To Develop a working model of Pneumatic Welding
Machine
Sumitted by- Sandeep kumar(1247840026) Submitted to-Prof. Ompal Singh
Dr. A.P.J. Abdul Kalam Technical University, formerly Uttar Pradesh Technical University
Lucknow, Uttar Pradesh

Content

INTRODUCTION
 Welding is a process which used to joint the two metal part and to give a permanent joint.
 This project aim to design an automatic pneumatic welding machine that uses to finding better quality of
welding joint.
 A machine is to move the welding torch along a defined weld path orientation.
 The welding machine makes uses of properly shaped MS alloy electrodes in order to apply pneumatic pressure
and to carry electrical current though the workpieces . Heat is generally generated at merging point between
two sheets. Then sheet are joint permanently.

Main components
 Frame
 Pneumatic Cylinder-(40*150)
diameter-40 mm
stroke -150mm
 Solenoid valve
 D .C . Air compressor (150 psi D.C. compressor)
 Control panel
 Welding rod
 Electrode holder
 Hose and Fitting
 D.C. Battery

Fig.1
Control panel
Solenoid valve
d.c. air compressor
Pneumati
c cylinder
Frame
Welding torch

Pneumatic cylinder
Introduction
 Pneumatic cylinder provide linear and rotary movement.
 They are devices providing power and motion to automated systems, machines and processes.
 A pneumatic cylinder is a simple, low cost, easy to install device that is ideal for producing powerful linear
movement.
 Speed can be adjusted over a wide range.
 A cylinder can be stalled without damage.
 Adverse conditions can be easily tolerated such as high humidity, dry and dusty environments and cleaning down
with a hose.
 The bore of a cylinder determines the maximum force that it can exert.
 The stroke of a cylinder determines the maximum linear movement that it can produce.
 The maximum working pressure depends on the cylinder design. School cylinders work up to 9 bar.
 Thrust is controllable through a pressure regulator.

Basic construction
1 cushion seal
2 magnet
3 cushion sleeve
4 barrel
5 guide bush
6 rod and wiper seal
7 front end cover
8 front port
9 reed switch
10 piston rod
11 wear ring
12 piston seal
13 rear end cover
14 cushion screw
1
2
3
4
5
6
7
8
9
10
11
12
13
14

 Double acting cylinders use compressed air to power both the outstroke and
instroke.
 Superior speed control is possible
Double acting

Cylinder sizing for thrust
 In the formula, P is divided by 10 to convert bar to Newtons per square millimetre (1
bar = 0.1 N/mm2)
Where
D = Cylinder bore in millimetres
P = Pressure in bar
F = Thrust or Pull in Newtons
Thrust F =
D
2
4
P
10
Newtons

Solenoid valve
 A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current through
a solenoid: in the case of a two-port valve the flow is switched on or off.
 The solenoid valve is a device aiming to stop or to allow the flow of pressurized media. It permit to convert an
electrical current into a fluid flow.
 In direct –acting solenoid valve . the plunger directly open and close an orifice inside the valve in pilot
operated valve (also called the servo type)the plunger open and close a pilot orifice .The inlet line pressure
which is lead through the pilot orifice open and closes the valve seal.
 Solenoid valves make automation of air control possible

Outlet port
Inlet port
Coil winding
Electric supply

 Main parts of solenoid valve:-
(1) valve body- this is the body of the valve to which solenoid valve is connected .the valve is usually
connected in the process flow pipeline to control the flow of certain fluid like air.
(2) Inlet port- this is the port through which the air entre inside the valve.
(3) Outlet port – air pass through the valve leaves valve through the outlet port.
(4)Coil/ solenoid- this is the body of solenoid coil. The body of the solenoid coil is cylindrical in shape and it is
hollow from inside.
(5) Coil windings – the solenoid consists of several turns of the enameled wire wound around the ferromagnetic
Material like iron or steel.
(6)Lead wires – these are the external connection of the solenoid valve that are connected to the electrical
supply.
(7) Plunger – the plunger tends to the move vertically in the hollow space.

(8) orifice-it is the connection between the inlet and outlet port . orifice is the controlled by the plunger
and spring.

Air compressor
 A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume.
 An air compressor is a specific type of gas compressor.
 When tank pressure reaches its upper limit the air compressor shuts off. The compressed air, then, is held in
the tank until called into use.
 Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid
through a pipe
 In other words An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air).
 This compressor work on the D.C. 12volt battery .and regulate the ON/OFF switch.

 Fig. D . C . air compressor

Specification of air compressor
 Voltage- DC 12v
 Max current -16 Amp
 Duration- 12-15 min
 Max. pressure- (150psi)
 Displacement- 35l/min

Control panel
 Control panel is used to control the solenoidal valve with the help of timer circuit and regulate the
pneumatic cylinder forward and backward direction.
 Function of control panel
1. operate solenoid valve
2. control a pneumatic cylinder

Step down
transformer
Relay
LED
CAPACITOR
MICRO PROCESSER
switch
Re-set switch

 Step down transformer – convert 220 volt to 12 volt.
 Capacitor-these are the storage device and used to electrical energy temporarily in an electrical field
 LED-these are the indicate the time.
 Switch –ON/OFF
 Relay –control the high power or high voltage circuit with a low power circuit.
 Micro processer or (I.C. chip )-drive relays to control electrical load beyond their direct drive capability

Welding rod
 The electrode is coated in a metal mixture called flux.
 And which gives off gases as it decomposes to prevent weld contamination, introduces deoxidizers to purify the weld.
 flux causes weld-protecting slag to form, improves the arc stability, and provides alloying elements to improve the weld
quality.
Electrode holder
• An electrode holder commonly called stinger ,is clamping device for holding the electrode securely in any
position
• The electrode holder is two clamps one is ground and second is the equipment

Hose and
 Hose is flexible hollow tube design to carry fluid from one location to another location.
 Hose are made from one or a combination of many different materials. Application mostly use nylon,
polyurethane, PVC, or synthetic or natural rubber.
D.C. Battery
 An electric battery is a device consisting of one or more electrochemical cells with external connections
provided to power electrical devices. A battery has a positive terminal, or cathode, and a negative terminal, or
anode.
 Specification
1. 12 volt
2. 7 amp

advantage
 Small in size.
 Cost is less compared to other welding machine.
 Due to the nature of portable it can be easily handled.
 Due to portable ability it is easily handled

APPLICATIONS:
There are many different uses..
 Automobile industry
 Automotive manufacturing
 Metal working
 Shipbuilding
 Fabrication
 Casting