73833830 design and fabrication of portable pneumatic fuel pump
TRANSCRIPT
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DESIGN AND FABRICATION OF PORTABLE
PNEUMATIC FUEL PUMP
A PROJECT REPORT
Submitted by
PRABHU J (080212100085)
RAJARAJAN N M (080212100097)
SARAVANAKUMAR S (080212100109)
VEERAMANIKANDAN A (080212100128)
in partial fu lf ilment for the award of the degree
Of
BACHELOR OF ENGINEERING
INMECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
ANNA UNIVERSITY OF TECHNOLOGY COIMBATORE
COIMBATORE641047
June 2011
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ACKNOWLEDGEMENT
First and foremost, we thank the Lord almighty for showering his
blessings and lifting us in our all endeavours.
We wish to express our deep sense of gratitude and heartfelt thanks to the
Vice Chancellor Dr. K. Karunakaran, Anna University of Technology
Coimbatore, for providing the efficient lab facilities and internet facilities which
paved the way for the successful completion of the project.
We wish to express our sincere thanks and deep sense of gratitude to the
Registrar Cdr. S. Premchand, Anna University of Technology Coimbatore, for
providing the necessary facilities along with sound moral support to carry out
this project work successfully.
We express our deep gratitude towards our respected Dean Academics,
Dr. M. Saravanakumar, Anna University of Technology Coimbatore, for his
continuous encouragement and support.
We would like to thank, Dr. M. Sakthivel, Head of the Department,
Mechanical Engineering, for giving his various ideas and suggestions which
helped in enhancing the project in efficient way.
We would like to express our sincere thankfulness and deep sense of
gratitude to our guide Dr. K. Sooryaprakash, Assistant Professor, Department
of Mechanical Engineering for giving his full support with encouraging words
and mind which helped in completing this project with interest and to learn
about various techniques.
We would also like to express our sincere thankfulness and deep gratitude
to all our beloved faculty of the Department of Mechanical Engineering.
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TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.
ABSTRACT i
LIST OF TABLES ii
LIST OF FIGURES iii
1 INTRODUCTION
1.1 Project Overview 1
1.2 Company Profile 5
2 LITERATURE REVIEW 6
3 OBJECTIVE 7
4 PROJECT DESCRIPTION
4.1 Introduction 8
4.2 Components and Descriptions 13
4.3 Block Diagram 17
4.4 Parts of the Pump 18
4.5 Parts Specifications 23
4.6 Working Principle 27
4.7 Design Calculation 29
4.8 Maintenance 31
4.9 Advantages and Limitations 32
5 BILL OF MATERIALS 33
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6 COST ESTIMATION 34
7 CONCLUSION AND FUTURE ENHANCEMENTS
7.1 Conclusion 35
7.2 Future Enhancements 35
8 REFERENCES 36
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ABSTRACT
This project DESIGN AND FABRICATION OF PORTABLE
PNEUMATIC FUEL PUMP is an outcome of basic instinct to increase the
discharge rate and decrease the time of pumping the fuel from storage barrels to
the machine or equipment especially industries where machineries are placed in
second or third floor.
By utilizing simple pneumatic mechanism, fuel can be pumped especially
with less power consumption and minimum human labour. When compared to
traditional fuel pumping the time taken is also dramatically reduced, as the
discharge rate is increased drastically.
Added advantage in this is portable and occupies less space. It is ideal for
fuel pumping, as no electric field around the fuel pumping area.
This project is of great use to companies where pumping of fuel is
everyday duty, even this project can be used in ration shops.
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LIST OF FIGURES
FIGURE
NOTITLE
PAGE
NO
4.3.1 BLOCK DIAGRAM OF FUEL PUMP 17
4.4.1 PRESSURE GAUGE 18
4.4.2 AIR HOSE 19
4.4.3 GATE VALVE 21
4.4.4 O RINGS 22
4.5.1 CYLINDER HEAD 23
4.5.2 CYLINDER 24
4.5.3 ONE WAY VALVE 24
4.5.4 SUCTION PIPE 25
4.5.5 ISOMETRIC VIEW OF PNEUMATIC FUEL PUMP 26
4.6.1 FUNCTION CHART 28
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LIST OF TABLES
TABLE NO TITLE PAGE NO
1 BILL OF MATERIALS 33
2 COST ESTIMATION 34
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CHAPTER 1
INTRODUCTION
1.1 PROJECT OVERVIEW
In the pursuit of excellence, the manufacturing industries are seeking now in a new
technology to improve productivity, quality of the product and reduce product cost. The cited
subjects are seriously discussed in these days.
Most of the manufacturing industries use centrifugal pumps for pumping fuel from
barrels to the required location. The discharge rate of centrifugal pump is low. The discharge
head has also some limitations which restrict the use of centrifugal pump where high head is
required.
