UNIT-IV

Low cost automation:

 Mechanical & Electro mechanical Systems,

 Pneumatics and Hydraulics,
 Illustrative Examples and case studies.

MECHANICAL & ELECTRO MECHANICAL SYSTEMS

Electro Mechanical systems

A electro-mechanical system converts electrical energy into mechanical energy or vice
versa. A armature-controlled DC motor as in Figure represents such a system, where the input
is the armature voltage, Va(t), and the output is motor speed, ω(t), or angular position θ(t).

Mechanical and Electromechanical

 Electromechanical devices are ones which have both electrical and mechanical
processes.
 A manually operated switch is an electromechanical component due to the mechanical
movement causing an electrical output.

Mechanical Systems
 Mechanical systems means
i. HVAC - Heating, ventilation, and air conditioning,
ii. Refrigeration, and
iii. Hydronic systems.

 Examples of common electromechanical devices

 Household appliances such as dishwashers, refrigerators or vacuum cleaners.
 Transportation, such as trains and trams.
 The automobile industry, with alternators and electric motors.
 CD and DVD players, printers.
 Motors and other hydraulic presses.
  Mechanical systems are of 6 types:
i.The lever,
ii.inclined plane,
iii.wheel and axle,
iv.wedge, pulley and
v.the screw.

 Examples of Mechanical Systems?

Plumbing, elevators, escalators, and heating and air-conditioning systems.

 A mechanical system is a system of elements that interact on mechanical principles.

Manages power to accomplish a task that involves forces and movement.

Difference between mechanical and electrical systems

Mechanical engineering deals with the moving parts of any machine or system, Electrical
engineering involves the creation and application of equipment that uses (or produces)
electricity.

Electromechanical systems are used in:

 Almost every moving device is powered by an electro mechanical system.

 These systems are present in most electric motors, solenoids and mechatronics.
 From vehicle power windows and power seats to washers and dryers, many of the
products we use in our everyday lives rely on these systems.

Mechanical systems are hardware products, often with integrated controls, which
shall simplify and improve our lives.
A few examples are manufacturing machines, positioning devices, vehicles and their
components, etc.

A mechanical system is a system of elements that interact on mechanical principles.

It manages power to accomplish a task that involves forces and movement.
Modern machines are systems consisting of
i. a power source and actuators that generate forces and movement,
ii. a system of mechanisms that shape the actuator input to achieve a specific application of
output forces and movement,
iii. a controller with sensors that compare the output to a performance goal and then directs the
actuator input, and

iv. an interface to an operator consisting of levers, switches, and displays.

 In Watt's steam engine the power is provided by steam expanding to drive the piston.
 The walking beam, coupler and crank can transform the linear movement of the piston into
rotation of the output pulley.
 Finally, the pulley rotation drives the flyball governor which controls the valve for the steam input
to the piston cylinder.
 The adjective "mechanical" refers to skill in the practical application of an art or science, as well
as relating to or caused by movement, physical forces, properties or agents such as is dealt with
by mechanics.
 Power flow through a machine provides a way to understand the performance of devices
ranging from levers and gear trains to automobiles and robotic systems.
 According to German mechanician Franz Reuleaux, "a machine is a combination of resistant
bodies so arranged that by their means the mechanical forces of nature can be compelled to do
work accompanied by certain determinate motion."
 Forces and motion combine to define power.
 Uicker et al stated that a machine is "a device for applying power or changing its direction."
McCarthy and Soh describe a machine as a system that "generally consists of a power source
and a mechanism for the controlled use of this power."

Working of the 3 most Common Electro Mechanical Systems and Devices Work

 Almost every moving device is powered by an electro mechanical system. These systems are
present in most electric motors, solenoids and mechatronics. From vehicle power windows
and power seats to washers and dryers, many of the products we use in our everyday lives
rely on these systems.

The three most common electro mechanical systems and devices are as follows:
i. Electric Motors
ii. Solenoids
iii. Mechatronic

i. Electric Motors
 Electric motors are essentially electrical machines that convert electrical energy (electricity) into
mechanical energy (torque) using a system of gears and magnetic fields, powered by an
electrical system.

 Electrical systems can derive power from a number of various direct current (DC) and
alternating current (AC) sources, including batteries and rectifiers (DC sources) and power
grids, inverters, and electric generators (AC sources).

 Common products that use electric motors include fans, blenders, and power windows.

 Applications

 Electric motors are not limited only to household applications.

 Electric motors are intrinsically tied to some of the things that make globalization possible.

 For instance, electric motors are used to propel some of the largest cargo ships that deliver
goods from all over the world for domestic consumption.

