Automation of Swing Gate

7/31/2019 Automation of Swing Gate

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AUTOMATION OF SWING GATE

BY

VIKAS KATNA

81307114058

SAURAV

81307114051

KRISHAN

81307114028

GURNAM SINGH

81307114016

Mechanical Engineering Department

RAYAT BAHRA INSTITUTE OF ENGG. & NANOTECHNOLOGY

HOSHIARPUR, INDIA.

NOV, 2011


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A PROJECT REPORT ON

AUTOMATION OF SWING GATE

SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

BY

VIKAS KATNA

( 81307114058 )

SAURAV

( 81307114051 )

KRISHAN

( 81307114028 )

GURNAM SINGH

( 81307114016 )

UNDER THE GUIDENCE OF

Er. HARBIR SINGH

Mechanical Engineering Department

RAYAT BAHRA INSTITUTE OF ENGG. & NANO TECHNOLOGY

HOSHIARPUR, INDIA.


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ABSTRACT

In this final year project work, we attempt to construct a small and simple Automatic Gate

System, which uses a AC motor which uses is used commonly for in many electric applications.

The primary aim of this project is to learn in details about how the automatic gate system

works and to understand to concepts involved. The secondary aim is to fabricate a simple

automatic gate to show how the system works.

The main activities involved in this project are the research done on how the automatic gate

works, sketching a detailed plan of the gates, purchasing the correct AC motor and circuits and

gate together and finally the test run.

Although we had many hiccups during the fabrication of the gate but we were able to

learned a lot from this project such as team work, innovation, the skill and ability to put into

practice what we have learned to achieve our desired outcome.

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ACKNOWLEDGEMENT

Every Orientation work has an imprint of many people and we hereby take this excellent

opportunity to acknowledge all the help, guidance & support that we have received for the

completion of this project.

With supreme sincerity and deep sense of appreciation, we express our thanks to Mr.

Narinder Singh, Head, Department of Mechanical Engineering, for his co-operation.

We express my gratitude to Mr. Harbir Singh (lecturer RBIENT, Hoshiarpur) who has

guided us regarding the project, for his kindness, courtesy, valuable suggestions and inspirations.

Above all, we would like to thank our beloved parents for their direct and indirect help,

moral support and blessings, without which, this would not have been possible. We would also like

to express thanks to my colleagues and friends, for their help and moral support.

Lastly we would like to thank all those who directly or indirectly helped me throughout my

work.

TABLE OF CONTENTSii


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CHAPTER NO . TITLE PAGE NO.

ABSTRACT i

ACKNOWLEDGEMENT ii

LIST OF FIGURES v

LIST OF SYMBOLS vi

LIST OF ABBREVIATIONS vii

1. INTRODUCTION.........................................................................................1

2. PROJECT REVIEW.....................................................................................2

2.1 COMPONENTS OF SYSTEM.........................................3

2.1.1 ELECTRIC MOTOR.................................4

2.1.2 BELT DRIVE.............................................8

2.1.3 MOTORS GEARBOX............................11

2.1.4 CHAIN DRIVE........................................14

2.1.5 BEARINGS..............................................17

2.1.6 TIRE.........................................................25

2.1.7 SUSPENSION SYSTEM.........................26

2.1.8 ELECTRIC ARC WELDING..................29

2.1.9 ELECTRIC WIRING AND ELECTRONIC

SWITCH.................................................30

3. PROJECT WORK............................................................................32

3.1 FABRICATION OF SYSTEM ............................32

3.2 DESIGN CONSIDERATIONS .............................34

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3.3 WORKING .............................................................35