As a fuel pump, the centrifugal pump is always risky because of electric motor placed
just behind the impeller, which may lead to fire accidents.
Hence having this in mind, usage of reciprocating pump instead of centrifugal pump
looked like the best alternate. Rather than keeping the idea in mind we brought it to reality.
We tested the performance of both the pumps.
In this work a double acting reciprocating pump is used as fuel pump.
PNEUMATICS
The word pneuma comes from Greek and means breather wind. The word
pneumatics is the study of air movement and its phenomena is derived from the wordpneuma. 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 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 the
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pneumatic system is being adopted for the first time, however it wills 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 compressed and delivered and the
volume expressed is that of the air at intake conditions namely at atmosphere pressure and
normal ambient temperature.
The compressibility of the air was first investigated by Robert Boyle in 1962 and that
found that the product of pressure and volume of a particular quantity of gas.
The usual written as
PV = C (or) P1V1= P2V2
In this equation the pressure is the absolute pressured which for free is about 14.7 Psi
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 the control
system (although equally pneumatic control systems may be economic and can be
advantageously applied to other forms of power).
The main advantage of an all pneumatic system are usually economic and simplicity
the latter reducing maintenance to a low level. It can also have outstanding advantages in
terms of safety.
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PRODUCTION OF COMPRESSED AIR
Pneumatic systems operate 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 wills 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 compressed and delivered and the
volume expressed is that of the air at intake conditions 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 in increased
precipitation of condense from the compressed air. Compressor may be classified in two
general types.
1. Positive displacement compressor.2. Turbo compressor
Positive displacement compressors are most frequently employed for compressed
air plant and have proved highly successful and supply air for pneumatic control application.
The types of positive compressor
1. Reciprocating type compressor2. Rotary type compressor
Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
application unless built in multistage designs and are seldom encountered in pneumatic
service.
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ROTARY TYPE COMPRESSORS
Rotary screw compressors use two meshing helical screws, known as rotors, to
compress the gas. In a dry running rotary screw compressor, timing gears ensure that themale and female rotors maintain precise alignment. In an oil-flooded rotary screw
compressor, lubricating oil bridges the space between the rotors, both providing a hydraulic
seal and transferring mechanical energy between the driving and driven rotor. Gas enters at
the suction side and moves through the threads as the screws rotate. The meshing rotors force
the gas through the compressor, and the gas exits at the end of the screws .
RECIPROCATING COMPRESSORS
Built for either stationary (or) portable service the reciprocating compressor is by far
the most common type. Reciprocating compressors lap be had is sizes from the smallest
capacities to deliver more than 500 m/
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 compressors that of three & four stages.
Single stage and 1200 stage models are particularly suitable for pneumatic
applications, with preference going to the two stage design as soon as the discharge pressure
exceeds 6 bar, because it in capable of matching the performance of single stage machine at
lower costs per driving powers in the range.
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1.2 COMPANY PROFILE
NAME : PERFECT POLY COATS
ADDRESS : S.F No. 408 / 1C,
PRICOL PLANT I,
Ramakrishna nagar,
Jothipuram Post
Coimbatore - 641047
NATURE OF WORK : Painting automobile components
M/S. Perfect poly coats is the painting shop where most of the PRICOL manufactured
components like clusters, speedometer consoles etc., are painted. This is the only painting
shop which runs under PRICOL.
It supplies products to the companies like Toyota, Ashok Leyland, TVS, Yamaha,Mahindra & Mahindra etc.,
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CHAPTER 2
LITERATURE REVIEW
The following solutions are drawn by referring various national and internationaljournals in context with the existing problem definition.
According to European Patent EP0398209 (Reciprocating oil pump), anexisting idea was identified. It works on a reciprocating pump providing oil
for low pressure, self-contained oil-filled cables. The pressure head we
required for our work was yet higher than the existing patent and large
changes are needed on the outlet valve arrangements.
An international journal titled Design and Experimental Analyses of Small-flow High-head centrifugal-vortex Pump for Gas-Liquid Two-phase Mixture
proposed an idea relevant to the current issue, but portability could not be
achieved. Also, centrifugal pumps are operated by electrical means but in our
system pneumatic source should only be used.
Based on an international journal titled Analysis of gear pumps used to pumphigh density oils, the idea of using a gear pump for our work was revived.
This idea was aborted due to insufficient discharge rate and high cost of the
equipment.
With reference to a United States Patent 6685443 (Pneumatic reciprocatingpump) the idea of using a pneumatically actuated pump was considered.
Hence the pump needed electrical source after actuation, the idea was ignored.
Based on a United States Patent 5158439 (Pneumatic pumping device)whichproposed an idea about a pneumatic pump for pumping acids, this pump can
be used but the density of operating fluid i.e, Diesel was much higher.