 Electric motors are also used to compress oil and natural gas so that it can safely travel through
the miles of pipelines that connect well and refinery – an application that has become
increasingly vital as the world’s population and consumption of technology continues to grow
with an appetite for energy to match.
  There are many types and sizes of electric motor available, with three main categories operating
in the lower voltage range (6-24 volts). These are:
● Brushed DC Motors
● Brushless Motors
● Stepper Motors

i.1. Brushed DC Motor

i. A brushed DC motor is an internally commutated electric motor designed to be run from a direct
current power source.

ii. The motor consists of several key parts.

iii. Permanent magnets known as stator magnets, are located on the outside of motor casing, are
positive on one side, negative on the other.

iv. It is connected to the motor shaft at the center of the motor and there are several wire (or
armature) windings (a wire winding consists of one or more turns of a wire to form a continuous
coil that allows an electric current to pass) that are in turn connected to metal plates.

v. The windings are also connected to a pair of metal plates called the commutator.

vi. When operating, the metal brushes come into contact with the commutator; as DC voltage is
applied to the metal brushes, the current is transferred to the commutator which causes the
magnetic field around the armature coils to change so that the coils rotate between permanent
magnets.

vii. The speed and torque characteristics of a brushed motor can be altered to adapt to the power
supply.

viii. Among the benefits associated with brushed DC motors include relatively low cost to procure,
ease of operation (simply connect a DC power supply), and high torque output at low speeds,
which can be useful when there is a load on the motor upon startup.

ix. Brushed motors are commonly used for electrical propulsion, cranes, paper machines and steel
rolling mills and are used almost everywhere.
x. In smartphone there is a small, brushed DC motor located to generate haptic feedback
(vibration). Since the brushes wear down and require replacement, brushless DC motors using
power electronic devices have replaced brushed motors from many applications.
i.2. Brushless DC Motor

i. Like brushed DC motors, brushless DC motors are motors powered by DC electricity.

ii. It consists of permanent magnets connected to the rotor and fixed stator coils
(electromagnets).

iii. As the rotor turns, one or more sensors close to its edge sends a signal to a control circuit
that energizes the stator coils in a sequence.

iv. The advantages of a brushless motor over brushed motors are longevity (the brushes used
in brushed motors can wear out over time which in turn reduces the overall lifespan of the
motor), high power to weight ratio, high speed, and electronic control.

v. Since a brushless motor is controlled by a computer, it is much more precise.

vi. Precision of brushless motors can also be increased by increasing the number of
electromagnets on the stator.

vii. Computer control is also widely responsible for the superior efficiency of brushless motors;
while brushed DC motors operate at around 75-80% efficiency, brushless DC motors operate
closer to the 85-90% range.

viii. Brushless motors are quieter and there is no chance of dangerous sparking since there are
no brushes within the motor.

ix. Brushless motors can be found in computer peripherals (disk drives, printers), hand-held
power tools, robotics used in the industrial sector and vehicles ranging from model aircraft to
automobiles.
i.3. Stepper Motor

i. Unlike brushless DC motors, stepper motors do not require any sensors.

ii. They have a permanent magnet rotor within the center that’s free to rotate within the fixed
stator coils.

iii. Using a driver circuit, current is pumped into the coils periodically, which generates a
magnetic field.

iv. Repelling the end of the magnet with the same polarity as the coil, and attracting the other,
causes the magnet to turn and the motor to run.

v. On a more granular level, the inner magnet is divided into many sections, resembling the
teeth you would, for example, find on a gear wheel used in a watch or clock.

vi. The outer coil that surrounds the magnet has the corresponding “teeth” and generates the
magnetic pulses required to attract or repulse the inner magnet.

vii. This results in the wheel being able to move in a very precise manner.

viii. In terms of applications, stepper motors can be found in industrial robotics where a robot’s
precise movements and ability to hold perfectly still is integral to the manufacturing process.

ix. Stepper motors are often very energy efficient.

2. Solenoids

 A solenoid is a type of electromagnet that generates a controlled magnetic field when current
passes through its wire in order to create a linear motion.

 It can also be used as an inductor, rather than an electromagnet, which impedes changes in the
electric current.

 A solenoid consists of a coil of wire in a corkscrew shaped wrapped around a piston, often made of
iron.

 Since solenoids use electromagnets, which can be switched on and off by a computer application
or by removing the current, they are especially useful as switches or valves, and are commonly
found in products like car keys, a doorbell and a host of automated industrial systems.

