This document provides details on the fabrication of a mini water service station. It includes chapters on the introduction, literature review, description of equipment like pneumatic cylinders, solenoid valves, air compressors, and non-return valves. It discusses the design, working principle, merits and demerits, applications, material list, and cost estimation. The station uses a hand operated pump to pressurize water in a tank using compressed air, which is then delivered through a nozzle at high pressure for cleaning purposes.

1. FABRICATION OF MINI WATER SERVICE
STATION

2. CONTENTS

3. CONTENTS
CHAPTER NO TITLE
SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Pneumatic cylinder
3.2 Solenoid Valves
3.3 Air compressor
3.4 Non return valve
4 Design and drawing

4. 4.1 General machine Specification
4.2 Overall diagram
5 Working Principle
6 Merits and demerits
7 Application
8 List of material
9 CostEstimation
10 Conclusion
Bibliography
Photography
LIST OF FIGURES

5. LIST OF FIGURES
Figure
Number Title
1 Block Diagram
2 Overall Diagram

7. NOMENCLATURE
NOMENCLATUR

8. 
A = Area of cylinder (m2)

D = Diameter of Piston (m)

F = Forceexerted on the piston (N)

H = Height (m)

L = Length (m)

P = Pressure (N/M2)

V = Volume (m3)

9. SYNOPSIS

10. SYNOPSIS
This machine can be used for cleaning light vehicles especially for two
wheelers and 3 wheelers and it has a better performance in agricultural purposes.
Now days this machine can have a good market because of the following reasons.
1) It is very simple in construction and using simple mechanism.
2) Easy to operate
3) Since it is hand operated no electrical power is required.
4) Available at low cost
5) It saves time and money.
6) It is portable
7) If needed it can also be operated with a compressor
Using a hand operated pump the water is pressurized by compressing the air
in the water tank. Then it is delivered through a nozzle under high pressure about
15 kg/cm².

11. CHAPTER– 1
INTRODUCTION

12. CHAPTER – 1
INTRODUCTION
Mechanization is broadly defined as the replacement of manual effort by
mechanical power. Pneumatics is an attractive medium for low costmechanization

13. particularly for sequential or repetitive operations. Many factories and plants
already have a compressed air system, which is capable of providing both the power
or energy requirements and the control system (although equally pneumatic control
systems may be economic and can be advantageously applied to other forms of
power). The main advantages of an all-pneumatic system are usually economy and
simplicity, the latter reducing maintenance to a low level. It can also have out
standing advantages in terms of safety.
A pump is a Mechanical device which converts mechanical energy into hydraulic
energy. This pump is classified into two types;
i. Positive Displacement and
ii. Non-Positive Displacement pump
In positive displacement pump is the one, in which the liquid is transferred
positively from one stage to another stage by the to and fro motion of the plunger or
piston of the pump.
In non-positive displacement pump the liquid is transferred by the centrifugal
force. This force is cause due to the rotary movement of an impeller. In this, our
project, pneumatic water pump is of positive displacement pump. The salient
features of a pneumatic water pump have been retained in our project modeland this
has been achieved with great care.
Due to high precision work involved in producing pneumatic water pump
besides higher cost these pumps are not widely manufactured by most of the
industries. The very name itself indicates that it works with the help ofa piston. This
piston is reciprocated with the help of a solenoid valve.

