INTELLIGENT BRAKING SYSTEM LITERATURE REVIEW

DESIGN

1. Electronic Speed Regulator Motor is an commutator motor ie, the current to motor is supplied to motor by means of carbon brushes . The power input to motor is varied by changing the current supply to these brushes by the electronic speed variator, thereby the speed is also is changes. 2. Electronic relay The electronic relay is mounted on the sheet metal panel on the base frame. The electronic relay is connected to the proximity sensor and the motor input circuit. The function of the electronic relay is to cut off power supply when the proximity sensor is operated.

3. Electronic Proximity sensor The electronic proximity sensor is mounted on the sheet metal panel on the base frame by means of an Z shaped clamp. The proximity sensor as the name suggests senses the proximity of the indexer buttons which acts as stops, such that when they come in front of the proximity sensor the table the relay is operated to stop the table motion. The proximity sensor is connected to the electronic relay and the power source.

4. Inching switch The inching switch is connected between the electronic relay and the proximity sensor , this switch when operated bypasses the proximity sensor , thereby operating the motor momentarily as long it is kept pressed.

DESIGN METHODOLOGY DESIGN OF MULTI AXIS WELDING POSITIONER :In our attempt to design a special purpose machine we have adopted a very a very careful approach, the total design work has been divided into two parts mainly;

System design Mechanical design System design mainly concerns with the various physical constraints and ergonomics, space requirements, arrangement of various components on the main frame of machine no of controls position of these controls ease of maintenance scope of further improvement; height of m/c from ground etc. In Mechanical design the components are categoriesed in two parts. Design parts Parts to be purchased. For design parts detail design is done and dimensions thus obtained are compared to next highest dimension which are readily available in market this simplifies the assembly as well as post production servicing work. The various tolerances on work pieces are specified in the manufacturing drawings. The process charts are prepared & passed on to the manufacturing stage .The parts are to be purchased directly are specified &selected from standard catalogues.

System Design:-

In system design we mainly concentrate on the following parameter

1.System selection based on physical constraints:While selecting any m/c it must be checked whether it is going to be used in large scale or small scale industry In our case it is to be used in small scale industry So space is a major constrain .The system is to be very compact. The mechanical design has direct norms with the system design hence the foremost job is to control the physical parameters.

2. Arrangement of various components:-

Keeping into view the space restriction the components should be laid such that their easy removal or servicing is possible moreover every component should be easily seen & none should be hidden every possible space is utilized in component arrangement.

3. Components of system:-

As already stated system should be compact enough so that it can be accommodated at a corner of a room. All the moving parts should be well closed & compact A compact system gives a better look & structure.

Following are some example of this section Design of machine height Energy expenditure in hand operation Lighting condition of m/c 8. Chances of failure:The losses incurred by owner in case of failure of a component are important criteria of design. Factor of safety while doing the mechanical design is kept high so that there are less chances of failure. Periodic maintenance is required to keep the m/c trouble free. 9. Servicing facility:The layout of components should be such that easy servicing is possible especially those components which required frequent servicing can be easily dismantled. 10. Height of m/c from ground:Fore ease and comfort of operator the height of m/c should be properly decided so that he may not get tired during operation .The m/c should be slightly higher than that the level also enough clearance be provided from ground for cleaning purpose.

11. Weight of machine:The total wt of m/c depends upon the selection of material components as well as dimension of components. A higher weighted m/c is difficult for transportation & in case of major break down it becomes difficult to repair.

MOTOR SELECTION Thus selecting a motor of the following specifications Single phase AC motor Commutator motor TEFC construction Power = 1/15hp=60 watt Speed= 0-6000 rpm (variable) Motor is an Single phase AC motor , Power 60 watt , Speed is continuously variable from 0 to 6000 rpm. The speed of motor is variated by means of an electronic speed variator . Motor is an commutator motor ie, the current to motor is supplied to motor by means of carbon brushes . The power input to motor is varied by changing the current supply to

these brushes by the electronic speed variator, thereby the speed is also is changes. Motor is foot mounted and is bolted to the motor base plate welded to the base frame of the indexer table Motor Torque P= 2NT 60 T = 60 x 60 2 x 6000 T = 0.095 N-m

Power is transmitted from the motor shaft to the input shaft of drive by means of an open belt drive, Motor pulley diameter = 20 mm IP _ shaft pulley diameter = 110 mm Reduction ratio = 5 IP_shaft speed = 6000/5 = 1200 rpm Torque at IP_shaft = 5 x 0.095 = 0.475 Nm