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CHAPTER 3
OBJECTIVE
The primary objective of our work is to set up a pumping arrangement to pump diesel
for a heating oven in a painting shop. Diesel is used as the fuel for the oven and hence it has
to be pumped to an overhead storage tank from barrels at the ground level. The main
concerns involved were
The pump should be fire proof in order to avoid any fire accidents. Theinternal atmosphere of the painting shop contains a considerable amount of
highly inflammable substances like thinner vapours.
The pump must be portable. There are four overhead tanks where the fuel hasto be pumped separately.
Electric motors cannot be used as the driving source due to the increased riskof fire accidents.
It was better to use pneumatic source as the primary source of power. It wasthe highly available source in the paint shop as it was used throughout the
painting process for spraying and drying procedures.
Thus through our search for a suitable way satisfying all the above concerns we
decided to work on this project which we found simple and economical.
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CHAPTER 4
PROJECT DESCRIPTION
4.1 INTRODUCTION
Positive displacement pumps
A positive displacement pump causes a fluid to move by trapping a fixed amount of it
then forcing (displacing) that trapped volume into the discharge pipe.
A positive displacement pump has an expanding cavity on the suction side and a
decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the
suction side expands and the liquid flows out of the discharge as the cavity collapses. The
volume is constant given each cycle of operation.
Positive displacement rotary pumps are pumps that move fluid using the principles of
rotation. The vacuum created by the rotation of the pump captures and draws in the liquid.
Rotary pumps are very efficient because they naturally remove air from the lines, eliminating
the need to bleed the air from the lines manually.
Positive displacement rotary pumps also have their weaknesses. Because of the nature
of the pump, the clearance between the rotating pump and the outer edge must be very close,requiring that the pumps rotate at a slow, steady speed. If rotary pumps are operated at high
speeds, the fluids will cause erosion. Rotary pumps that experience such erosion eventually
show signs of enlarged clearances, which allow liquid to slip through and reduce the
efficiency of the pump.
Positive displacement rotary pumps can be grouped into three main types. Gear
pumps are the simplest type of rotary pumps, consisting of two gears laid out side-by-side
with their teeth enmeshed. The gears turn away from each other, creating a current that trapsfluid between the teeth on the gears and the outer casing, eventually releasing the fluid on the
discharge side of the pump as the teeth mesh and go around again. Many small teeth maintain
a constant flow of fluid, while fewer, larger teeth create a tendency for the pump to discharge
fluids in short, pulsing gushes.
Screw pumps are a more complicated type of rotary pumps, featuring two or three
screws with opposing thread - that is, one screw turns clockwise, and the other
counterclockwise. The screws are each mounted on shafts that run parallel to each other; the
shafts also have gears on them that mesh with each other in order to turn the shafts together
http://en.wikipedia.org/wiki/Screw_pumphttp://en.wikipedia.org/wiki/Screw_pump -
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and keep everything in place. The turning of the screws, and consequently the shafts to which
they are mounted, draws the fluid through the pump. As with other forms of rotary pumps,
the clearance between moving parts and the pump's casing is minimal.
Moving vane pumps are the third type of rotary pumps, consisting of a cylindrical
rotor encased in a similarly shaped housing. As the rotor turns, the vanes trap fluid between
the rotor and the casing, drawing the fluid through the pump.
Reciprocating - type
Positive displacement pumps have an expanding cavity on the suction side and a
decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on the
suction side expands and the liquid flows out of the discharge as the cavity collapses. The
volume is constant given each cycle of operation.
The positive displacement pumps can be divided into two main classes
Reciprocating Rotary
The positive displacement principle applies to the following pumps. They are,
Rotary lobe pump Progressive cavity pump Rotary gear pump Piston pump Diaphragm pump Screw pump Gear pump Hydraulic pump Vane pump Regenerative (peripheral) pump Peristaltic pump
Positive displacement pumps, unlike centrifugal or roto-dynamic pumps, will produce
the same flow at a given speed (RPM) no matter what the discharge pressure. Positive
displacement pumps are "constant flow machines"
http://en.wikipedia.org/wiki/Progressive_cavity_pumphttp://en.wikipedia.org/wiki/Gear_pumphttp://en.wikipedia.org/wiki/Piston_pumphttp://en.wikipedia.org/wiki/Diaphragm_pumphttp://en.wikipedia.org/wiki/Screw_pumphttp://en.wikipedia.org/wiki/Gear_pumphttp://en.wikipedia.org/wiki/Hydraulic_pumphttp://en.wikipedia.org/wiki/Vane_pumphttp://en.wikipedia.org/w/index.php?title=Regenerative_pump&action=edit&redlink=1http://en.wikipedia.org/wiki/Peristaltic_pumphttp://en.wikipedia.org/wiki/Peristaltic_pumphttp://en.wikipedia.org/w/index.php?title=Regenerative_pump&action=edit&redlink=1http://en.wikipedia.org/wiki/Vane_pumphttp://en.wikipedia.org/wiki/Hydraulic_pumphttp://en.wikipedia.org/wiki/Gear_pumphttp://en.wikipedia.org/wiki/Screw_pumphttp://en.wikipedia.org/wiki/Diaphragm_pumphttp://en.wikipedia.org/wiki/Piston_pumphttp://en.wikipedia.org/wiki/Gear_pumphttp://en.wikipedia.org/wiki/Progressive_cavity_pump -
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A positive displacement pump must not be operated against a closed valve on the
discharge side of the pump because it has no shut-off head like centrifugal pumps. A positive
displacement pump operating against a closed discharge valve, will continue to produce flow
until the pressure in the discharge line are increased until the line bursts or the pump is
severely damagedor both.