15. CHAPTER – 2
LITERATURE REVIEW
CHAPTER – 2
2.LITERATURE SURVEY`

16. PNEUMATICS:
The word ‘pneumatic’ comes from Greek and means wind. The word
pneumatics is the studyofair movement and its phenomena is derived from the word
pneumatic. Today pneumatics is mainly understood to means the application of air
as a working medium in industry especially the driving and controlling of machines
and equipment.
Pneumatics has for some considerable time between used for carrying out the
simplest mechanical tasks in more recent times has played a more important role in
the development of pneumatic technology for automation.
Pneumatic systems operate ona supplyofcompressed air which must bemade
available in sufficient quantity and at a pressure to suit the capacity of the system.
When the pneumatic system is being adopted for the first time, however it will
indeed the necessary to deal with the question of compressed air supply.
The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at a
certain pressure and delivered the air at a high pressure.
Compressor capacity is the actual quantity of air compressor and delivered
and the volume expressed is that of that of the air at intake conditions namely at
atmosphere pressure and normal ambient temperature.
The compressibility of the air was first investigated by Robot Boyle in 1962
and that found that the productofpressureand volumes ofparticular quantity of gas.
The usual written as
PV = C (or) P1V1= P2V2

17. In this equation the pressure is the absolute pressured which for free is about
14.7Psi and is of courage capable of maintaining a column of mercury, nearly 30
inches high in an ordinary barometer. Any gas can be used in pneumatic system but
air is the mostly used system now a days.
SELECTION OF PNEUMATICS
Mechanization is broadly defined as the replacement of manual effort by
mechanical power. Pneumatic is an attractive medium for low cost mechanization
particularly for sequential (or) repetitive operations. Many factories and plants
already have a compressed air system, which is capable of providing the power (or)
energy requirements and control system (although equally pneumatic control
systems may be economic and can be advantageously applied to other forms of
power).
The main advantages of an all pneumatic system are usually economic and
simplicity
the latter reducing maintenance to a low level. It can have outstanding advantages
in terms of safety.
PNEUMATIC POWER
Pneumatic systems use pressurized gases to transmit and control power.
Pneumatic systems typically use air as the fluid medium becauseair is safe, low cost
and readily available.

18. THE ADVANTAGES OF PNEUMATICS
1. Air used in pneumatic systems can be directly exhausted back in to the
surrounding environment and hence the need of special reservoirs and no-
leak system designs are eliminated.
2. Pneumatic systems are simple and economical.
3. Control of pneumatic systems is easier.
THE DISADVANTAGES OF PNEUMATICS
1. Pneumatic systems exhibit spongy characteristics due to compressibility
of air.
2. Pneumatic pressures are quite low due to compressor design limitations
(less than 250 psi).
PRODUCTION OF COMPRESSED AIR
Pneumatic system operates on a supply of compressed air, which must be
made available. In sufficient quantity and at a pressure to suit the capacity of the
system. When pneumatic system is being adopted for the first time, however it will
indeed the necessary to deal with the question of compressed air supply.
The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at a
certain pressure and delivered the air at a high pressure. Compressorcapacity is the

19. actual quantity of a compressed and delivered and volume expressed is that of the
air. At intake condition namely at atmosphere pressure and normal ambient
temperature.
Clean condition of the suction air is one of the factors, which decides the life
of a compressor. Warm and moist suction air will result increased precipitation of
condense from the compressed air.
COMPRESSOR MAY BE CLASSIFIED IN TWO GENERALTYPES
1. Positive displacement compressor
2. Turbo compressor
Positive displacement compressorsare most frequently employed for compressed
air plant and have proved highly successfuland supply air for pneumatic control
application.
The types of positive compressor
1. Reciprocating type compressor
2. Rotary type compressor
Turbo compressors are employed where large of air required at low discharge
pressure. They can’t attend pressure necessary pressure pneumatic control
application unless build in multi stage design and are seldom in encountered in
pneumatic service.
RECIPROCATING COMPRESSOR

20. Built for either stationary (or) portable service the reciprocating compressor
is by for the most common type. Reciprocating compressor lap be had is size from
the smallest capacity to deliver more than 500m3/min. In single stage compressor
the air pressure may be of 6 bar machines discharge of pressure is up to 15 bars.
Discharge pressure in the range of 250 bars can be obtained with high pressure
reciprocating compressor that of three & four stage. Single stage and 1200 stage
models are particularly suitable forapplications with reference going to the two stage
design soonas the discharge pressureexists 6 bars, becauseit in capable of matching
the performance of single stage machine at lower costperdriving powerin the range.