DESIGN OF OPEN BELT DRIVE Motor pulley diameter = 20 mm IP _ shaft pulley diameter = 110 mm Reduction ratio = 5 Coefficient of friction = 0.23 Maximum allowable tension in belt = 200 N Center distance = 120 = 180 sin-1 (D-d)/2C = 180 sin-1 (110-20)/2x200 = 1360

 = 2.37c Now , e/sin(/2) = e0.2 x 2.37sin (40/2) = 4 width (b2) at base is given by b2 = 6-2(4 tan 20) = 3.1 Area of cross section of belt = {6 + 3.1}x 4 A = 18.2 mm2 Now mass of belt /m length = 0.23 kg/m

V = DN/(60 x 1000) = 4.188m/sec

Tc = m V2 Tc = 4.034 N T1 = Maximum tension in belt Tc T1= 195.966 = 196 N T1 / T2 = e/sin(/2) =4 T2 = 49 N Result Table Tension in tight side of belt (T1) = 196 N Tension in slack side of belt (T2) = 49 N

DESIGN OF MAIN SHAFT.

MATERIAL SELECTION : Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION

ULTIMATE TENSILE STRENGTH N/mm2

YEILD STRENGTH N/mm2

800 EN 24

680

ASME CODE FOR DESIGN OF SHAFT.

Since the loads on most shafts in connected machinery are not constant , it is necessary to make proper allowance for the harmful effects of load fluctuations According to ASME code permissible values of shear stress may be calculated form various relation.

= 0.18 x 800 = 144 N/mm2 OR

fs

max

= 0.3 fyt =0.3 x 680 =204 N/mm

considering minimum of the above values ;

fs

max

= 144 N/mm2

Shaft is provided with key way; this will reduce its strength. Hence reducing above value of allowable stress by 25%

fs

max

= 108 N/mm2

This is the allowable value of shear stress that can be induced in the shaft material for safe operation.

TO CALCULATE WORM WHEELSHAFT TORQUE

POWER =

2 NT 60

Motor is 60 watt power, run at 6000 rpm, connected to worm shaft by belt pulley arrangement with reduction ratio 1:5 Hence input to worm gear box = 1200 rpm The worm gear box is the reduction gear box with 1:38 ratio Hence input speed at the input shaft = 1200/38 =31.5 =32 rpm (approx) T = 60 x P 2 x x N

60 X 60 2 X X 1200

 T = 0.477 N-m

T design = 0.48 N-m

CHECK FOR TORSIONAL SHEAR FAILURE OF SHAFT. Assuming minimum section diameter on input shaft = 16 mm d = 16 mm Td = /16 x fs
act

x d3

fs

act

= 16 x Td xd
3 3

16 x 0.48 x 10 x (16)
3

fs act = 0.5963 N/mm2 As fs act < fs all

I/P shaft is safe under torsional load

DESIGN (SELECTION OF WORM SHAFT BALL BRG 6003

In selection of ball bearing the main governing factor is the system design of the drive ie; the size of the ball bearing is of major importance ; hence we shall first select an appropriate ball bearing first select an appropriate ball

bearing first taking into consideration convinience of mounting the planetary pins and then we shall check for the actual life of ball bearing .

BALL BEARING SELECTION.

Series 62 ISI NO Brg Basic Design No (SKF) C kgf Co Kgf 17A C03 6003 17 19 35 33 10 4650 2850 d D 1 D D2 B Basic capacity

P = X Fr + Yfa. Where ; P=Equivalent dynamic load ,(N) X=Radial load constant Fr= Radial load(H) Y = Axial load contact Fa = Axial load (N) In our case;

Radial load FR= BELT TENSION = 196 + 49 N P= 245 N L= (C/p) p Considering 4000 working hours (SPEED = 1200 RPM) L = 60 n L h 106 288 = C 245 C = 1617 N AS; required dynamic of bearing is less than the rated dynamic capacity of bearing ; Bearing is safe.
3

= 288 mrev

SELECTION OF PNEUMATIC CYLINDER Y-Axis translation Standard cylinder (14167) DNU-40-20-PPV-A.

Specifications of Standard cylinder (14167) DNU-25-200-PPV-A.