There are various types of solenoids, including the following:

i. Electromechanical solenoids – These consist of an electromagnetically inductive coil,

wound around a movable steel or iron slug, and are commonly seen in electronic paintball
markers, pinball machines, dot matrix printers and fuel injectors.

ii. Rotary solenoids – These are used to rotate a ratcheting mechanism when power is
applied and were first applied in the 1950s for rotary snap-switch automation in
electromechanical controls.

iii. Rotary vice coils – These are the rotational version of a solenoid and are widely employed
devices such as disk drives.

iv. Pneumatic solenoid coils – This is a switch for routing air to any pneumatic device,
allowing a relatively small signal to control a large device. It is also the interface between
electronic controllers and pneumatic systems.

v. Hydraulic solenoid valves – These are valves that they control the flow of hydraulic fluid
and are found in everyday household items such as washing machines to control the flow
and amount of water into the drum.

vi. Automobile starter solenoids – These are part of the automobile starting system used to
start the motor by relaying large electric current from the car battery and a small current from
the ignition switch.
3. Mechatronic

i. Mechatronics is an interdisciplinary area of engineering that combines mechanical and

electrical engineering and computer science and is often considered the amalgamation of skill
sets that is and will be required to drive advanced automated manufacturing going forward.

ii. Examples of Mechatronics are robotics, electronics, and telecommunications used for creating
simpler and smarter systems. So some of the things mechatronics engineers do ranges from
working with large industrial robotics, to building responsive control systems, to prototype
development.
iii. A typical mechatronic system picks up signals from the environment, processes them to
generate output signals, transforming them into forces, motions, and actions.

iv. Many products that used to be purely mechanical now rely on mechatronics to function,
including a variety of automotive systems such as anti-lock brakes, as well as household items
like DSLR cameras. These kinds of systems represent the future of the electromechanical
field.

 Electromechanics have existed since electricity was invented and have become increasingly
more sophisticated over time.

 While the electric motors will still play an important role in the future, the market is shifting to
more mechatronic and solenoid-based systems.
 Automation In Manufacturing
Unit-1v
Pneumatics and Hydraulics
Pneumatics provides fluid power by means of pressurised air or gases. Hydraulics provides
fluid power by means of pressurised liquids, such as oil or water. In choosing one of the two, cost-
effectiveness, materials to be moved, availability of resources and space are all factors to be
considered.

The Importance of Hydraulics and Pneumatics

 There are mechanical differences between Hydraulics and pneumatics.
 Both are essential parts of various industries and are critical to the performance of several types of
tasks.
 The difference between hydraulics and pneumatics is in the substances used to operate them.
 Hydraulics have a pressurized fluid to initiate a mechanical process.
 Force that is applied at one point is sent to another point using incompressible fluid, which is
necessary since it does not change volume when pressure is applied.
 In the majority of cases, the fluid is oil.
 The applied force is multiplied as the liquid travels through the system to the point that it can create
nine times more force than the initial applied force.
 Most hydraulic systems involve a network of pistons, where a simple one may have two pistons.
 The greater the number of pistons or mechanisms the more complex the system, and the greater
the amount of force created.
 The one similarity between pneumatic and hydraulic processes is the use of pressure.
 In the case of a pneumatic system, a gas is used.
 Equipment using a pneumatic system has a set of connected parts.
 Compressed air is injected using a compressor, which is sent through a series of hoses.
 The flow of air is regulated by valves.
 The gas, much like a hydraulic system, under pressure, is transformed by a pneumatic cylinder into
mechanical energy.
 Some forms of pneumatics inject inert gases, ones that do not undergo a chemical change, into the
process for specialized tasks and operations.

Some of the primary benefits are:

1. Easy to control - Using a simple set of levers and buttons, an operator can start, stop, speed up or slow down
a procedure without making major changes.
2. Force - Force is created without the use of gears, pulleys, or levers and is multiplied from a few pounds into
hundreds of pounds.
3. Constant and consistent – The fluid power of a hydraulic system provides constant torque or force
regardless of speed changes.
4. Economical – Since hydraulic systems have fewer moving parts, they are easy to maintain and simple to use.
5. Safe – Since hydraulic systems are enclosed and have limited moving parts, they are safer than mechanical
or electrical systems.
 Applications
There are several applications for hydraulics that include hydraulic lifts, brakes, and many parts of aircraft.
As with hydraulic systems, there are many advantages to pneumatic ones that include:
1. Cost – Pneumatic systems cost half as much as hydraulic ones.
2. Efficient - Air in pneumatic devices is free of moisture, which eliminates any complications with internal parts.
3. Water treatment – When used to open and close underwater valves, pneumatic systems are ideal since they can
sustain overload pressure conditions.
4. Low maintenance - Pneumatic actuators have a long life and perform well with limited maintenance.
5. Distance – When power needs to be relayed over long distances, pneumatic systems can do it easily and
economically.
6. Uncomplicated devices - Pneumatic devices are air based with less complicated designs and made from
inexpensive materials.

 There are hundreds of uses of pneumatics from brakes and dental drills to vacuum pumps and sewer systems.
 The use and application of these devices is limitless mainly because of the low cost of manufacturing them.