A relief or safety valve on the discharge side of the positive displacement pump is
therefore necessary. The relief valve can be internal or external. The pump manufacturer
normally has the option to supply internal relief or safety valves. The internal valve should in
general only be used as a safety precaution, an external relief valve installed in the discharge
line with a return line back to the suction line or supply tank is recommended.
Reciprocating pumps
Typical reciprocating pumps are
Plunger pumps Diaphragm pumps
A plunger pump consists of a cylinder with a reciprocating plunger in it. The suction
and discharge valves are mounted in the head of the cylinder. In the suction stroke the
plunger retracts and the suction valves open causing suction of fluid into the cylinder. In the
forward stroke the plunger pushes the liquid out of the discharge valve.
With only one cylinder the fluid flow varies between maximum flow when the
plunger moves through the middle positions, and zero flow when the plunger is at the end
positions. A lot of energy is wasted when the fluid is accelerated in the piping system.
Vibration and "water hammer" may be a serious problem. In general the problems are
compensated for by using two or more cylinders not working in phase with each other.
In diaphragm pumps, the plunger pressurizes hydraulic oil which is used to flex a
diaphragm in the pumping cylinder. Diaphragm valves are used to pump hazardous and toxic
fluids.
An example of the piston displacement pump is the common hand soap pump.
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Gear pump
This uses two meshed gears rotating in a closely fitted casing. Fluid is pumped around
the outer periphery by being trapped in the tooth spaces. It does not travel back on the
meshed part, since the teeth mesh closely in the centre. Widely used on car engine oil pumps.it is also used in various hydraulic power packs..
Progressing cavity pump
Widely used for pumping difficult materials such as sewage sludge contaminated with
large particles, this pump consists of a helical shaped rotor, about ten times as long as its
width. This can be visualized as a central core of diameter x, with typically a curved spiral
wound around of thickness half x, although of course in reality it is made from one casting.
This shaft fits inside a heavy duty rubber sleeve, of wall thickness typically xalso. As the
shaft rotates, fluid is gradually forced up the rubber sleeve. Such pumps can develop very
high pressure at quite low volumes.
Roots-type pumps
The lowpulsation rate and gentle performance of this Roots-type positive
displacement pump is achieved due to a combination of its two 90 helical twisted rotors, and
a triangular shaped sealing line configuration, both at the point of suction and at the point of
discharge. This design produces a continuous and non-vorticuless flow with equal volume.
Some applications are:
High capacityindustrial air compressors Roots Type Superchargers on internal combustion engines. A brand of civil defense siren, theFederal Signal Corporation'sThunderbolt.
Peristaltic pump
A peristaltic pump is a type of positive displacement pump used for pumping a variety
offluids. The fluid is contained within a flexible tube fitted inside a circular pump casing
(though linear peristaltic pumps have been made). Arotor with a number of "rollers", "shoes"
or "wipers" attached to the external circumference compresses the flexible tube. As the rotor
turns, the part of the tube under compression closes (or "occludes") thus forcing the fluid to
be pumped to move through the tube. Additionally, as the tube opens to its natural state after
http://en.wikipedia.org/wiki/Pulsationhttp://en.wikipedia.org/wiki/Gas_compressorhttp://en.wikipedia.org/wiki/Roots_Type_Superchargerhttp://en.wikipedia.org/wiki/Federal_Signal_Corporationhttp://en.wikipedia.org/wiki/Thunderbolt_sirenhttp://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Rotor_(turbine)http://en.wikipedia.org/wiki/Rotor_(turbine)http://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Thunderbolt_sirenhttp://en.wikipedia.org/wiki/Federal_Signal_Corporationhttp://en.wikipedia.org/wiki/Roots_Type_Superchargerhttp://en.wikipedia.org/wiki/Gas_compressorhttp://en.wikipedia.org/wiki/Pulsation -
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4.2 COMPONENTS AND DESCRIPTION
PNEUMATIC CONTROL COMPONENT
Pneumatically controlling valves are valves that control the flow of pressurized air.
