ABSTRACT

The proposed work describes the design of automatic pneumatic stamping

machine controlled by PLC and shedding light on the working principle and
the hardware structure of the system. Stamping process is one of the
most important and necessary process for packaging industries, who
achieve this by using localized compressive force. In manual operated
stamping machine, hand operated lever is used to put stamp on a work
piece. Manual stamping depends on the operator i.e. productivity depends
on operator efficiency. In manual operated stamping machine operator
performs operations like loading work piece to work holder, operating
hand lever to perform stamping, checking whether stamping is performed
perfectly, unloading of work piece and counting of finished work pieces.
Thus the loading of work piece, to operate hand lever and unloading of
work piece will take more cycle time. This leads to increase in
manufacturing lead time and work in process. The main limitations of
manual operations are that it is tedious and provides less productivity. In
fast replication process where mass production requires continuous
operation, manual operated stamping machine does not suit hence
innovation requires to enhance fast replication continuous mass
production. To overcome this problem in manual operated stamping
machine, the concept of automation is used. By interfacing PLC controls
with the conventional machines, it is possible to achieve good results in
the form of reduced manufacturing lead time, reduced cost and increased
safety of the worker. In these machine operations like pushing the work
piece to stamping position, detecting if the work piece is of required
material, stamping and ejecting the work piece out of the platform are
performed automatically.

APPENDICES
LIST OF FIGURES
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Figur

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3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
4.1
4.2
4.3
4.4
4.5

Name of Figure

Automation Power System

Pneumatic System
Trainer kit of Pneumatic components
Architecture of PLC
PLC Processor Module
PLC Memory
Power Supply
Diagram showing PLC Components
Allen Bradley MicroLogix 1000
Allen Bradley MicroLogix 1200
Allen Bradley SLC 500
Flowchart
Ladder Diagram Symbols
Basic Logic Functions
Stages of PLC scan
Cross-sectional view of basic cylinder
Internal structural of basic cylinder
Cross-sectional view of single acting cylinder
Internal structural of single acting cylinder
(a) Photo of Single acting cylinder

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12
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(b) Pneumatic symbol of single acting cylinder

21.

4.6

28

4.7
4.8
4.9

Diagram showing working of Single acting cylinder

Cross-sectional view of double acting cylinder
Internal structural of double acting cylinder
(a)Double acting cylinder

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29

25.
26.
27.
28.

4.10
4.11
4.12
4.13

(b) Pneumatic symbol of double acting cylinder

Diagram showing working of double acting cylinder
Cylinder end cushions
Representation of valve
(a) Direction control valve

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32

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4.14

(b) Symbol
Proximity sensor

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24.

II

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4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11

Stages of proximity sensor

NPN wiring of proximity sensor with PLC
Micro 810 PLC
Controller Diagram
Controller Description
LCD Display
LCD Display options
T-Joint
Push Buttons
Pilot Light
Clamping Stamping Ejection unit
Block diagram of hardware model layout
Rung 1
Rung 2
Rung 3
Rung 4
Rung 5
Rung 6
Rung 7
Rung 8
Rung 9

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LIST OF TABLES

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No.
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Table No.
4.1

Name of Table
MICRO 810 Attributes

III

Page No.
37

Fig. GROUP PHOTO WITH INDUSTRIAL GUIDE

IV