Similarities and Differences between Hydraulics and Pneumatics

 Hydraulics and pneumatics both use pressure and another medium to perform their operations.
 Also, both are economical and safe as well as being self-contained with few working parts.
 Hydraulics and pneumatics work as an actuator using a pump, which are controlled by valves used
to convert pressure into mechanical motion.
 The amount of force created by the process is greater than that which is initially applied.
 Though both processes use pressure, the medium to create the pressure is different where
hydraulics use oil or water and pneumatics use a gas, which is mainly air.
 The type of medium used in a hydraulic system is incompressible.
 The volume of it remains the same regardless of the amount of pressure applied.
 Hydraulic systems tend to be large and complex.
 They need room to store their reservoir of fluid, and the components of a system are large and bulky to create
the necessary pressure, which makes them more expensive than pneumatic systems.
 They have the advantage of being able to take on larger loads than pneumatic systems due to their bulk.
 Since hydraulic systems use oil, which is very viscous, they require time to begin operation and operate
slowly.
 Also, the mechanism to move the oil through the pipes requires more energy, which further slows its
operation.
 Pneumatic systems are powered by air or inert gases.
 Since air is the main medium in a pneumatic system, they operate cleaner than hydraulic systems and can be
proposed for tasks where food is present or in antiseptic environments.
 This makes them available to the pharmaceutical and biotech industries.
 Most pneumatic systems are very simple and require only an on and off switch to activate them, a feature that
makes them less expensive than hydraulic systems.
 They are easy to store and take up less room since they do not have the large reservoir of a hydraulic system.
 Another benefit of a pneumatic system is the capability of expelling the gas from their operation into the
environment.
 Pneumatic systems operate faster with smaller cylinders since air flows quickly with little resistance or
viscosity.
 Each system, hydraulic or pneumatic, has specific uses.
Basic summary of the differences between the two systems.
1. Medium
Hydraulics – some form of liquid, usually oil
Pneumatics – inert gas or air
2. Speed
Hydraulics – very slow to operate due to their complex and complicated mechanism
Pneumatics – operate much faster since air or gas is their medium
3. Cost
Hydraulics – Maintenance and installation is expensive and time consuming
Pneumatics – Easy to install and maintain with a very simple operating system
4. Pressure
Hydraulics – 3000 to 5000 psi
Pneumatics – 100 psi up to 150 psi

Hydraulics
Uses of Hydraulics
 The scientific definition of hydraulics is the mechanical study of fluids, which have the ability to
perform complicated work.
 When a pressure is applied to a liquid in a confined space, the pressure is applied equally to all
parts of the space.
 A hydraulic system is capable of multiplying the force created by the pressure.
 This simple principle enables to lift thousands of pounds by using a very small amount of force.
 The most common and everyday use of hydraulics is in a braking system that works through the use
of fluids.
 The fluid in the system is activated by applying pressure to the brake pedal that sends a message to
the hydraulic fluid that engages the drum shoes or disc calipers.
 The mechanical force from the brake pedal is converted into hydraulic pressure in the master
cylinder.

 These same principles are used in several types of devices such as airplanes where they slow the craft when
it lands or trash compactors that are seen on trash trucks.
 The space program uses hydraulics since they are able to work in a zero G environment.
 Since their discovery, hydraulics has become a vital part of many industries and their uses have greatly
multiplied.

Types of Hydraulics and Illustrations

 The type of fluid used in hydraulics is determined by its viscosity.
 In most hydraulic systems, the fluid has a low viscosity that ensures an easy flow to perform the needed work.
 Three of the types of hydraulic systems are gear pumps, screw pumps, and fixed placement vane pumps.
 Each has a rotary type mechanism designed for low tolerances between moving parts.
 The majority of hydraulic devices have a low rotational speed.
 Gear pumps are a common type of hydraulic pump that have a pair of meshed gears inside a casing.
 The gears in the pump apply the pressure to the fluid.
 The gears transfer the fluid from one part of the pump to another to apply force.
 They are reliable since they provide a fixed flow rate.
 Rotary vane pumps have adjustable vanes in an enclosed housing.
 As a rotor moves around the housing, the vanes adjust the tips of the vanes touching the inner surface of the
housing. The fluid enters the housing and is discharged as the vane and rotor turn.
 Rotary vane pumps operate best with a low viscosity fluid.
 The rotary hydraulic pumps are more efficient than gear hydraulic ones.

 Screw hydraulic pumps have meshing spiral gears in a cylinder.

 It operates on the same principles as the Archimedes' screw where oil is forced along the cylinder between the
teeth of the gears.
 Apart from gear, rotary vane, and screw hydraulic pumps other examples are radial piston, axial piston, and
generator hydraulic pumps.
 Each type is designed to perform a specific function.