Another medium such as water (hydraulics) or electricity, for example, may be used to
control the valves.
Pneumatic cylinder
Pneumatic cylinders (sometimes known as air cylinders) are mechanical
devices which utilize the power of compressed gas to produce a force in areciprocating linear motion. Like hydraulic cylinders, pneumatic cylinders use the stored
potential energy of a fluid, in this case compressed air, and convert it into kinetic energy as
the air expands in an attempt to reach atmospheric pressure. This air expansion forces
a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod
transfers the force it develops to the object to be moved. Engineers prefer to use pneumatics
sometime because they are quieter, cleaner, and do not require large amounts or space for
fluid storage.
An air cylinder is an operative device in which the state input energy of compressed
air i.e. pneumatic power is converted in to mechanical output power, by reducing the pressure
of the air to that of the atmosphere.
Single acting cylinder
Single acting cylinder is only capable of performing an operating medium in only one
direction. Single acting cylinders equipped with one inlet for the operating air pressure, can
be production in several fundamentally different designs.
Single cylinders develop power in one direction only. Therefore no heavy control
equipment should be attached to them, which requires to be moved on the piston return stoke
single action cylinder requires only about half the air volume consumed by a double acting
for one operating cycle.
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Double acting cylinders:
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 stock. 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 stock 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 stokes in the other direction at full force and velocity.
Parts of Pneumatic Cylinder
Piston
A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors and pneumatic cylinders, among other similar mechanisms. It is the moving
component that is contained by a cylinder and is made gas-tight by piston rings. In an engine,
its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via
a piston rod and/or connecting rod. In a pump, the function is reversed and force is
transferred from the crankshaft to the piston for the purpose of compressing or ejectingthe fluid in the cylinder. In some engines, the piston also acts as a valve by covering and
uncovering ports in the cylinder wall.
In other words, the piston can be defined as a cylindrical member of certain length
which reciprocates inside the cylinder. The diameter of the piston is slightly less than that of
the cylinder bore diameter and it is fitted to the top of the piston rod. It is one of the
important parts which convert the pressure energy into mechanical power.
The piston is equipped with a ring suitably proportioned and it is relatively soft
rubber which is capable of providing good sealing with low friction at the operating pressure.
The purpose of piston is to provide means of conveying the pressure of air inside the cylinder
to the piston of the oil cylinder.
Generally piston is made up of
Aluminium alloy-light and medium work. Brass or bronze or CI-Heavy duty.
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The piston is double acting type. The piston moves forward when the high-pressure
air is turned from the right side of cylinder. The piston moves backward when high pressure
acts on the piston from the left side of the cylinder. The piston should be as strong and rigid
as possible.
The efficiency and economy of the machine primarily depends on the working of the
piston. It must operate in the cylinder with a minimum of friction and should be able to
withstand the high compressor force developed in the cylinder and also the shock load during
operation.
The piston should posses the following qualities.
a. The movement of the piston not creates much noise.b.
It should be frictionless.
c. It should withstand high pressure.
Piston Rod
The piston rod is circular in cross section. It connects piston with piston of other
cylinder. The piston rod is made of mild steel ground and polished. A high finish is essential
on the outer rod surface to minimize wear on the rod seals. The piston rod is connected to the
piston by mechanical fastening. The piston and the piston rod can be separated if necessary.
One end of the piston rod is connected to the bottom of the piston. The other end of
the piston rod is connected to the other piston rod by means of coupling. The piston transmits
the working force to the oil cylinder through the piston rod. The piston rod is designed to
withstand the high compressive force. It should avoid bending and withstand shock loads
caused by the cutting force. The piston moves inside the rod seal fixed in the bottom cover
plate of the cylinder. The sealing arrangements prevent the leakage of air from the bottom of
the cylinder while the rod reciprocates through it.
Cylinder Cover Plates
The cylinder should be enclosed to get the applied pressure from the compressor and
act on the pinion. The cylinder is thus closed by the cover plates on both the ends such that
there is no leakage of air. An inlet port is provided on the top cover plate and an outlet ports
on the bottom cover plate. There is also a hole drilled for the movement of the piston.
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Cylinder Mounting Plates:
It is attached to the cylinder cover plates and also to the carriage with the help of L
bends and bolts.
Control valve:
Various types of control valves are used to regulate, control and monitor the air
energy for control of direction pressure, flow, etc.
Pneumatic energy is regulated and controlled by pneumatic valves. Functionally
valves are divided into four major groups.
