solenoid
valve is actuated by the INFRA RED SENSOR which is placed in front of
the gate.
The IR sensor has one IR transmitter and one IR receiver .when any
object crosses between these two sensor ,the solenoid valve is actuated and
hence the gate opened automatically.

11. CONSTRUCTIO
N

12. CONSTRUCTION
The construction of this project is shown in fig.

13. AUTOMATIC GATE OPENING SYSTEM
CABIN
DOUDLE ACTING CYLINDER
DOOR
BASE
IR TRANSMITTER AND
RECEIVER
This project consist of
1. M.S fabricated cabin with sliding door.
2. Pneumatic control system
3. Electrical control system (PLC unit)

14. 4. Power supply.
1. M.S FABRICATED CABIN WITH SLIDING DOOR:
The cabin is fabricated at the size of 1”x3/4”x3/4”
(Height x Breath x width) with the M.S ‘L’ angle material 25mm x 25mm x
2.5mm thickness. A sliding door arrangement is made at the front portion of
the cabin and the other sides are closed with 28-gauge thickness tin sheet.
The cabin is extended at both sides of cabin as shown in
figure for mounting the pneumatic component and the sliding door.

15. BASE
CABIN
DOOR
2. PNEUMATIC CONTROL SYSTEM:

16. The sliding door is fitted with the end of piston rod of
double acting cylinder.
The cylinder is actuated by the 5/2 way double solenoid
direction control valve. The solenoid valve is actuated through the IR sensor
relay. The pneumatic control circuit is shown in fig.
CABIN
DOOR
DOUDLE ACTING CYLINDER
PNEUMATIC CIRCUIT DIAGRAM FOR AUTOMATIC
DOOR OPENING AND CLOSING

18. IR SENSOR UNIT;
To DETECT the object an I.R. sensor is used..The I.R. sensor is fixed at
the front of the door which is held in between the two plates.
TRANSMITTER
RECEIVER
TRANSMITTER AND RECEIVER

19. IR TRANSMITTER AND
RECEIVER
DOOR
TRANSMITTER
RECEIVER
TRANSMITTER AND RECEIVER

20. WORKING
PRINCIPLE

21. WORKING PRINCIPLE
The working principle is shown in fig.
AUTOMATIC GATE OPENING SYSTEM
CABIN
DOUDLE ACTING CYLINDER
DOOR
BASE
IR TRANSMITTER AND
RECEIVER
The IR transmitter and IR receiver sensor is mounted in front of the
door and both are facing each other. Hence IR receiver continuously
receives IR rays if any object crossing or disturbing these IR rays.
The relay in the sensor energies, the NO contact in the relay
becomes NC and the solenoid valve coil gets ON and allows the
pressurized air to the double acting cylinder. The door is opened after

22. entering in to cabin the person may press the push button to close
the door.
PNEUMATIAC CIRCUIT
DIAGRAM

23. PNEUMATIC CIRCUIT DIAGRAM

24. INTRODUCTION TO
PROGRAMMABLE
LOGIC CONTROLLER

25. PROGRAMMABLE LOGIC CONTROLLER
It is a solid-state equipment, designed to perform the function of logical
decision-making Industrial Control Applications.
It acts as a total replacement for hard-wired relay logic with an
effective reduction in wiring and panel size and of course, with increase in
flexibility and reliability.
It has been experienced that majority of the faults with systems using
PLC’s are due to external cause like, malfunctioning of field or external
devices such as sensors, limit switches, push buttons etc.
The Keyence PLC is a unique product by itself offering the most
advanced features in a compact size. It finds application in areas like small
SMPS, Conveyors, Industrial Washing machine, Welding machine, Screen
Printing machine, Generator control, Small automation process etc.
FEATURES OF KEYENCE PLC:
 Compact
 Economical
 Easily mountable
 Choice of selecting either AC (220V)/24V DC

26.  R (24V) DC powered PLC
 High speed counter input upto 4 KHz
 Pulse catch inputs 500 μs or more
 Variety of function blocks and powerful instruction set
 Availability in 3 modules 6/4, 10/8 and 16/12
 Source or sink type inputs
 Relay outputs
 Sink type DC outputs
BLOCK DIAGRAM:
I
NP
UT
POWER SUPPLY
PROCESSOR
PROGRAMMING DEVICE
OUTPUT
The Block Diagram of PLC is shown in the Figure. The PLC is
designed to replace relays, timers, counters, etc. The necessary voltage and
current requirements for the internal working of the PLC are given by the
Power supply. The field elements are interfaced to the input or output
sections. Typical input elements are push buttons, limit switches, proximity
switches, relay contacts, selector switches, thumb wheels etc. Typical
output elements are solenoid valves, relay coils, indicator lights, LED
displays etc. These field elements are selected by the end user.