Materials used to make Hydraulic Pumps

 Manufacturers of hydraulic pumps select the basic materials for construction based on the type of
pump they produce.
 An important part of the process is to select a metal with sufficient thickness to be able handle the
pressure that is produced.
 In the majority of cases, it is some form of steel or iron where the gauge is a significant factor.
 The mechanism and fluid for a hydraulic pump is enclosed in a tube or housing, which has to be
completely sealed.
 This is confirmed through testing before installation of the components.
 Basic hydraulic pumps are enclosed in a cylinder, which is found in screw and rotary vane hydraulic
pumps.
 Gear type hydraulic pumps consist of housing.
 The size of this type depends on the work to be completed and the size of the gears.

Pneumatics
Uses of Pneumatics
 Pneumatic systems use compressed air to move solid objects through a system of tubes.
 Pneumatic systems use compressed air to create controlled energy and are used in a variety of industries.
 These systems rely on compressed air provided by an air compressor, which sucks in air from the
environment and stores it under high pressure in a receiver.
 The air is sent to the system through pipes and valves normally at a pressure of 6 kg/sq. mm to 8 kg/sq. mm
where maximum force can be 50 KN.
 The work of the compressed air is performed by a piston or vane.
 In this era of environmental concern, pneumatics have become a popular replacement for hydraulics since the
waste product from its operation is air.
 Air brakes are a form of pneumatic using compressed air for a form of friction brake, which begins
by the activation of a piston that applies pressure on brake pads.
 Exercise machines use the resistant factor of a pneumatic cylinder that can be adjusted to fit the
user.
 Pneumatic motors where compressed air is converted to mechanical energy by a linear motion.
 Pressure regulators designed to stop the flow of a liquid or gas at a specific pressure.
 Pipe organs use pressurized air through the pipes to produce musical notes.
 Cable-jetting used to put cables into ducts through the use of compressed air.
 Pneumatic mail systems deliver mail through pressurized air tubes, which was one of the original
uses of a pneumatic system from the 19th Century.

Rodless Pneumatic Cylinders –

 Rodless pneumatic cylinders are unlike traditional pneumatic cylinders in that they move a load
alongside the piston.
 They have the same stroke length but use less space than a pneumatic cylinder with a rod and have
the same force in both directions of their stroke.
 The stroke of a rodless pneumatic cylinder is completely in the body of the cylinder, which gives it a
smaller footprint.
 The three rodless pneumatic cylinder types are magnetic, cable, and slotted, which refer to how the
piston is connected to the carrier with the most secure connection being slotted.
 On each end of a rodless pneumatic cylinder are cushions to prevent hard stops.
 Magnetic: The piston and the carrier are connected by magnet, which creates a leak free cylinder.
 Cable: A cable connects to the piston. A pulley at each end of the cylinder is connected to the carrier and
moves it along the barrel. It is a very simple and uncomplicated structure.
 Slotted: A slot is located in the cylinder’s length that has an inner and outer metal band that makes a direct
mechanical connection to the piston. The slotted version of rodless pneumatic cylinders is the most common
type.
 Rodless pneumatic cylinders do not cause deflection due to the position of the rod, which is unlike traditional
pneumatic cylinders with a rod that have deflection due to the lateral load.
 This aspect of rodless pneumatic cylinders makes it possible to produce cylinders with a very long stroke.
 Additionally, rodless pneumatic cylinders are environmentally friendly since they are sealed to prevent leakage
of lubricant or moisture from the compressed air.
 With traditional pneumatic cylinders, moisture and lubricant are expelled when the rod is extended.

Types of Pneumatic Systems

 Pneumatic systems create force through the use of contained air systems where energy is stored under
pressure and released by valves.
 The air continues to expand until it gets to atmospheric pressure.
 The implementation of a pneumatic system is best in conditions that do not need a lot of power in a limited
space. Four types of pneumatic systems are dilute phase, dense phase, vacuum based, and pressure
based.
 Dilute-phase pneumatics is used to move powders or particles at a high gas velocity.
 It is ideal for moving dry bulk materials as well as being cost effective.
 Feeds or grain are dumped into a high velocity gas stream using a rotary airlock valve where it is
carried through pipes.
 This method is widely used as a conveying system for grain and cereal production.
 Dense-phase pneumatics has a line pressure calibrated to match the characteristics of the material
being moved allowing solid material to transform into a liquid state when being moved at a slower
velocity.
 It can be used to transport abrasive materials without damaging system components. To assist the
movement of materials and avoid clogs, busters are placed along the pipe to keep the material
moving.
 Vacuum based pneumatic systems pull materials to them.
 This form of pneumatic system is used when materials are being sent to one central location and
can lift items from open containers. Since vacuum systems seldom have leak problems, they can be
used for the movement of hazardous materials.
 Pressure based pneumatic systems can send objects to multiple locations by using diverter valves,
which open and close to control the flow of air in the system.
 This type of system can be controlled by the operator who has the ability to raise and lower the
pressure.
 Pressurized systems can carry heavier materials over long distances. Pressure in the system is
controlled by a rotary airlock valve.