3.4 COMPLETE SYSTEM WITH PARTS NAME .....37

4. RESULTS AND DISCUSSIONS.....................................................38

5. CONCLUSIONS................................................................................40

ADVANTAGES & DISADVANTAGES.........................................41

REFERENCES..................................................................................42

LIST OF FIGURES

Figure No. Title Page

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2.1.1 Electric Motor 5

2.1.2 V-belt drive 9

2.1.3 Motors Gearbox 11

2.1.4 Chain drive 15

2.1.5 Journal bearing 20

2.1.6 Compression spring 28

2.1.7 Reversing switch 31

3.4 Complete system with parts name 37

LIST OF SYMBOLS

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m Metre

Dynamic viscosity

N Newton

k Stiffness

V Voltage

N Speed

hp Horse power

Hz Hertz

mm Millimetre

N/m Newton per mitre

rad Radian

LIST OF ABBREVIATIONS

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RPM Revolutions Per Minute

EP Extreme Pressure

AC Alternating Current

DC Direct Current

EMF Electromagnetic Force

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INTRODUCTION

There are several ways to operate a gate either manually or by any automation technique.

Gate operator is a mechanical device used for opening and closing a swing gate, such as one at the

end of a driveway. Automatic gate openers are typically powered by electricity in commercial uses.

The principle of this unique automatic gate system is a 12volt motor working on a moving

chassis. The advantage of this most basic principle is that we can open bigger gates, faster and with

far less power than other systems Electric powered gate operator is powered by AC motor which

can open and close a gate. An electric gate operator uses a circuit to open, close or reverse the gate

when it receives a signal from an access control as per desired direction of swing .

PROJECT REVIEW

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Automatic gate operator is an easy way to ensure the security of private premises and

can be used for all sized properties. Though not very commonplace at the moment, have found

their niche in the market today. For those who find the security of their premises (be it residential

or commercial) important, electric gates are the way to go. There is a decrease in the cost of

electric gate kits and their installation. The backbone of any electric gate, whether automatic or not,

is the electric gate motor, the mainly used motor is electromechanical. This is the electric device

which actually enables the electric gate to open and close without having to manually push the

gate. All types of electric gates and barriers make use of a motor of some kind.

This automatic gate operators consist of simpler design as compared with other systems

present in the market, in result which assess in decreasing the power requirements for the working

of the system. Also, it is much cheaper in cost and user friendly due to ease of operation. The

backup battery and position sensors are also a improved option. But due to area of application, cost

cutting and backup power supply , these are not used in project.

COMPONENTS OF SYSTEM

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The automatic gate system is made of following parts :-

1. Electric motor

2. Belt drive

3. Gear box

4. Chain drive

5. Bearings

6. Tire

7. Suspension system

8. Electric arc welding

9. Electric wiring and switch.

ELECTRIC MOTOR

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An electric motor converts electrical energy into mechanical energy. Most electric motors

operate through the interaction of magnetic fields and current-carrying conductors to generate

force. Electric motors are found in applications as diverse as industrial fans, blowers and pumps,

machine tools, household appliances, power tools, and disk drives. They may be powered by direct

current, e.g., a battery powered portable device or motor vehicle, or by alternating current from a

central electrical distribution grid or inverter. The smallest motors may be found in electric

wristwatches. Medium-size motors of highly standardized dimensions and characteristics provide

convenient mechanical power for industrial uses. The very largest electric motors are used for

propulsion of ships, pipeline compressors, and water pumps with ratings in the millions of watts.

Electric motors may be classified by the source of electric power, by their internal construction, by

their application, or by the type of motion they give.

AC MOTOR

AC motors are the most common motors used in industrial motion control systems, as well

as in main powered home appliances. Simple and rugged design, low-cost, low maintenance and

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direct connection to an AC power source are the main advantages of AC motors. Various types of

AC motors are available in the market. Different motors are suitable for different applications.

Although AC motors are easier to design than DC motors, the speed and the torque control in

various types of AC motors require a greater understanding of the design and the characteristics of

these motors. This application discusses the basics of an AC motor.