21. CHAPTER-3
DESCRIPTION OF EQUIPMENTS

22. CHAPTER-3
DESCRIPTION OF EQUIPMENTS
3.1 PNEUMATIC CONTROL COMPONENT
Pneumatic cylinder:
An air cylinder is an operative device in which the state input energy of
compressed air i.e, pneumatic power is converted into mechanical output power by
reducing the pressure of the air to that of the atmosphere.
Single acting cylinder
Single acting cylinder is only the capable of performing an operating medium
in only one direction. Single acting cylinders equipped with one inlet for the
operating air pressure can be productionin several fundamentally different designs.
Single cylinder develops power in one direction only.

23. Therefore no heavy control equipment should be attached to them which
requires to be moved on the piston returns stoke single action cylinder requires only
about half the air volume in consumed by the double acting for one operating cycle.
Double acting cylinder
A double acting cylinder is employed in control systems with the full
pneumatic cushioning and it is essential when the cylinder itself is required to retard
heavy messes. This can only be done at the end positions of the piston stroke. In all
intermediate position a separate externally mounted cushioning derive most be
provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end of
the stroke is required. As a result the sit in the cushioning chamber is again
compressed since it cannot escape but slowly according to the setting made on
reverses. The air freely enters the cylinder and the piston strokes in the other
direction at full force and velocity.
3.2VALVES
SOLENOID VALVE
The directional valve is one of the important parts of a pneumatic system.
Commonly known as DCV; this valve is used to control the direction of air flow in
the pneumatic system. The directional valve does this by changing the position of its
internal movable parts.

24. This valve was selected for speedy operation and to reduce the manual effort
and also for the modification of the machine into automatic machine by means of
using solenoid valve.
A solenoid is an electrical device that converts electrical energy into straight
line motion and force. These are also used to operate a mechanical operation which
in turn operates the valve mechanism. 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
recognised when called upon to make repairs, to do service work or to install them.
PARTS OF A SOLENOID
1.Coil

25. The solenoid coil is made of copper wire. The layers of wire are seperated by
insulating layer. The entire solenoid coilis covered with a varnish that is notaffected
by solvents, moisture, cutting oil or often fluids. Coils are rated in various voltages
suchas 115 volts AC, 230 volts AC, 460volts AC, 575 volts AC, 6 volts DC,12 volts
DC, 24 volts DC, 115 volts DC & 230 volts DC they are designed for such
requiencies as 50Hz to 60Hz.
2. Frame
The solenoid frame servesseveral purposes. Since it is made of laminated
sheets, it is magnetized when the current passes through the coil. The magnetized
coils attract the metal plunger to move. The frame has provisions for attaching the
mounting. They are usually bolted orwelded to the frame. The frame has provisions
for receivers the plunger. The wear strips are mounted to the solenoid frame, and are
made of materials such as meterial or impregnated less fibre cloth.
3.Solenoid plunger
The solenoid plunger is the mover mechanism of the solenoid. The plunger is
made of steel laminations which are riveted together under high pressure, so that
there will be no movement of the lamination with respectto one another. At the top
of the plunger a pin hole is placed for making a connection to some device. The
solenoid plunger is moved by a magnetic force in one directioin and is usually
returned by sping action.
Solenoid operated valves are usually provided with cover either the solenoid
or the entire valve. This protects the soleniod from dirt and other foregn matter, and
protects the actuator. In many application it is necessary to use explotion proof
solenoids.

