AUTOMATIC GEAR MILLING MACHINE USING PROXIMITY SENSOR
Roberto Magalhães
To share
AUTOMATIC GEAR MILLING MACHINE USING PROXIMITY SENSOR
The Gera milling machine is a metal milling machine designed to cut/grind metal by applying pneumatic pressure. The machines are intended exclusively for mass production and represent the fastest and most efficient way to cut metal. Low speed operation occurs in a milling operation. This machine is a multifunctional machine.
Saws are used to cut thin, soft metals. The milling spindle is used for milling operation by replacing the saw frame. The operation of the unit is simplified to a few simple operations involving a cylinder block and piston arrangement.
There are various types of milling machines in the Engineering field, which are used to meet the requirements. We are interested in introducing pneumatic systems especially in milling machines and also in milling operations. The main function of pneumatic milling is to cut thin and soft metals through pneumatic energy.
INTRODUCTION
The word 'pneuma' comes from the Greek and means wind-breather. The word pneumatics is the study of air movement and its phenomena derive from the word pneuma. Today, pneumatics is understood mainly as the application of air as a working medium in industry, especially in the activation and control of machines and equipment.
Pneumatics have been used for some time to perform the simplest mechanical tasks; in more recent times it has played a more important role in the development of pneumatic technology for automation.
AUTOMATIC GEAR MILLING MACHINE USING PROXIMITY SENSOR
As pneumatic circuit plays a vital role in this device, it is very necessary to explain the working of this circuit. Starting initially with air packs, their function is to compress air from a low inlet pressure (usually atmospheric) to a higher pressure level. This is achieved by reducing the air volume.
WORKING PRINCIPLE
Air compressors are generally positive displacement units and are of the reciprocating piston type or rotary screw or rotary vane type. The air compressor used here is a two-stage compressor unit, typically small in size. It also consists of a compressed air tank, electric rotor and pulley drive, pressure controls and instruments for quick connection and use. The stored air from the compressor passes through an air filter where the compressed air is filtered of fine dust particles. However, before air is sucked into the compressor, a filtration process takes place, but not enough to operate in the circuit where the filter is used. It then has a pressure regulator where the desired pressure is adjusted to the operator. Here a variable pressure regulator is adopted.
Through a variety of available direction control values, a manually operated solenoid valve with control unit is applied. The solenoid valve used here has 5 ports and 3 positions. There are two exhaust ports, two outlet ports and one inlet port. In two extreme positions, only the directions can be changed, while the Center ore is a neutral position and no physical changes occur.
The 2 output ports are connected to an actuator (cylinder). The pneumatic drive is a double-acting, single-rod cylinder. The cylinder output is coupled to another purpose. The piston end has an air horn effect to prevent sudden thrusts at the ends.
WORKING PRINCIPLES
Compressed air from the compressor reaches the solenoid valve. The solenoid valve changes the flow direction according to the signals from the timing device.
Compressed air passes through the solenoid valve and is admitted to the front end of the cylinder block. The air pushes the piston into the spring end milling stroke. At the end of the spring end milling stroke, air from the solenoid valve reaches the rear end of the cylinder block.
The pressure remains the same but the area is smaller due to the presence of the piston rod. This puts greater pressure on the piston, pushing it at a faster rate, thus allowing for a faster return stroke.
The piston stroke length can be changed by making a suitable adjustment to the timer.
BENEFITS
There is no need to feed each cut due to the presence of weight.
The milling/milling speed can be varied according to our needs by adjusting the timer.
It's portable
It does not have any main engine such as electric motor related to the unit.
As air is freely available, we can utilize it to cut metal and hence it is economical.
Simpler to build than a mechanical saw and grinder
It's compact
Less maintenance
LIMITATIONS
Only smaller size and soft metal can be cut
It is more expensive than the mechanical saw because of the compressor unit.
Less efficiency when compressed in a mechanical device.
AUTOMATIC GEAR MILLING MACHINE USING PROXIMITY SENSOR