Figure 2.1.1: Electric motor

BASIC CONSTRUCTION AND PRINCIPLE

Like most motors, an AC motor has a fixed outer portion, called the stator and a rotor that

spins inside with a carefully engineered air gap between the two. Virtually all electrical motors use

magnetic field rotation to spin their rotors. A single-phase AC motor depends on extra electrical

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components to produce this rotating magnetic field. Two sets of electromagnets are formed inside

any motor. In an AC induction motor, one set of electromagnets is formed in the stator because of

the AC supply connected to the stator windings. The alternating nature of the supply voltage

induces an Electromagnetic Force (EMF) in the rotor (just like the voltage is induced in the

transformer secondary) as per Lenzs law, thus generating another set of electromagnets; hence the

name induction motor. Interaction between the magnetic field of these electromagnets generates

twisting force, or torque. As a result, the motor rotates in the direction of the resultant torque.

STATOR

The stator is made up of several thin laminations of aluminum or cast iron. They are

punched and clamped together to form a hollow cylinder (stator core) with slots. Coils of insulated

wires are inserted into these slots. Each grouping of coils, together with the core it surrounds,

forms an electromagnet (a pair of poles) on the application of AC supply. The number of poles of

an AC induction motor depends on the internal connection of the stator windings. The stator

windings are connected directly to the power source. Internally they are connected in such a way,

that on applying AC supply, a rotating magnetic field is created.

ROTOR

The rotor is made up of several thin steel laminations with evenly spaced bars, which are

made up of aluminum or copper, along the periphery. In the most popular type of rotor (squirrel

cage rotor), these bars are connected at ends mechanically and electrically by the use of rings.

Almost 90% of induction motors have squirrel cage rotors. This is because the squirrel cage

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rotor has a simple and rugged construction. The rotor consists of a cylindrical laminated core with

axially placed parallel slots for carrying the conductors. Each slot carries a copper, aluminum, or

alloy bar. These rotor bars are permanently short-circuited at both ends by means of the end rings,

as shown in . This total assembly resembles the look of a squirrel cage, which gives the rotor its

name. The rotor slots are not exactly parallel to the shaft. Instead, they are given a skew for two

main reasons. The first reason is to make the motor run quietly by reducing magnetic hum and to

decrease slot harmonics. The second reason is to help reduce the locking tendency of the rotor. The

rotor teeth tend to remain locked under the stator teeth due to direct magnetic attraction between

the two. This happens when the number of stator teeth are equal to the number of rotor teeth. The

rotor is mounted on the shaft using bearings on each end; one end of the shaft is normally kept

longer than the other for driving the load. Some motors may have an accessory shaft on the non-

driving end for mounting speed or position sensing devices. Between the stator and the rotor, there

exists an air gap, through which due to induction, the energy is transferred from the stator to the

rotor. The generated torque forces the rotor and then the load to rotate. Regardless of the type of

rotor used, the principle employed for rotation

BELT DRIVE

Belt drive can be defined as the the transmission of power between shafts by means of a belt

connecting pulleys on the shafts. Pair of pulleys attached to usually parallel shafts and connected

by an encircling flexible belt (band) that can serve to transmit and modify rotary motion from one

shaft to the other A mechanism that transmits rotational motion from one pulley mounted on a shaft

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to another by means of a belt. The belt transmits torque from the driving pulley to the driven pulley

by means of the forces of friction that arise between the taut belt and the pulleys

The advantages of belt drives are their simplicity of design, relative low cost, capacity to

transmit power over significant distances (up to 15 m and more), and smooth and noiseless

operation. In addition, the elastic properties of the belt and its ability to slip on the pulleys help

prevent overload. The disadvantages include the short lifetime of the belts, relatively large size,

heavy stress on the shafts and bearings, and variation in the tension ratio caused by the inevitable

slipping of the belt.

Belts made of highly elastic, strong synthetic materials, narrow V-belts, and timing belts

are becoming increasingly common. Belt drives are widely used in agricultural machines, electric

generators, certain machine tools, and textile machines. They are ordinarily used for transmitting

power up to 3050 kilowatts, but there are machines in which belt drives are used to transmit

power of hundreds and even thousands of kilowatts.