Parts of a Pneumatic System

 Cylinders, rotary actuators, and air motors create the force and energy of a pneumatic system for
the movement and processing of materials.
 Other components required to control and operate the system include air service units for the air
compressor and valves to monitor air pressure as well as the direction and movement of the
actuators.
 The system can be broken into two components – air pressure production and a consuming system.
 Essential parts of the system include a compressed air transportation and distribution system consisting of an
air compressor, electric motor, pressure switch, check valve, storage tank, pressure gauge, auto drain, air
dryer, filters, air lubricator, pipelines, and different types of valves.
 The air consuming system has an intake filter, compressor, air take off valve, auto drain, air service unit,
directional valve, actuators, and speed controllers.
 When the system is activated, an intake filter removes contaminants from the surrounding air as the
compressor draws in the air.
 The compressor converts mechanical energy into the potential energy of compressed air.
 Since there are several types of compressors, the type chosen depends on the needed delivery pressure and
air flow.
 The air that is compressed is stored in a receiver tank to smooth the pulsating flow from the compressor and
cool and condense any moisture.
 The receiver has the added function of removing the heat created by the compressed air.
 A very important part of the operation of a pneumatic system is to keep it maintained with regular lubrication of
the cylinders and valves.
 Most systems put a fine mist of oil into the compressed air, which helps to lubricate the moving parts.
 Oil viscosity is between 20 to 50 centistokes.

Deciding Between a Hydraulic or Pneumatic System

 Hydraulic and pneumatic systems are a part of engineering that deals with fluid power or fluid mechanics, a
branch of science that deals with how fluids react. Hydraulics create, control, and produce power through the
use of pressurized liquids or fluids, which are a form of matter that include liquids, gases, and plasmas.
 When making the decision to use a hydraulic or pneumatic system, it is important to examine the advantages
of each form since each type of system is engineered to perform specific functions.

Advantages of Hydraulics
 Safe and easy to maintain with fewer moving parts
 Responsive and supplies more power
 Liquid does not absorb supplied energy
 Easily controlled

Advantages of Pneumatics
 Uses air
 The compressibility of air.
 Simple in construction and easy to handle.
 Ability to control pressure and force
 Low Maintenance
 Explosion-proof
 Low cost
 Fire-proof
Manufacturing of a Hydraulic System
 The theory behind a hydraulic system was established by the use of Pascal’s law, the fluid in a system is
equal to its area.
 Most systems use some form of piston and cylinder apparatus though there are gear forms as well.
 The convenience of a cylinder type system is where a small amount of torque can produce great force.

 By adjusting the volume of the fluid in the system, the amount of force that can be controlled through the
efficiency of the adjustments is very limited. In cases where motors are used, there is greater control over the
system.
 Presently, motor driven systems are more popular than rotating ones since motor systems offer the operator
greater control.
 Most cooling systems are manufactured using rotating hydraulics. Hydraulic systems tend to take up less
room than motor driven ones making them easier to use.

Manufacturing of a Pneumatic System

 Pneumatic systems rely on some form of gas to produce force. In most cases, pressurized air is used to drive
the system with a spray of lubricant. Most pneumatic systems operate at 100 psi with few systems able to
produce 3000 to 5000 psi.
 Pneumatics is designed to handle small loads.
 At the heart of every pneumatic system is an air compressor designed to reduce the volume of air, which
increases the pressure.
 Hoses, controlled by valves, are used to send air to an actuator. A central part of the system is the filter that
keeps contaminants out of the system.
 Since a pneumatic system depends on an air compressor, it is important to select one that best fits the use of
the pneumatic system.
 Three types of air compressors are reciprocating, rotary screw, and rotary centrifugal.
 The selection of the air compressor is the first step in the creation of a pneumatic system. In many cases, a
form of piston compressor is the most popular and widely used.
 LOW COST AUTOMATION (LCA) & CASE STUDIES

INTRODUCTION
Automation is a set of technologies that results in operation of machines and systems without significant human
intervention and achieves performance superior than manual operation. It means to minimize the human control in
industry or any work field to increase productivity, increasing product quality, reducing manufacturing time, reducing
cost and increasing safety in working operations.
With increasing globalization, industrialization and increasing demand of certain products in market, Industries are
concentrating on more and more automation by different methods to increase productivity and to increase
competitiveness in the market. Automation requires huge capital investment to replace conventional machines by
CNC‟s, VMC‟s etc. Large Scale Industries which do have large scale production and sells can afford huge cost
automation. But Medium and Small-Scale Industries which do not have that much production cannot afford such huge
cost automation, at such case alternative Low-Cost Automation (LCA) proves to be best solution.
Low Cost Automation (LCA) is the technology that is effective or promises to be helpful for any kind of
manufacturing organization.
Concept of Low Cost Automation (LCA)