Criterion Stroke Piston diameter Piston rod thread Cushioning

Feature

25
16 M6 Pneumatic cushioning, adjustable at both ends (PPV) Any ISO 6431 Male thread Piston Piston rod

Assembly position Conforms to standard Piston-rod end Design structure

Position detection Variants Operating pressure Mode of operation Operating medium

With proximity sensor Single-ended piston rod 0.3 - 12 bar Double-acting Dried compressed air, lubricated or un-lubricated 2

Corrosion resistance classification

CRC Ambient temperature Authorisation Cushioning length Theoretical force at 3 bar, return stroke Theoretical force at 3bar, advance stroke Additional weight per 10 mm stroke Basic weight for 0 mm stroke Mounting type Pneumatic connection Materials information for cover Materials information for seals Materials information for piston rod Materials information for cylinder barrel -20 - 80 C Germanischer Lloyd 30 mm 30 N

50N

76 g 2662 g With accessories G3/8 Aluminium TPE-U(PU) High alloy steel Materials information for cylinder barrel Anodised

Theoretical force at 3 bar when advancing of piston = 50 N

Piston rod threading end = M16 x 1 pitch

Design of piston rod Material selection: Ref :- (PSG 1.12) Designation Tensile Strength N/mm2 EN9 600 Yield Strength N/mm2 380

Direct Tensile or Compressive stress due to an axial load :W

fc

act

=
(/4 ) x dc
2

50

fc

act

=
(/4 ) x 5
2

fc As fc
act

act

= 2.54 N/mm2 Piston rod is safe in compression.

< fc

all

2. Shear stress in threaded end due to axial load :-

fs

act

= n dc t

t = width thread at root = p/2 t= 0.5 mm n = No of threads in contact = 12/1 =12

50 fs act = x12x5 x 0.25 fs

act

= 0.5305 N/mm2

As ; fs act < fs all , the screw threads are safe in shear.

Stresses due to buckling of piston rod :According to Rankine formula, Where Wcr = fc A

Where ; Wcr = Crippling load on screw (N)

A = Area of c/s at root (mm2) A= constant Le= Equivalent unsupported length of screw (mm) decided by end conditions. K= Radius of gyration = dc/4 (mm) Fc= Yield stress in compression (N/mm2) le = 0.707L;as one end of screw are considered to be fixed and other free(Ref . PSG Design Data Pg. No. 6.8) Here transverse of the piston is 50 mm, total length of piston rod =172 mm le = 0.707 x 72 = 50.94 mm 300 x (/4 x 102)

Wcr = 1+(1/7500)( 50.94/ (10/4))2

Wcr =23.56x103 N

As, The critical load causing buckling is high as compared to actual compressive load of 0.240 kN the piston rod is safe in buckling .

MATERIAL SPECIFICATION : EN24 PART NAME : INPUT SHAFT RAW MATERIAL SIZE: 30X 250

Sr. No

Description of Operation Jigs & Fixture M/c Tools

Tools

Time in minutes

Cutting Tools

Measurin g Instrume nt Vernier

Settin g Time 20 -

M/c Tim e 5

Tota l Tim e 20 5

1 2

Clamp stock Facing Both side to total length 242mm

Three jaw chuck Three jaw chuck

Lathe Lathe

Facing tool

Turning OD 21 mm through length StepTurning OD to 17mm through length 197 Centers supports & carrier Lathe

Turning tool Turning tool Vernier

10

15

4.

14

14

5.

StepTurning OD to 14mm through length187

Centers supports & carrier

Lathe

Turning tool

Vernier

6.

StepTurning OD to 12mm through length10

Centers supports & carrier

Lathe

Turning tool

Vernier

7.

StepTurning OD to 16mm through length40

Centers supports & carrier

Lathe

Turning tool

Vernier

PART NAME : LH_BRG_HSG

MATERIAL SPECIFICATION : EN 9 RAWMATERIAL SIZE: 50X50X20

Sr. No

Description of Operation Jigs & Fixture M/c Tools Milling ----

QUANTITY :- 01 NOS. Tools

Time in minutes

Cutting Tools Facing cutter

Measuring Instrumen t Vernier

Settin g Time 15 5

M/c Time 44

Total Time 15 49

1. 2.

Clamp stock Facing All Sides Sq. to total length 40x12x40m m Clamp stock on lathe Drilling 18.5 through thickness Boring 28through thickness Counter Boring 32 through 10 thickness

M/C Vice ----

3. 4.

4 jaw chuck ----

Lathe ----

Twist drill

Vernier

25 15 10

25 25

5.

----

----

Boring tool

Vernier

15

10

25

6.