Direction Control Flow Control
Solenoid is another name for an electromagnet. Direction control valves are very
often actuated by electromagnets. An electromagnet is a temporary magnet. A magnetic
force is developed in an electromagnet when electrical current passes through it and force
drops down as soon as it is de energized.
This electromagnet is commonly termed as solenoid. The proper working of a
solenoid operated valve depends on the reliability of the electromagnets.
It ensures
Quick and sure action Long life. Easy maintenance. Less wastage of energy.
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4.3 BLOCK DIAGRAM
Fig. 4.3.1 Fuel Pump
The block diagram, as shown in the fig 4.3.1, shows the arrangement of the portable
pneumatic pump. This model is the actual output of this study.
AIR ADJUSTMENT SCREW
AIR INLET
PISTION ARRANGEMENT
FUEL DELIVERY
ONE WAY VALVE
SUCTION PIPE
PRE FILTER
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is used to measure the pressure in a vacuumwhich is further divided into two
subcategories, high and low vacuum (and sometimes ultra-high vacuum). The applicable
pressure range of many of the techniques used to measure vacuums has an overlap.
Filter
A pneumatic filter is a device which removes contaminants from a compressed air
stream. This can be done using a number of different techniques, from using a "media" type
that traps particulates, but allows air to pass through to a venturi, to a membrane that only
allows air to pass through.
Air hose
Air hose is shown in the fig 4.4.2. Air hoses are used in underwater diving, such as
scuba diving, to carry air from the surface or from air tanks or diving pumps to the diver. Air
hoses are therefore a necessary part of standard diving dress and any type of surface supplied
diving equipment. They are an essential part of scuba diving equipment, used to deliver
pressurised air from the first stage of a diving regulator to the other components.
Fig 4.4.2 Air hose
Air hoses are used between locomotives and railroad cars for their brakes, and are
also used between those tractors and semi-trailers which use air brakes.
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Locknut
A locknut, also known as a lock nut, locking nut, prevailing torque nut, stiff nut or
elastic stop nut, is a nut that resists loosening under vibrations and torque. Elastic stop nuts
and prevailing torque nuts are of the particular type where some portion of the nut deforms
elastically to provide a locking action.
Grease fitting
A grease fitting, grease nipple, Zerk fitting, or Alemite fitting is a metal fitting used in
mechanical systems to feed lubricants, usually lubricating grease, under moderate to high
pressure, into a bearing using a grease gun. The fitting is permanently installed by a threaded
connection, leaving a nipple connection that the grease gun attaches to. The pressure supplied
by the grease gun forces a small captive bearing ball in the nipple to move back against the
force of its retaining spring. The arrangement is thus essentially a valve that opens under
pressure to allow lubricant to pass through a channel and be forced into the voids of the
bearing. When the pressure ceases, the ball returns to its closed position.
The ball excludes dirt intrusion and functions as a check valve to prevent greaseescaping back out of the nipple. The ball is almost flush with the surface of the nipple so it
can be wiped clean to reduce the amount of debris carried with the grease into the bearing.
The convex shape of the fitting allows the concave tip of the grease gun to seal against the
nipple easily from many angles, yet with a sufficiently tight seal to force the pressured
greased to move the ball and enter the fitting, rather than simply oozing past this temporary
annular (ring-shaped) seal. Grease nipples are commonly made from zinc-plated steel,
stainless steel, or brass.
Gate valve
A gate valve, also known as a sluice valve, is a valve that opens by lifting a round or
rectangular gate/wedge out of the path of the fluid as shown in the fig 4.4.2. The distinct
feature of a gate valve is the sealing surfaces between the gate and seats are planar, so gate
valves are often used when a straight-line flow of fluid and minimum restriction is desired.
The gate faces can form a wedge shape or they can be parallel. Typical gate valves should
never be used for regulating flow, unless they are specifically designed for that purpose. On
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opening the gate valve, the flow path is enlarged in a highly nonlinear manner with respect to
percent of opening. This means that flow rate does not change evenly with stem travel. Also,
a partially open gate disk tends to vibrate from the fluid flow. Most of the flow change occurs
near shutoff with a relatively high fluid velocity causing disk and seat wear and eventual
leakage if used to regulate flow. Typical gate valves are designed to be fully opened or
closed. When fully open, the typical gate valve has no obstruction in the flow path, resulting
in very low friction loss.
Fig 4.4.3 Gate valve
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O Rings
An O-ring, also known as a packing, or a toric joint, is a mechanical gasket in the
shape of a torus; it is a loop of elastomer with a disc-shaped cross-section, designed to be
seated in a groove and compressed during assembly between two or more parts, creating a
seal at the interface as shown in the fig 4.4.4. The O-ring may be used in static applications or
in dynamic applications where there is relative motion between the parts and the O-ring.