V-BELT DRIVE

Vee belt drive consist of a vee belt and a vee grooved pulley for power transmission. Vee

belts (also known as V-belt or wedge rope) solved the slippage and alignment problem. It is now

the basic belt for power transmission. They provide the best combination of traction, speed of

movement, load of the bearings, and long service life. They are generally endless, and their general

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cross-section shape is trapezoidal. The "V" shape of the belt tracks in a mating groove in the pulley

(or sheave), with the result that the belt cannot slip off. The belt also tends to wedge into the

groove as the load increases, improving torque transmission and making the V-belt an effective

solution, needing less width and tension than flat belts. V-belts trump flat belts with their small

center distances and high reduction ratios.

Figure 2.1.2: V-belt drive

V-belts need larger pulleys for their larger thickness than flat belts. They can be supplied at

various fixed lengths or as a segmented section, where the segments are linked (spliced) to form a

belt of the required length.

BELT FRICTION

Belt drives depend on friction to operate but, if the friction is excessive, there will be waste

of energy and rapid wear of the belt. Factors which affect belt friction include belt tension, contact

angle and the materials from which the belt and pulleys are made. Due to this, slip and creep are

very less in V-belt drive.

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BELT TENSION

Power transmission is a function of belt tension. However, also increasing with tension is

stress (load) on the belt and bearings. The ideal belt is that of the lowest tension which does not slip

in high loads. Belt tensions should also be adjusted to belt type, size, speed, and pulley diameters.

Belt tension is determined by measuring the force to deflect the belt a given distance per inch of

pulley. Timing belts need only adequate tension to keep the belt in contact with the pulley.

BELT WEAR

Fatigue, more so than abrasion, is the culprit for most belt problems. This wear is caused by

stress from rolling around the pulleys. High belt tension; excessive slippage; adverse

environmental conditions; and belt overloads caused by shock, vibration, or belt slapping all

contribute to belt fatigue.

MOTORS GEARBOX

Gear motors are complete motive force systems consisting of an electric motor and a

reduction gear train integrated into one easy-to-mount and -configure package. This greatly reduces

the complexity and cost of designing and constructing power tools, machines and appliances

calling for high torque at relatively low shaft speed or RPM. Gear motors allow the use of

economical low-horsepower motors to provide great motive force at low speed such as in lifts,

winches, medical tables, jacks and robotics. They can be large enough to lift a building or small

enough to drive a tiny clock.

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Figure 2.1.3: Motors Gearbox

OPERATION PRINCIPLE

Most synchronous AC electric motors have output ranges of from 1,200 to 3,600

revolutions per minute. They also have both normal speed and stall-speed torque specifications.

The reduction gear trains used in gear motors are designed to reduce the output speed while

increasing the torque. The increase in torque is inversely proportional to the reduction in speed.

Reduction gearing allows small electric motors to move large driven loads, although more slowly

than larger electric motors. Reduction gears consist of a small gear driving a larger gear. There may

be several sets of these reduction gear sets in a reduction gear box.

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SPEED REDUCTION

Sometimes the goal of using a gear motor is to reduce the rotating shaft speed of a motor in

the device being driven, such as in a small electric clock where the tiny synchronous motor may be

spinning at 1,200 rpm but is reduced to one rpm to drive the second hand, and further reduced in

the clock mechanism to drive the minute and hour hands. Here the amount of driving force is

irrelevant as long as it is sufficient to overcome the frictional effects of the mechanism.

TORQUE MULTIPLICATION

Another goal achievable with a gear motor is to use a small motor to generate a very large

force albeit at a low speed. These applications include the lifting mechanisms on hospital beds,

power recliners, and heavy machine lifts where the great force at low speed is the goal. Therefore

they are used broadly.

MOTOR VARIETIES

Most industrial gear motors are AC-powered, fixed-speed devices, although there are

fixed-gear-ratio, variable-speed motors that provide a greater degree of control. DC gear motors are

used primarily in automotive applications such as power winches on trucks, windshield wiper

motors and power seat or power window motors.