26. WORKING OF SOLINOID VALVE
The solenoid valve has 5 openings. Three ensure easy exhausting of 5/4 valve
the spoolof the 5/4 valve slide inside the main bore accordind to spoolposition the
ports get connected and disconnected.
The working principle is as follows.
Position-1
When the spoolis actuated towards outer direction port ‘p’ gets connected to
‘B’ and ‘S’ remains closed while ‘A’ gets connected to ‘R’.
Position-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to each
other and ‘B’ to ‘S’ while port ‘R’remains closed.
SOLENOID VALVE (OR) CUT OFF VALVE
The controlvalve is used to control the flow direction is called cutoff valve or
solenoid valve. This solenoid cutoff valve is controlled by the electronic control
unit.
In our project seperate solenoid valve is used to flow direction of vice
cylinder. It is used to flow the air from compressor to the single acting cylinder.
Flow control valve

27. In any fluid power circuit flow contol valve is used to control the speed of
actuator. The flow controlcan beachieved byvarying the aera offlow through which
the air in passing.
When area is increased, more quantity of air will be sent to actuator as a result
its speed will increase.If the quantity of air entering into the actuator is reduced, the
speed of the actuator is reduced.
Pressure control valve
The main function of the pressure control valve is to limit (or) control the
pressure required in a pneumatic circuit.
Depending upon the method of controlling they are classified as
1. Pressure relief valve
2. Pressure reducing valve
Hoses
Hoses used in this pneumatic system are made up of polyurethane.
These hose can with stand at a maximum pressure level of 10 x 105N/m2.
Connectors
In our system there are two type of connectors used. One is the Hose
connectorand the other is the reducer. Hose connectots normally comprise an
adopthosenipple and cap nut. Thesetypes ofconnectors are made up of brass
(or) aluminium (or) hardened pneumatic steel.

28. 3.3 AIR COMPRESSOR
Compressoris the air producingmachine. They collect the airs from the
atmosphere are in the running of machine are engine. Air compressors are
utilized to raise the pressureof a volume of air. Air compressureare available
in many configurations and will operate over a very wide range of flow rates
and pressure compressed air was expelled by primitive man to give glowing
embers sufficient oxygen to allow them to flare up into a fire. During the
compression oprocess the tempreture increases as the presssure increses this
is known as polytypic compression. The amount of compression power also
increases as the temp also increases. Compressorare staged their by reducing
the temp rice and improving the compression efficiency.The temp of tha air
leaving each stage is cooled prior to entering to the next stage. The cooling
process is called inter cooling. Volumetric efficiency also increases with multi
stage copressionsincethe pressure ratio over the first stage will be decreased.
Seletion of the air compressor is only the first step in designing an
efficient and reliable compressed air system. The air exciting the compressor
structured with moisture and will have compressor lubricant. The other
chemical that may have been darw in to the compressorin take may also be
present. This contamination is harmful to many process, Pneumatic tools
,equipments,air purification eqipment ,fillters,air driers,breathing air
purifier,monitoring eqipment used alone are in combination will remove this
contamints. Selection and purchase of the compressor and necessary
purification eqipment can be easily done on the compreese air site. Our
application engineers are ready to answer all question and to assert you in
placing your orderand it work in the process ofrotating the fan and the piston
movement with the help of the current supply.

29. 3.4 NON-RETURN VALVE
A check valve,non return valve or one way valve is a mechanical
device, a valve ,which normally allow fluids (liquied or gas) to flow through
it in only one direction.
Check valve are two parts valves,meaning they have two opening in the
body, one for fluid to enter and the other for fluid to leave. There are various
types of check valve used in a wide variety of application. Check valve often
part of common house hold items all through there are available in a wide

30. range of size and cost.Check valve are generally are very sall,simple,and/or
cheap. Check valve work automatically most are no controoled by a persion
or any external control,accordingly most do not have any valve handle or
steam. The bodies the most check valve are made of plastic or metal.
On important concept in check valve is the tracking pressure which is
the minimum upstream pressureat which the valve will operate. Typically the
check valve is designed for and can therefore the specified for a specific
cracking pressure.