Dynamic examples include rotating pump shafts and hydraulic cylinder pistons. O-rings are
one of the most common seals used in machine design because they are inexpensive, easy to
make, reliable, and have simple mounting requirements.
Fig 4.4.4 O rings
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Fig.4.5.2 Cylinder
ONE WAY VALVE
LENGTH : 52 mm
DIAMETER : 48 mm
MATERIAL : Mild steel
DESCRIPTION : It is made up of cast iron used to connect the suction
pipe and piston cylinder. Internal thread is provided
for fastening.
Fig.4.5.3. One Way Valve
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SUCTION PIPE
LENGTH : 888 mm
DIAMETER : 27 mm
MATERIAL : Galvanised iron
DESCRIPTION : It is made up of galvanised iron material. V Notch
is provided at the end of the suction pipe for effective
suction.
Fig.4.5.4. Suction Pipe
PRESSURE GAUGE
RANGE : 110 bar
DESCRIPTION : It is used monitor the operating pressure. It is directly
connected to the inlet pipe just after the compressor
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FILTER
LENGTH : 30 mm
MATERIAL : Iron filter (Copper coated)
DESCRIPTION : It is cone shaped which helps to filter the fuel from
foreign materials, debris and dusts. It is fitted in the
end of the suction pipe.
AIR HOSE
LENGTH : 3000 mm
DIAMETER : 8 mm
MATERIAL : Nylon
DESCRIPTION : It is used to connect the compressor to the pump inlet
The isometric view of the portable pneumatic pump is shown in the fig 4.5.5.
Fig.4.5.5 Isometric View of pneumatic fuel pump
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4.6 WORKING PRINCIPLE
Initially starting with air compresses, its function is to compress air from a low inlet pressure
(usually atmospheric) to a higher pressure level. This is an accomplished by reducing the volume ofthe air.
Air compressors are generally positive displacement units and are either of the reciprocating
piston type or the rotary screw or rotary vane types. The air compressor used here is a typically small
sized, two-stage compressor unit. It also consists of a compressed air tank, electric rotor and pulley
drive, pressure controls and instruments for quick hook up and use. The compressor is driver by a
10HP motor and designed to operate in 145 175 PSI range. If the pressure exceeds the designed
pressure of the receiver a release value provided releases the excesses air and thus stays a head of any
hazards to take place.
The stored air from compressor is passed through an air fitter where the compressed air is
filtered from the fine dust particles. However, before the suction of air into compressor a filter
process take place, but not sufficient to operate in the circuit here the filter is used.
Then having a pressure regulator where the desired pressure to the operated is set. Here a
variable pressure regulator is adopted.
Through a variety of direction control value are available, a hand operated solenoid Valve
with control unit is applied.
The solenoid valve used here is 5 ports, 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 Centro
ore is a neutral position and no physical changes are incurred.
The 2 outlet ports are connected to an actuator (Cylinder). The pneumatic activates is a
double acting, single rod cylinder. The cylinder output is coupled to further purpose. The piston end
has an air horning effect to prevent sudden thrust at extreme ends.
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Fig. 4.6.1. Function Chart
The function chart, shown in the fig 4.6.1 shows the working of the pump. The
compressed air from the compressor is passed into the pump head which moves the double
acting cylinder. This makes the other side of the piston to suck fuel from suction valve andsend it to the outlet valve.
PRINCIPLE:
The compressed air from the compressor reaches the solenoid valve. The solenoidvalve changes the direction of flow according to the signals from the timing device.
The compressed air pass through the solenoid valve and it is admitted into the frontend 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
DOUBLE ACTING CYLINDER
ONE WAY VALVE
FUEL FROM BARREL
SUCTION PIPE
FUEL OUT
PISTON
PUMP HEAD
COMPRESSOR AIR
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block. The pressure remains 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). The stroke length of the piston can be changed by making suitable adjustment in the
timer.
4.7 DESIGN CALCULATION
Single acting reciprocating pump
Diameter = 85 mm = 0.085 m
Length = 100 mm = 0.1 m
Area
The area of the cylinder,
A = ()* d2
= ()*(0.0852)
= 5.674*10-3 m2
Theoretical Volume/stroke
The volume of the cylinder,
V = A*L m3
= 5.674*10-3*0.1
=5.674*10-4 m3
Number of delivery
One stroke/sec = N/60
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N = 60 rpm
Theoretical Discharge Qt
The theoretical discharge of the pump is,
Qt =A*L*N/60
=(5.674*10-3*0.1*60)/60
=5.674*10-4 m3 s-1
=5.674*10-4*1000
= 0.5674 litre/sec
= 0.5674*3600
= 2042.82 litre/hour
Calculation Verification
The output of the pump is then verified by practical method. The results are given
below,
10 Sec = 5 litre
1 min = 30 litre
1 sec = 0.5 litre.