APPLICATIONS

What power can openers, garage door openers, stair lifts, rotisserie motors, timer cycle

knobs on washing machines, power drills, cake mixers and electromechanical clocks have in

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common is that they all use various integrations of gear motors to derive a large force from a

relatively small electric motor at a manageable speed. In industry, gear motor applications in jacks,

cranes, lifts, clamping, robotics, conveyance and mixing are too numerous to count.

CHAIN DRIVE

Chain drive is a way of transmitting mechanical power from one place to another. It is often

used to convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also

used in a wide variety of machines besides vehicles.

Most often, the power is conveyed by a roller chain, known as the drive chain or

transmission chain, passing over a sprocket gear, with the teeth of the gear meshing with the holes

in the links of the chain. The gear is turned, and this pulls the chain putting mechanical force into

the system. Sometimes the power is output by simply rotating the chain, which can be used to lift

or drag objects. In other situations, a second gear is placed and the power is recovered by attaching

shafts or hubs to this gear.

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Though drive chains are often simple oval loops, they can also go around corners by

placing more than two gears along the chain; gears that do not put power into the system or

transmit it out are generally known as idler-wheels. By varying the diameter of the input and output

gears with respect to each other, the gear ratio can be altered.

ROLLER CHAIN DRIVE

Roller chain or bush roller chain is the type of chain drive most commonly used for

transmission of mechanical power on many kinds of domestic, industrial and agricultural

machinery, including conveyors, wire and tube drawing machines, printing presses, cars,

motorcycles, and simple machines like bicycles. It consists of a series of short cylindrical rollers

held together by side links. It is driven by a toothed wheel called a sprocket. It is a simple, reliable,

and efficient means of power transmission.

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Figure 2.1.4: Chain drive

SPROCKET

A sprocket is a profiled wheel with teeth that mesh with a chain, track or other perforated or

indented material. The name 'sprocket' applies generally to any wheel upon which are radial

projections that engage a chain passing over it. It is distinguished from a gear in that sprockets are

never meshed together directly, and differs from a pulley in that sprockets have teeth and pulleys

are smooth.

Sprockets and chains are also used for power transmission from one shaft to another where

slippage is not admissible, sprocket chains being used instead of belts or ropes and sprocket-wheels

instead of pulleys. They can be run at high speed and some forms of chain are so constructed as to

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be noiseless even at high speed. Sprockets are used in bicycles, motorcycles, cars, tracked vehicles,

and other machinery either to transmit rotary motion between two shafts where gears are unsuitable

or to impart linear motion to a track

ROLLER CHAIN

There are actually two types of links alternating in the bush roller chain. The first type is

inner links, having two inner plates held together by two sleeves or bushings upon which rotate two

rollers. Inner links alternate with the second type, the outer links, consisting of two outer plates

held together by pins passing through the bushings of the inner links.

WEAR

The effect of wear on a roller chain is to increase the pitch (spacing of the links), causing

the chain to grow longer. Note that this is due to wear at the pivoting pins and bushes, not from

actual stretching of the metal (as does happen to some flexible steel components such as the hand-

brake cable of a motor vehicle).

LUBRICATION

There are also many chains that have to operate in dirty conditions, and for size or

operational reasons cannot be sealed. Examples include chains on farm equipment, bicycles, and

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chain saws. These chains will necessarily have relatively high rates of wear, particularly when the

operators are prepared to accept more friction, less efficiency, more noise and more frequent

replacement as they neglect lubrication and adjustment.

BEARINGS

A bearing is a device to allow constrained relative motion between two or more parts,

typically rotation or linear movement. Bearings may be classified broadly according to the motions

they allow and according to their principle of operation as well as by the directions of applied loads

they can handle.

SLIDING ELEMENT BEARINGS

A linear-motion bearing or linear slide is a bearing designed to provide free motion in one

dimension. There are many different types of linear motion bearings and this family of products is

generally broken down into two sub-categories: rolling-element and plane.