31. CHAPTER-4
DESIGN AND DRAWING
CHAPTER - 4
DESIGN OF EQUIPMENT AND DRAWING

32. 4.1 PNEUMATIC COMPONENTS AND ITS SPECIFICATION
The design and fabrication of pneumatic reciprocating water pumping
system is consists of the following components to full fill the requirments of
complete operation of the machine.
1. Double acting pneumatic cylinder
2. Solenoid valve
3. Air compressor
4. Non return valve

34. CHAPTER-5
WORKING PRINCIPLE

35. WORKING PRINCIPLE
 The compressed air from the compressor reaches the solenoid valve.
The solenoid valve changes the direction offlow accordingto the signals from
the timing device.
 The compressed air pass through the solenoid valve and it is admitted into the
front end of the cylinder block. The air pushes the piston for the cutting
stroke. At the end of the cutting stroke air from the solenoid valve reaches
the rear end of the cylinder block. The pressureremains 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.
 The non-return valve is fixed to the hydraulic cylinders two side (Four
numbers).

36. CHAPTER – 6
MERITS AND DEMERITS

37. CHAPTER – 6
MERITS AND DEMERITS
ADVANTAGES
Portable in size
easy handling and operation
Low operational cost
Independence from the supply of vacuum or compressed air.
Low Cost Machine
APPLICATION
Industrial application
All Automobile Service Station

38. CHAPTER – 7
APPLICATIONS

39. APPLICATIONS
It is applicable in all small scale and large industries for lubrication.
 Higher efficiency
 It does not required any prime mover like electric motor
 As the air is freely available

40. CHAPTER – 8
LIST OF MATERIALS

41. LIST OF MATERIALS
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material are discussed below.
1. PROPERTIES
The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface finish, rigidity,
ability to withstand environment attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively affect their
selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal conductivity, specific
heat, coefficient of thermal expansion, specific gravity, electrical conductivity, magnetic
purposes etc.
The various Mechanical properties concerned are strength in tensile, compressive shear,
bending, torsional and bucking load, fatigue resistance, elastic limit, endurance limit and
modulus of elasticity, hardness, wear resistance and sliding properties.

42. The various properties concerned from the manufacturing point of view are,
 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.
2. MANUFACTURING CASE
Sometimes the demand for lowest possible manufacturing costor surface
qualities obtainable by the application of suitable coating substances may
demand the use of special materials.
3. QUALITY REQUIRED
This generally affects the manufacturing process and ultimately the
material. Forexample, it would never be desirable to go casting of a less
number of components which can be fabricated much more economically by
welding or forging the steel.
4. AVAILABILITY OF MATERIAL
Some materials may be scarce or in short supply, it then becomes
obligatory for the designer to use some other material which though may not be
a perfect substitute for the material designed. The delivery of materials and the
delivery date of productshould also be kept in mind.

43. 5. SPACE CONSIDERATION
Sometimes high strength materials have to be selected becausethe forces
involved are high and spacelimitations are there.
CHAPTER – 9
COST ESTIMATION

44. COST OF ESTIMATION
As in any other problem, in selection of material the costof material plays
an important part and should not be ignored.
Some times factors like scrap utilization, appearance and non-maintenance
of the designed part are involved in the selection of proper materials.
COMPONENTS NAME QTY RATE AMOUNT
FRAME STAND WHEEL 1 1500 1500
WATER TANK 1 500 500
AIR GATE VALE 2 1400 700
OVER HEAD COST 500
FABICATION COST - 1200
I.R SENSOR 1000
TOTAL 6100

45. FABRICATION OF MINI WATER SERVICE STATION

47. CHAPTER – 10
CONCLUSION
CONCLUSION
The project carried out by us made and impressing task in the field of
medical department for water purifier.
This project will reduce the costinvolved in the concern. Project has been
designed to perform the entire requirement task at the shortest time available.

48. BIBLIOGRAPHY

49. BIBLIOGRAPHY
1.Design data book - P.S.G.Tech.
2.Machine tool design handbook - Central machine tool Institute, Bangalore
3. Strength of Materials - R.S.Kurmi
4.Manufaturing Technology - M.Haslehurst
5.Design of machine elements -R.S.Kurumi
6.http://www.solarpanelinfo.com/