COOLANT OIL CONTROL SYSTEM IN VMC MACHINE A PROJECT REPORT Submitted by RAJAGANAPATHY.S (13BEI111) GOWTHAMVEL.P (13BEI018) SANTHOSE PRABU.R (13BEI050) in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING in ELECTRONICS AND INSTRUMENTATION ENGINEERING KUMARAGURU COLLEGE OF TECHNOLOGY (An Autonomous Institution, Affiliated to Anna University,Chennai) COIMBATORE 641049 APRIL 2017 1 COOLANT OIL CONTROL SYSTEM IN VMC MACHINE A PROJECT REPORT Submitted by RAJAGANAPATHY.S (13BEI111) GOWTHAMVEL.P (13BEI018) SANTHOSE PRABU.R (13BEI050) in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING in ELECTRONICS AND INSTRUMENTATION ENGINEERING KUMARAGURU COLLEGE OF TECHNOLOGY (An Autonomous Institution, Affiliated to Anna University,Chennai) COIMBATORE 641049 APRIL 2017 2 BONAFIDE CERTIFICATE Certified that this project report “COOLANT OIL CONTROL SYSTEM IN VMC MACHINE ”is the bonafide work of RAJAGANAPATHY.S (13BEI111) GOWTHAMVEL.P (13BEI018) SANTHOSE PRABU.R (13BEI050) who carried out the project work under my supervision. SIGNATURE SIGNATURE Dr.N.EZHILARASI Mr.S.SARAVANA KUMAR HEAD OF THE DEPARTMENT SUPERVISOR Dept. of Electronics and Instrumentation Assistant Professor Kumaraguru College of Technology Dept. of Electronics and Instrumentation Coimbatore-641049 Kumaraguru College of Technology Coimbatore-641049 The candidates were examined by us in the project viva voce examination held on INTERNAL EXAMINER EXTERNAL EXAMINER 3 ACKNOWLDEGEMENT The satisfaction that accompanies the successful completion of any task would be incomplete without mentioning about the people whose constant guidance and encouragement crowns all effort with success. We are greatly indebted to our beloved Principal Dr.R.S.KUMAR, who has been the backbone of all our deeds. We express our gratitude to Dr.N.EZHILARASI, Head, Department of Electronics and Instrumentation Engineering, Kumaraguru College of Technology for her constant encouragement. We take immense pleasure to record our heartfelt gratitude to our esteemed project coordinator and our project guide Mr.S.SARAVANA KUMAR, Assistant Professor, Department of Electronics and Instrumentation Engineering,for her valuable guidance,timely help,constant encouragement and advice rendered throughout the project period for the successful completion of project. We are grateful to the faculty members of the Department of Electronics and Instrumentaion Engineering , who have helped us in innumerable ways.We also thank our parents without whom we could not have come so far and friends for their timely help that culminated as good in the end. 4 ABSTRACT Most of the automation and precision machine tools industries are using automation systems for all kind of their operations. Although some simple and very most important operations are done by manually .By that way nowadays Coolants in VMC machine are controlled manually, in this project we are proposing an idea of automatic control of coolant oil in a VMC machine by measuring the level of coolant oil from its tank. Relating the level of coolant oil with the set point the controller will drain the coolant or fill the coolant in the machine. In this project we are going to rectify the problems when doing the manual operations in coolant oil tank in VMC machine. During the precision machining operations the most of the automation machines are producing high temperature. So this will cause heavy damages in machine tools as well as decrease the production in precision machining industries. So we are introducing the temperature monitoring system in VMC machine for displaying the operator by immersing the temperature sensor into the coolant oil tank. It can continuously monitor the temperature range of the coolant oil in the machine tank. This coolant oil automation system will help to reduce the manual problems from the coolant oil transferring in precision machining industries and also increase the life time of the machine tools. By using the limit switches as the level sensor we have reduced the cost of the system. 