Motorized linear slides such as machine slides, XY tables, roller tables and some dovetail

slides are bearings moved by drive mechanisms. Not all linear slides are motorized, and non-

motorized dovetail slides, ball bearing slides and roller slides provide low-friction linear movement

for equipment powered by inertia or by hand. All linear slides provide linear motion based on

bearings, whether they are ball bearings, dovetail bearings or linear roller bearings. XY Tables,

linear stages, machine slides and other advanced slides use linear motion bearings to provide

movement along both X and Y multiple axis. comprising just a bearing surface and no rolling

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elements. Therefore the journal (i.e., the part of the shaft in contact with the bearing) slides over the

bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple

linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it

rests on or the ways on the bed of a lathe.

JOURNAL BEARING

Journal bearings are widely used in gasoline and diesel fueled piston engines in motor

vehicles, and allow parts to move together smoothly. Two types are used in these engines. Main

bearings are a type of journal bearing used to support a rapidly rotating crankshaft within an engine

block. Connecting rod bearings are a type of journal bearing that help resolve the reciprocating

linear motion of pistons to the rotating motion of the crankshaft by means of crankpin journals on

the crankshaft. An in-line four cylinder engine would normally have a main bearing on each end

plus one between each cylinder for a total of five, and one connecting rod bearing for each piston

for a total of four

CONSTRUCTION

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The four major parts of a journal bearing are the shaft journal; the removable bearing shell

halves, usually steel with a soft alloy lining; the bearing shell support halves; and the oil that

actually comprises the bearing action. Since most crankshafts are either cast or forged, they are one

piece, and the bearing journals are machined into the rough shape that comes from the casting or

forging process. The bearing shells and supports are split exactly in half at the bottom of the engine

block to allow the crankshaft to be inserted into top half-rounds in the block. The bearing caps

comprising the bottom half rounds of each bearing are then bolted into place under the crankshaft

such that each crankshaft main bearing and connecting rod journal is completely surrounded by a

bearing surface that conforms tightly. It hydraulically fills the bearing clearance, thus providing a

viscous damping effect. It also cools the metal bearing surfaces as it circulates.

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Figure 2.1.5: Journal bearing

It achieves this by using at least two races to contain the balls and transmit the loads

through the balls. In most applications, one race is stationary and the other is attached to the

rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to

rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if

two flat surfaces were rotating on each other.

.

ADVANTAGES

The journal bearing has several advantages over other types of bearing, providing it has a

constant supply of clean high-grade motor oil. First, it handles high loads and velocities because

metal to metal contact is minimal due to the oil film. Second, the journal bearing is remarkably

durable and long lasting. Finally, because of the damping effects of the oil film, journal bearings

help make engines quiet and smooth running. Journal bearings with their inherent advantages are

also used in other high-load, high-velocity applications, such as machines and turbines.

LIFESPAN

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The calculated life for a bearing is based on the load it carries and its operating speed. The

industry standard usable bearing lifespan is inversely proportional to the bearing load cubed.

Nominal maximum load of a bearing is for a lifespan of 1 million rotations, which at 50 Hz (i.e.,

3000 RPM) is a lifespan of 5.5 working hours. 90% of bearings of that type have at least that

lifespan, and 50% of bearings have a lifespan at least 5 times as long. Many variations of the exist

that include factors for material properties, lubrication, and loading. Factoring for loading may be

viewed as a tacit admission that modern materials demonstrate a different relationship between

load and life.

FAILURE MODES

If a bearing is not rotating, maximum load is determined by force that causes non-elastic

deformation of balls. If the balls are flattened, the bearing does not rotate. Maximum load for not or

very slowly rotating bearings is called "static" maximum load.

If that same bearing is rotating, that deformation tends to knead the ball into roughly a ball

shape, so the bearing can still rotate, but if this continues for a long time, the ball fails due to metal

fatigue. Maximum load for rotating bearing is called "dynamic" maximum load, and is roughly two

or three times as high as static max load.

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If a bearing is rotating, but experiences heavy load that lasts shorter than one revolution,

static max load must be used in computations, since the bearing does not rotate during the

maximum load.