Automation means to replace human control through machines and technology. This includes automation in any unit
i.e. storage systems, production lines, assembly lines, Software etc. Low Cost Automation (LCA) is defined as
technology that creates some degree of automation using existing tools, methods and equipment. Low cost automation
involves the introduction of standard equipment, mechanisms and devices to convert manual operations to automatic
ones. Investment cost is low, as the term itself implies, and the Return of Investment in terms of improved
productivity and better work efficiency is high. LCA may best be paraphrased as “simple automation” Jigs, fixtures,
drills etc are the few tools used in LCA.
Low Cost Automation (LCA) can be achieved by following methods-
 Using mechanical tools or apparatus i.e. using shafts, gears etc.
 Using fluid power I.e. pneumatics and hydraulics
 By electrical or electronic means
Fluid power and its scope in low cost automation
Fluid power means using pressurized gas or liquid in a confined space to control force or to achieve certain movement
of the mechanical element. Fluid power consists of pneumatic and hydraulic systems. Pneumatic system makes use of
compressed gas for performing the work whereas in hydraulics pressurised liquid, oils, petroleum etc is used for
performing the work.
Merits of using fluid power system
 Fluid power is easy to produce, transmit, regulate, control and can be operated easily.
 Low weight to power ratio.
 Multiplication and variation of forces.
 Frictional resistance is less.
 Noise and vibrations produced is minimal.
 We can start, stop, accelerate, decelerate, reverse or position change with great accuracy using simple leversand push
buttons.
 Economical
 FPS can be used where safety is of vital importance. [2]

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 CASE STUDIES
A. Low cost automation using pneumatic grippers for pick and place
Gripping means to hold the object firmly. To move the object from one place to another it is needed to grip that
object. Traditionally, in industries the products are transferred by gripping the products by labours. This mean is
very time consuming and costly so it is needed to atomize. It can be automated by using gripping system actuated
mechanically, electrically, pneumatically etc
Pneumatic actuation of gripping system
This type of actuation is frequently used for gripping systems, due to its advantages:
 Simple control schemes;
 Possibility of system overloading;

 Easy maintenance;
 Environment-friendly working medium;
 Easily adjustable torques, speeds and forces, by means of simple devices;
 Pneumatic transmissions allow damage-free frequent starting and stopping, as well as sudden changes of
direction;
 Compliance etc.
The structure of a pneumatic actuation system generally includes a source of compressed air (compressor), an air
preparation system (filter, pressure regulator, and lubricator), adjustment and control elements of the pneumatic
quantities and final consumers (motors) that transform the input pneumatic energy into useful work.
Case study on pneumatic gripper used for Low Cost Automation
Problem definition
The Solar Panel manufacturing company was facing the problems in transferring the solar panels from one station to
another. The solar panels are made up of glasses and it is very delicate, so most of the time while transferring, it was
breaking. The company was breaking more panels than they were manufacturing. Also, they were facing the
problem of transferring the huge dimensioned solar panel. The 14” diameter parabola shaped glass bowl solar panel
they made was very delicate so every time while transporting, it was either being dropped or being squeezed to their
breaking point. They were disappointed with the downtime and broken product they had suffered with what had
been commercially available. Most available grippers in the market was not able to handle the fragile glass. Also,
the magnetic pick and transport is not possible as the glass is not magnetic. So, they turned to pneumatic grippers
which can grip the glass with the help of compressed air and can transport it with ease. And due to breaking of
glasses it caused many injuries to workers like cuts etc. which created unsafe working conditions for workers.
Solution
The Pneumatic grippers were used which is specifically a type of pneumatic actuator that involves either a parallel
or angular motion i.e. the „tooling jaws, fingers or rubber suction diaphragm‟ that will grip on object. In pneumatic
grippers, the vacuum is created in the rubber cups by creating pressure difference with the help of the force from the
compressed air by compressor. The gripper is placed directly on a product and with vacuum generation the rubber
cups creates sucking action which in turn grip the object firmly and tightly. The 14” parabolic shaped glass bowl
solar panel is gripped firmly and is being transferred from one station to another with ease and without breakage.
Thus, the loss of company due to breaking is minimized by automating the transfer line of the company using
pneumatic gripping system.

Fig 1.- Image showing lifting of solar panel using pneumatic gripper Fig. 2- Image showing use of pneumatic grippers in other industries

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 Fig. 3- Components of Pneumatic gripping system

Results
1. Breakage of the solar panels got reduced.
2. Ease in transfer of solar panels.
3. Production rate increase.
4. More safe working conditions.