27. The necessary power supply for the Input and Output elements are
provided externally to the PLC. The power supply for PLC is supplied to
operate only the internal electronics and not to power the field elements.
ADVANTAGES OF USING PLC OVER CONVENTIONAL
ELECTRICAL RELAY PANELS:
1. Maximum Reliability
2. Logic easily changeable
3. Single PLC can be used in multiple applications by mere change of
programme.
4. Indicator lights provided at the major diagnostic points to simplify
trouble shooting.
5. Powerful software features like timers, counters, table operations etc.
in conjunction with optional display to assist trouble shooting.
6. Availability of unlimited number of N0 / NC contacts for Input and
Output Internal Logic Coils (Flags).
7. Very compact and rugged design leading to less down loading time.
8. Smaller cabinet size leading to less floor space requirements
9. Easy installation
10.Low cost

28. PNEUMATIC
COMPONENTS
DETAILS

29. DESCRIPTION OF PNEUMATIC COMPONENTS
1. Double acting air cylinder with piston arrangement.
2. Spool valve (2 position 5 ports valve)
3. Pneumatic fittings
a. Bulk head union
b. Flexible hoses
c. Air compressors
DOUBLE ACTING AIR CYLINDER WITH PISTON
ARRANGEMENT:
It consists of a piston inside a cylindrical housing called a barrel.
Attached to one end of the piston is a rod which the rod end has one port.
This rod end port is used for entrance of air and extends outside one end of
the cylinder. At another end is a port for exit of air.
Double acting cylinder can be extended and retracted pneumatically.
The smallest bore size of an double acting cylinder is 1 1/8 inch. The piston,
which is made of ductile Iron, contains u-cup packing to seal against leakage
between the piston and barrel. The ports are located in the end caps, which
are secured to the barrel by bolts and nuts.

30. DIRECTING CONTROL VALVES:
A direction control valve is used to change the direction of air flow as
and when required by the system for reversing the machine tool devices. A
direction control valve may be classified, according to the construction of
the internal moving parts, as
1. Rotary spool Type.
2. Sliding Spool Type.
3. Solenoid operated valves
SOLENOID OPERATED VALVES:
Solenoid valves are electromechanical devices like relays and
contractors. A solenoid valve is used to obtain mechanical movement in
machinery by utilizing fluid or air pressure. The fluid or air pressure is
applied to the cylinder piston through a valve operated by a cylindrical
electrical coil. The electrical coil along with its frame and plunger is known
as the solenoid and the assembly of solenoid and mechanical valve is known
as solenoid valve. The solenoid valve is thus another important
electromechanical device used in control of machines. Solenoid valves are
of two types,

31. 1. Single solenoid spring return operating valve,(5/2)
2. Double solenoid operating valve.
In fig 1 is shown a single solenoid spring return valve in its de-energized
condition. The symbol for the solenoid and the return are also shown. The
solenoid valve is shown connected to the cylinder to help readers understand
the solenoid valve action. In the de energized condition, the plunger and the
valve spool position as shown in figure 1.

32. In this position of spool, port P is connected to port A and port B is
connected to tank or exhaust (i.e. atmosphere) if air is used. Spring pressure
(S) keeps the spool in this condition as long as the coil is de energized.
Fluid pressure from port P through port A is applied to the left side of the
cylinder piston. Thus the cylinder piston moves in the right direction. Now
when the solenoid coil is energized, plunger is attracted and it pushes the
spool against spring pressure.
The new position of plunger and spool are shown in fig 2.
In this position of spool, port A gets connected to tank and port P gets connected
to port B. Thus pressure is applied to the cylinder piston from right and moves

33. the piston rod to the left. At the same time fluid in the other side is drained out to
the tank. When the solenoid coil is again de energized, the spring (S) will move
the spool to its original position as shown in figure 1. Thus, normally when the
solenoid coil is de energized the piston rod remains extended.

34. PNEUMATIC FITTINGS:
There are no nuts to tighten the tube to the fittings as in the
conventional type of metallic fittings. The tube is connected to the fitting by
a simple push ensuring leak proof connection and can be released by
pressing the cap and does not require any special tooling like spanner to
connect (or) disconnect the tube from the fitting.
SPECIFICATION OF THE FITTING:
Body Material - Plastic
Collect/Thread Nipple - Brass
Seal - Nitrate Rubber
Fluid Used - Air
Max. Operating Pressure - 7 Bar
Tolerance on OD of the tubes - ± 1 mm
Min. Wall thickness of tubes - 1 mm.
FLEXIBLE HOSES:
The Pneumatic hoses, which is used when pneumatic components
such as actuators are subjected to movement. Hose is fabricated in layer of
elastomer or synthetic rubber, which permits operation at high pressure. The
standard outside diameter of tubing is 1/16 inch. If the hose is subjected to
rubbing, it should be encased in a protective sleeve.

