IoT Based Pneumatic Sheet Metal Cutting Machine

Abstract

This paper introduces an advanced automatic sheet metal cutting system that seamlessly integrates Programmable Logic Controller (PLC) and Human-Machine Interface (HMI) technologies, revolutionizing manufacturing processes. The system\'s primary objectives include enhancing operational efficiency, accuracy, and safety standards. By utilizing precision sensors and responsive actuators, the system performs intricate metal cutting operations according to customer specifications. The HMI touch screen serves as the interface through which operators interact with the system, while the PLC processes data and dispatches instructions to the pneumatic cylinder, orchestrating the cutting operations. The HMI interface empowers operators with real-time oversight and control over the cutting process, enabling prompt adjustments based on feedback. Safety measures such as emergency stop buttons and interlocks further ensure operator well-being and prevent accidents. The integration of PLC and HMI technologies significantly reduces human errors, boosting productivity and ensuring precise cutting results. This innovationredefines industrial automation benchmarks, offering industries an efficient, accurate, and secure solution for high-speed cutting processes.Building effective industrial systems are now possible with the help of the Internet of Things abbreviated as IoT. In nowadays automatic systems are recommended over manual systems. IoT is the latest and rising internet technology. IoT is a developing network of everyday products, from industrial machineryto consumer goods which exchange information and carry out tasks while consumers are attending to otherresponsibilities. Amachine tool is used to punchsheet metals to increase the static stability of the section of the sheet. The movementof the piston in the pneumatic punching machine is from the compressed air which generates high pressure on the piston. The focus of this project is on the development of an IoT- enabled sheet metal punching machine. Themainobjectiveofthisproject isto develop anIoT-basedpneumaticpunching machine that is capable of monitoring the production parameters of the pneumaticpunching machine through an easily manageable web interface. Additionally this technology is innovative in that it allows the control of the punching machine through the Internet of Things as well as the tracking of production data or production values

Introduction

1. Introduction

The IoT-Based Accident Avoiding Punching Machine is an advanced safety system designed to reduce injuries in industrial environments using IoT technologies. Traditional punching machines pose risks due to high-speed operations and moving parts. This system uses real-time monitoring, smart sensors, and automated safety mechanisms to detect potential hazards and halt machine operations, improving user safety and operational efficiency.

2. Project Objectives

• Automation & Precision: Automates sheet metal cutting using pneumatics with IoT-enhanced precision, reducing manual errors.

• IoT Integration: Enables remote monitoring, control, and data analytics via mobile/web platforms for predictive maintenance.

• Energy & Cost Efficiency: Reduces air consumption and operational costs using automation and real-time analytics.

• Safety & Reliability: Features include emergency stops, force monitoring, and predictive maintenance alerts.

• Scalability: Designed for various metal thicknesses and industrial applications with customizable settings.

3. Literature Review (Key Insights from Related Work)

• Prior works explored PLC-HMI systems, IR sensors, wireless controls, and Industry 4.0 technologies.

• Integration of IoT with pneumatic systems improves real-time control, data tracking, safety, and automation.

• Studies emphasized benefits like reduced human error, improved precision, and remote operability for better performance and safety.

4. Problem Identification

• Manual systems are labor-intensive, error-prone, and inconsistent.

• Conventional machines lack real-time monitoring and predictive capabilities.

• Operators cannot remotely monitor or control machines, increasing downtime and safety risks.

• IoT addresses these issues by enabling automated control, real-time monitoring, and predictive maintenance for improved performance, safety, and cost-efficiency.

5. Methodology

• An object detection sensor is installed to trigger an emergency shutdown if a human is detected too close to the machine.

• Uses pneumatic systems with double-acting cylinders and 5/2 solenoid valves for controlled cutting strokes.

• A relay circuit and alarm are integrated to alert and stop operations during risky situations.

6. Design and Fabrication

• Combines mechanical, electrical, and software engineering disciplines.

• Incorporates:

  • Precise pneumatic cutting mechanisms.

  • IoT devices for sensor data collection and analysis.

  • Microcontroller or IoT gateway for real-time data transmission.

  • A cloud-based platform for analytics, visualization, and remote access.

• Prioritizes safety, data security, and compliance with industrial standards.

• Offers an intuitive user interface for monitoring and control.

Conclusion

1) Enhanced Automation: The integration of IoT with pneumatic sheet metal cutting machines reduces human intervention, ensuring precise and consistent cutting operations. 2) Real-Time Monitoring: IoT-enabled sensors allow continuous tracking of parameters such as air pressure, cutting force, and machine status, leading to improved operational efficiency. 3) Predictive Maintenance: The system can detect faults and schedule maintenance before failures occur, minimizing downtime and reducing repair costs. 4) Remote Access & Control: Operators can monitor via a cloud-based dashboard, increasing convenience and productivity. 5) Improved Safety: Automated control mechanisms and real-time alerts help prevent accidents, ensuring a safer working environment. 6) Energy & Cost Efficiency: Optimized pneumatic operations reduce energy consumption and material wastage, making the system more cost-effective. 7) Scalability & Industrial Integration: The system can be easily adapted for different industrial applications, supporting various sheet metal cutting needs. 8) Overall, an IoT-based pneumatic sheet metal cutting machine enhances precision, efficiency, and reliability, offering a smart, automated, and cost-effective solution for modern manufacturing industries.

References

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Copyright

Copyright © 2025 Mr. G. Nirmal Kumar, J. Jebin Christopher, A. Shiva, V. Sri Santh, S. Arulsivam. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.