II. CONCLUSION

The requirements of the industries like high productivity, low cost, etc. can be fulfilled by automating the
industries using pneumatics i.e. by using pneumatic grippers at a very low cost. This technology is also portable
and reliable as it has very small machine structures and can give thelarge tonnage. Apart from this it also provides
safety to the workers.

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B. Low Cost automation using pneumatic power clamping system for machining processes
Power clamping is a phenomenon in which number of clamps can be operated simultaneously. It is classified as
1. Fluid power clamping.
• Pneumatic actuation clamping
• Hydraulic actuation clamping
• Air to hydraulic booster circuit clamping
2. Magnetic clamping
3. Electrostatic clamping
Pneumatic Actuation Clamping
 Compressed air is used for power transmission
 Depressurized air is exhausted directly into atmosphere
 As load resistance increases speed of pneumatic devices drops and vice versa.
 Moisture in air causes rusting of pneumatic cylinders and valves which can be minimized by usinglubricator
 Pressure regulator can be used to vary system pressure.
Construction and Working
 It consists of three stations
 At first station, the power in the form of pneumatic pressure (6-12 bar) is produced through pressurized airsystem.
 Pressurized air system consists of following components
a. Air inlet
b. Filter, lubricator, regulator device
c. The safety valve and release valve
 The second station of the system consists of hydraulic booster consisting of booster, check valve and
manifold.
 The third and final station is clamping system to hold, support and support the workpiece.
Advantages
 Increased production rate
 Controlled clamping forces
 Automatic sequencing of operations
 Remote clamp operation
 Consistent and repeatable operation
 Automatically adjusting work support

Case Study on pneumatic power clamping system for low cost automation
Problem definition
In industry a plastic filter core was needed to be trimmed, drilled in length and ends to be reamed. The machining on
the plastic filter core was to be done on three separate working stations. So transferring the work piece after each
operation was very time consuming. Also, the set-up and material movement time resulted in a bottleneck. As all the
machining operations were done manually, many errors were present and the required precision was not achieved. Also,
as all operations were done manually so quality of the product was an issue. Quality, slow production rate and low
precision were the problems of the industry.

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 Solution
There is a machine that would perform the required operation of trimming, reaming, drilling etc. The machines consists
of the grippers mounted on the slides, take the 12” long core blank and placed it on the first station of operation. The
pneumatic hold-down clamps hold the tube blank firmly and the pneumatic clamp with a knife blade mounted on the
clamp arm, cuts the end of the tube at precise length. Then grippers grip the work piece and then with the help of the
sliders it is moved to the next station where it is drilled along the length. Then, again with the help of the grippers and
the sliders the work piece is moved to the final station where the inner diameter of the tube is reamed on both ends.
Pneumatic swing clamps hold the tubes during the operation.

Fig. 4 - Pneumatic toggle clamp

Fig 5 - Pneumatic swing clamp Fig. 6 - Image of pneumatically clamped workpiece undergoing drilling

Results
1. Working speed and rate increases.
2. Clamping is tight and firm. So, ease in operations.
3. Précised job is done.
4. Quality of the job is increased.
5. Safety of the workers.

III. CONCLUSION
The requirements of the industries like high productivity, low cost, etc. can be fulfilled by automating the
industries using pneumatics i.e. by pneumatic power clamped system at a very low cost. This technology is also
portable and reliable as it has very small machine structures and can give thelarge tonnage. Apart from this it also
provides safety to the workers.

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 REFERENCES
[1]. G. Tamizharasi, S. Kathiresan, D. Balaji and S. Jegathiesan, “Low cost automation in power press”, Indian Journal
of Science and Technology, November 2015.
[2]. S R. Majumbdar, “Principles and Maintenance of Oil and Pneumatic systems”, McGraw Hill Education
publications.
[3]. M. Muthukkarapun and K. Manoj, “Low cost automation using pneumatic system- An online case study in multi
station part transfer, drilling and tapping machine,” 24th International Symposium on automation and robotics in
construction (ISARC 2007).
[4]. Antonio Carlos Valdiero Ivan Jr. Mantovani, Andrei Fiegenbaum, Giovani P. B. Dambroz,and Luiz A. Rasia,
“Development of a Pneumatically Driven Cell for Low Cost Automation”.
[5]. Sree Vani Yabaluri, C. Mukul, Mude Murali Mohan Naik, A. Manish, Chalivendula Srikar Rao, “Utilization of
Low Cost Automation (LCA) by Implementing Electro- Pneumatic System in Industries for Printing Codes and
Dates on Manufactured Bottles for Better Production Rate and Reduction of Labour Work”, International Journal of
Advanced Mechanical Engineering, November 2017.
[6]. Information on “Hydraulic and Hydro-pneumatic Clamping Elements for Production Tooling”.
[7]. Rituparna Datta and Bishakh Bhattarcharya, “Analysis and Optimization of Robotic gripper using multiobjective
genetic algorithm”.