35. ADVANTAGES AND LIMITATIONS
ADVANTAGES:
¨ The Pneumatic arm is more efficient in the technical field
¨ Quick response is achived
¨ Simple in constructions
¨ Easy to maintain and repair
¨ Cost of the unit is less when compared to other robotics
¨ No fire hazrd problem due to over loading
¨ Comparatively the operation cost is less
¨ The operation of arm is faster because the media to operate is air
¨ Continuous operation is possible without stopping.
LIMITATIONS:
¨ High torque cannot be obtained.
¨ Load Carrying capacity of this unit is not very high (3 – 5 kgs).
While working, the compressed air produces noise, therefore a silencer may be
used.

37. APPLICATIONS
DISCHARGE OF WORKPIECE:
The arm fed has wide application in low cost automation. It can be
used in automated assembly lines to pick-up the finished product from
workstation and place them in the bins. It can also be used to pick-up the
raw material and place them on the conveyor belts and vice versa.
JOB CLAMPING:
This unit can also be used in clamping operations in certain areas of
mass productions where clamping and unclamping have to be done at high
speeds. The applications of this unit is limited to operations which involves
moderate clamping forces.
TRANSFER OF JOBS BETWEEN WORK STATION:
The gripping method used in a low cost automation to move the
workpiece from one workstation to another. The combination of an angular

38. rotary motion is the principle behind this method. The gripper holds the
work rigidly. The to and fro motion is achieved by means of the actuating
cylinder.
TOOL CHANGING APPLICATION:
When the pneumatic arms are made smaller in size they can be used
in automatic tool changer in CNC turning and drilling machines, by
attaching suitable tool holding device to the rotary cylinder.

39. FEATURES OF THE
AUTOMATIC GATE
OPENING AND
CLOSING

40. FEATURES OF THE AUTOMATIC GATE
OPENING AND CLOSING
 It is compact in size
 It can be move
 The electrical power consumption is very low
 This principle can be utilized at any places
 It is simple in construction
 Low cost
 Less weight and easy to handle
 It eliminate the man power

41. FINISHING PAINTING

42. FINISHING AND PAINTING
JOB PREPARATION;
Before welding, remove any bend in the L angle with the sludge
hammer on the anvil block. Then it is cut to the required length with the
hacksaw blade and fabricated to required dimensional shape with arc
welding.
FINISHING OPERATION BEFORE PAINTING;
After welding, any slag on the welded area is removed with the
chipping hammer and cleaned with the metal wire brush. Then all the
surfaces are rubbed with the emery sheet.
Metal primer is applied on the surfaces with the brush .After drying the
metal primer, the second coating is applied with the paint.

43. COST ESTIMATION

44. COST ESTIMATION
1. Double Acting Cylinder (1x800)-------------- 800.00
2. Solenoid Valve 5/2 Way (1x1100)------------ 1200.00
3. Valve Connectors (10x50) --------- ----------- 500.00
4. M.S Stand ---------------------- 800.00
5. IR SENSOR unit ----------- ------------ 1000.00
6. Power supply unit ------------------ 600.00
7. Tube (5 Meters)---------------------------------- 100.00
8. Transportation Charges-------------------------- 200.00
9. Miscellaneous charges -------------------------- 100.00
10.Report ----------------------------------- 600.00
-------------------
TOTAL ------------- 5900.00
-------------------

45. CONCLUSION

46. CONCLUSION
We make this project entirely different from other projects. Since
concepts involved in our project is entirely different that a single unit is used
to various purposes which is not developed by any of other team members.
By doing this project we gained the knowledge of pneumatic system
is how automation can be effectively done with the help of pneumatic
system.
It is concluded that any automation system can be done with the help
of pneumatic system.
We have successfully completed the project work on using
Pneumatics system at our Institute.
By doing this project work, we understood the working principle and
uses of various Cylinders, Valves, etc. .
It will be of no doubt that Pneumatics will be an integrated part of any
process in industry in the near future and we developed a through knowledge
in Automation with Pnematics
Once again we express our sincere thanks to our staff members.

47. BIBLIOGRAPHY

48. BIBLIOGRAPHY
1. FESTO MANUAL
2. Production technology by Hajra Choudry
3. Hydraulic & pneumatics for Power Production - Harry L – Stewart
4. Fluid mechanics by E.SUNDRAMOORTHY
5. Design with Micron roller – John Peatman
6. Customizing and programming PIC Micro controller – Myke Predko
7. Electronics for you Projects – Volume 1 to 15
8. Sensors – Keyence Manual
9. Micro controller and its application – Kenneth Ayala
10.www.google.com

49. PHOTOVIEW