Thus the values are calculated with reference to standard formulae and the theoretical
design values are calculated above. The actual output of the pump is also noted by
experiments.
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4.8 MAINTENANCE
Maintenance
It is the activity carried to increase the life and performance of the pumps.
Types of Maintenance
1. Preventive maintenance2. Breakdown maintenance3. Schedule maintenance
Preventive maintenance
It is carried out regularly say every day, before and after the pump is operated.
Breakdown maintenance
It is done only after the pump stops working completely.
Schedule maintenance
It is carried in routine as per the schedule. It is carried out periodically.
The following are the maintenance which are done in order to avoid breakdown of the
pump,
Lubrication Periodic inspection Adjustment of parts Cleaning Periodic overhauling Repair and replacement
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4.9 ADVANTAGES AND LIMITATIONS
4.9.1 ADVANTAGESEven if all the other pumps are similar in use the Pneumatic water pump is more
advantageous than the other pumps.
1. This is of compact in size2. Less Maintenance is enough3. The oil or water pumped is of higher pressure4. Quite running and smooth operation is achieved.5. Higher efficiency6. Full efficient positive displacement pump7. Effective working principle8. It does not have any Prime mover, like electric motor related to the unit.9. As the air is freely available, we can utilize the air to pumping the water and
hence it is economical.
10. Less Maintenance
4.9.2 LIMITATIONS
1. It is costlier than the other types of pump because of compressor unit.2. Less efficiency when compressed to other device.3. Leakage of air affects the working of the unit.
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CHAPTER 5
BILL OF MATERIALS
S.NO PARTS MATERIALS QUANTITY
1 PRESSURE GAUGE STEEL PLATE 1
2 AIR ADJUSTMENT SCREW MILD STEEL 1
3 PISTON MILD STEEL 1
4 CYLINDER GALVANISED IRON 1
5 SUCTION PIPE GALVANISED IRON 1
6 FILTER IRON FILTER 1
7 PISTON ROD MILD STEEL 1
8 HOSE NYLON 2
9 GREASE NIBBLE ALUMINIUM CASTING 1
10 GATE VALVE GALVANISED IRON 1
11 CONNECTING PIN BRASS 1
12 ONE WAY VALVE MILD STEEL 2
13 ORINGS RUBBER 3
14 TUBE COUPLER MILD STEEL 1
15 LOCK NUT BRASS 1
Table 2. Bill of Materials
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CHAPTER 6
COST ESTIMATION
S.NO NAME OF THE EQUIPMENT NO OF QUANTITYCOST in
(Rupees)
1 PRESSURE GAUGE 1 250
2 AIR ADJUSTMENT SCREW 1 150
3 PISTON 1 1500
4 CYLINDER 1 350
5 SUCTION PIPE 1 375
6 FILTER 1 150
7 PISTON ROD 1 125
8 HOSE 2 225
9 LOCK NUT 1 50
10 GREASE NIPPLE 1 350
11 INCH GATE VALVE 1 240
12 OUTLET HOSE 1 90
13 CONNECTING PIN 1 75
14 BALLS AND ONE WAY VALVE 2 450
15 ORINGS 3 125
16 CYLINDER HEAD 1 1225
17 TUBE COUPLING 1 30
18 SPOOL VALVE 1 500
TOTAL 6250
Table 3. Cost Estimation
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CHAPTER 7
CONCLUSION & FUTURE ENHANCEMENTS
7.1 CONCLUSION
In this pneumatic fuel pump variable speeds can be obtained by adjusting the pressure
of the compressed air. Since the mechanism is so simple and versatile it can be handled by
any operator, construction of the unit is very simple. Handling the machine is easy and
smooth operation is achieved. This pump also provides fire proof pumping. This increases
fuel discharge and reduces human effort & operating time. The main feature of this pump is,
it is portable.
7.2 FUTURE ENHANCEMENTS
In this pump, an accumulator can be attached. This attachment of accumulatorprovides constant discharge.
The diameter of the outlet pipe can be decreased to increase the head.
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REFERENCES
Antonio Esposito - Fluid power with application. Prentice hall of India privatelimited, 1980.
Bolton,W., - Pneumatic and hydraulic systems, Butterworth-Heinemann, Jordan Hill,Oxford,1997.
Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore. Design data book compiled by Faculty of Mechanical Engineering, P.S.G. college
of technology, Coimbatore
Festo Didactic KGFundamentals of control technology, Esslingen-1998. Festo Pneumatic Catlogue - Festo Pvt Ltd.Bangalore. Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag
Wurzburg, 1998.