----

----

Boring tool

Vernier

15

10

25

PART NAME : RH_BRG_HSG

MATERIAL SPECIFICATION : EN 9 RAWMATERIAL SIZE: 50X50X20

Sr. No

Description of Operation Jigs & Fixture M/c Tools Milling ----

QUANTITY :- 01 NOS. Tools

Time in minutes

Cutting Tools Facing cutter

Measuring Instrumen t Vernier

Settin g Time 15 5

M/c Time 44

Total Time 15 49

1. 2.

Clamp stock Facing All Sides Sq. to total length 40x12x40m m Clamp stock on lathe Drilling 18.5 through thickness Boring 28through thickness Counter Boring 32 through 10 thickness

M/C Vice ----

3. 4.

4 jaw chuck ----

Lathe ----

Twist drill

Vernier

25 15 10

25 25

5.

----

----

Boring tool

Vernier

15

10

25

6.

----

----

Boring tool

Vernier

15

10

25

 BILL OF MATERIALS:-

SR NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 0. 1 1. 1 2. 1 3. 1 4. 1 5. 1 6. 1 7. 1 8.

PART CODE

DESCRIPTION

QTY

MATERIAL

WK -1 WK -2 WK -3 WK -4 WK -5 WK -6 WK -7 WK 8 WK 9 WK 10

ENGINE BELT REDUCTION PULLEY INPUT SHAFT LH_BRG_HOUSING DRVER GEAR PLANET GEAR PLANET GEAR SHAFT PGS_BRG_HSG COUPLER SHAFT

01 01 01 01 01 01 02 02 02 02

STD STD MS EN24 EN9 EN9 EN9 EN24 EN9 EN24

WK 11

COUPLER CLUTCH

02

EN24

WK 12

PLANET CONE

02

EN24

WK 13

SPHERICAL BUSH

02

GM

WK 14

GM_BUSH HOLDER

02

EN9

WK 15

DRIVEN HUB

01

EN24

WK 16

OUTPUT SHAFT

01

EN24

WK 17

SPRING

01

STD

WK 18

SPRING HOLDER

01

EN9

MATERIAL PROCUREMENT Material is procured as per raw material specification and part quantity. Part process planning is done to decide the process of manufacture and appropriate machine for the same.
GENERAL MATERIAL USED EN24- ALLOY STEEL EN9- PLAIN CARBON STEEL MS-MILD STEEL STD- STANDARD PARTS SELECTED FROM PSG DESIGN CATALOGUE DATA/MANUFACTURER

RAW MATERIAL COST

The total raw material cost as per the individual materials and their corresponding rates per kg is as follows, Total raw material cost = Rs4400/-

MACHINING COST
OPERATION RATE Rs /HR LATHE MILLING DRILLING HOBBING TOTAL 80 90 60 30 18 4 TOTAL TIME HRS TOTAL COST Rs/2400 1620 240 1380 5640

MISCELLANEOUS COSTS

OPERATION FABRICATION SAWING TOTAL

COST(Rs) 200 120 320

 COST OF PURCHASED PARTS :SR NO. 1. 2. 3. 4. ENGINE BELT GRUB SCREW BEARINGS 01 01 09 10 2450 110 36 1400 DESCRIPTION QTY COST

The cost of purchase parts = Rs 3996

TOTAL COST
TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost + cost of Purchased Parts +Overheads Hence the total cost of machine = Rs 14556/-

BRAKE APPLICATION ---PNEUMATIC ARRNGEMENT

PNEUMATIC ARRANEGEMENT
1. Double acting cylinder : The double acting cylinder IS connected end to end , and cylinder piston rods is clamped to the shifter for the dis-engagement 2. 5/2 way direction control valve : These are lever type (detent) valves that suppy compressed air to the either cylinder. The lever on the respective valve acts as the gear shifting button.

Working
The pneumatic circuit is as shown , the motor is started to drive the main shaft by means of belt and pulley arrangement, initially the gear box is in neutral ie, the output shaft doesnot rotate. When the 5/2 way direction control valve -1 is operated the cylinder -operates the piston to move in the right hand direction thereby bringing the clutch into dis- engagement.

REFFERENCES 1. Mechanisms & Mechanical Linkages I A Chironis 2. Performance Investigations of Novel Rolling Traction CVT Akehurst S , et al, SAE Technical Paper 20001-01-0874. 3. PSG Design Data 4. Design of Machine Elements V B Bhandari 5. Machine Design R S Khurmi