5 TABLE OF CONTENTS CHAPTER NO TITLE PAGE NO ABSTRACT LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS 1 INTRODUCTION 9 2 HARDWARE DESCRIPTION 10 2.1 Dc Motor 10 2.1.1 Electromagnetic motors 10 2.1.2 Brushed motor 12 2.1.3 Brushless motor 13 2.1.4 Uncommutated 13 2.1.5 Permanent magnet stators 14 2.1.6 Wound stators 15 2.2 Limit Switch 17 2.3 PIC Microcontroller 18 2.3.1 Device families 20 2.3.2 Core architecture 28 2.3.3 Hardware features 35 2.3.4 Development tools 36 2.3.5 Device programmers 37 2.3.6 Operating systems 39 2.3.7 Clones 39 2.4 Power Supply 43 2.4.1 DC power supply 44 2.4.2 AC-to-DC supply 44 2.4.3 Linear regulator 45 2.4.4 AC power supply 45 6 2.4.5 Switched mode power supply 46 2.4.6 Programmable power supply 47 2.4.7 Uninterruptible power supply 48 2.4.8 High voltage power supply 48 2.5 Pump 49 2.5.1 Positive displacement pump 51 2.5.2 Impulse pumps 59 2.5.3 Velocity pumps 60 2.5.4 Gravity pumps 62 2.5.5 Steam pumps 62 2.5.6 Valveless pumps 63 2.6 Solenoid Valve 64 2.6.1 Operations 64 2.6.2 Internally piloted 65 2.7 Flow Chart 67 3 RESULTS 68 4 CONCLUSION 71 REFERENCE 71 LIST OF FIGURES 2.1 Image of Limit Switch 18 2.2 Image of PIC Microcontroller 42 2.3 Circuit diagram of Power Supply 49 2.4 Image of Pump 63 2.5 Image of Solenoid Valve 66 7 2.6 Flow chart 67 3.1 Proteus output of Pump ON 68 3.2 Proteus output of Pump OFF 68 3.3 Proteus output of SV2 ON 69 3.4 Proteus output of SV2 OFF 69 3.5 Milling stop 70 LIST OF ABBREVIATIONS PIC Peripheral Interface Controller DC Direct Current PM Permanent Magnet EMF Electro Magnetic Force RAM Random Access Memory ALU Arithmetic Logic Unit CPU Central Processing Unit PVC Poly Vinyl Chloride ROM Read Only Memory 8 1. INTRODUCTION In this project we are going to rectify the problems when doing the manual operations in coolant oil tank in VMC machine. During the precision machining operations the most of the automation machines are producing high temperature. So this will cause heavy damages in machine tools as well as decrease the production in precision machining industries. So we are introducing the temperature monitoring system in VMC machine for displaying the operator by immersing the temperature sensor into the coolant oil tank. It can continuously monitor the temperature range of the coolant oil in the machine tank. This coolant oil automation system will help to reduce the manual problems from the coolant oil transferring in precision machining industries and also increase the life time of the machine tools. 9 2.HARDWARE DESCRIPTION 2.1 DC MOTOR A DC motor is any of a class of rotary electrical machines that converts direct current electrical energy into mechanical energy. The most common types rely on the forces produced by magnetic fields. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current flow in part of the motor. DC motors were the first type widely used, since they could be powered from existing direct-current lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using either a variable supply voltage or by changing the strength of current in its field windings. Small DC motors are used in tools, toys, and appliances. The universal motor can operate on direct current but is a lightweight motor used for portable power tools and appliances. Larger DC motors are used in propulsion of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of power electronics has made replacement of DC motors with AC motors possible in many applications. 2.1.1 ELECTROMAGNETIC MOTORS A coil of wire with a current running through it generates an electromagnetic field aligned with the center of the coil. The direction and magnitude of the magnetic field produced by the coil can be changed with the direction and magnitude of the current flowing through it. A simple DC motor has a stationary set of magnets in the stator and an armature with one or more windings of insulated wire wrapped 10 around a soft iron core that concentrates the magnetic field. The windings usually have multiple turns around the core, and in large motors there can be several parallel current paths. The ends of the wire winding are connected to a commutator. The commutator allows each armature coil to be energized in turn and connects the rotating coils with the external power supply through brushes. (Brushless DC motors have electronics that switch the DC current to each coil on and off and have no brushes.) The total amount of current sent to the coil, the coil's size and what it's wrapped around dictate the strength of the electromagnetic field created. The sequence of turning a particular coil on or off dictates what direction the effective electromagnetic fields are pointed. By turning on and off coils in sequence a rotating magnetic field can be created. These rotating magnetic fields interact with the magnetic fields of the magnets (permanent or electromagnets) in the stationary part of the motor (stator) to create a force on the armature which causes it to rotate. In some DC motor designs the stator fields use electromagnets to create their magnetic fields which allow greater control over the motor. At high power levels, DC motors are almost always cooled using forced air.