LUBRICATION

For a bearing to operate properly, it needs to be lubricated. In most cases the lubricant is

based on elastic hydrodynamic effect (by oil or grease) but working at extreme temperatures dry

lubricated bearings are also available. For a bearing to have its nominal lifespan at its nominal

maximum load, it must be lubricated with a lubricant (oil or grease) that has at least the minimum

dynamic viscosity (usually denoted with the Greek letter ) recommended for that bearing. If the

viscosity of lubricant is higher than recommended, lifespan of bearing increases, roughly

proportional to square root of viscosity.

If the viscosity of the lubricant is lower than recommended, the lifespan of the bearing

decreases, and by how much depends on which type of oil being used. For oils with EP ('extreme

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pressure') additives, the lifespan is proportional to the square root of dynamic viscosity, just as it

was for too high viscosity, while for ordinary oil's lifespan is proportional to the square of the

viscosity if a lower-than-recommended viscosity is used.

MAINTENANCE

Many bearings require periodic maintenance to prevent premature failure, although some

such as fluid or magnetic bearings may require little maintenance. Most bearings in high cycle

operations need periodic lubrication and cleaning, and may require adjustment to minimise the

effects of wear. Bearing life is often much better when the bearing is kept clean and well-

lubricated. However, many applications make good maintenance difficult. For example bearings in

the conveyor of a rock crusher are exposed continually to hard abrasive particles. Cleaning is of

little use because cleaning is expensive, yet the bearing is contaminated again as soon as the

conveyor resumes operation. Thus, a good maintenance program might lubricate the bearings

frequently but never clean them.

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APPLICATIONS

Today the journal bearing is used in numerous everyday applications. journal bearings are

used for dental and medical instruments. In dental and medical hand pieces, it is necessary for the

pieces to withstand sterilization and corrosion. Because of this requirement, dental and medical

hand pieces are made from 440C stainless steel, which allows smooth rotations at fast speeds.

Agricultural Equipment. The many moving parts in a piece of farm machinery depend on several

different types of bearings to operate. Under the heavy loads and dusty conditions, these bearings

need to be lubricated, repaired, or replaced often.

TIRE

Tire is a ring-shaped covering that fits around a wheel rim to protect it and enable better

vehicle performance by providing a flexible cushion that absorbs shock while keeping the wheel in

close contact with the ground. They consist of a tread and a body.

The tread provides traction while the body ensures support. he bead is that part of the tire

that contacts the rim on the wheel

ROLLING RESISTANCE

Rolling resistance is the resistance to rolling caused by deformation of the tire in contact

with the road surface. As the tire rolls, tread enters the contact area and is deformed flat to conform

to the roadway. The energy required to make the deformation depends on the inflation pressure,

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rotating speed, and numerous physical properties of the tire structure, such as spring force and

stiffness.

TREAD WEAR

There are several types of abnormal tread wear. Poor wheel alignment can cause

excessive wear of the innermost or outermost ribs. Gravel roads, rocky terrain, and other rough

terrain causes accelerated wear. Over-inflation above the sidewall maximum can cause excessive

wear to the center of the tread. Modern tires have steel belts built in to prevent this. Under-inflation

causes excessive wear to the outer ribs

SUSPENSION SYSTEM

The suspension is the prime mechanism that separates your moving machines parts from

the road. It also prevents your system from shaking itself to pieces. No matter how smooth you

think the road is, it's a bad, bad place to propel over a ton of metal at high speed. Suspension

system is the term given to the system of springs, shock absorbers and linkages that connects a

moving mechanism to its wheels. When a tire hits an obstruction, there is a reaction force. The size

of this reaction force depends on the wheel assembly.

ROLE OF SUSPENSION SYSTEM

The main role of suspension system are as follows:

1. It supports the weight of mechanism .

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2. Provides smoother ride for the mechanism i.e. acts as cushion.

3. Protects your mechanism from damage and wear .

4. It also plays a critical role in maintaining self driving conditions.

5. It also keeps the wheels pressed firmly to the ground for traction .

6. It isolates the body from road shocks and vibrations which would otherwise be

transferred to the mechanism and load.

COIL SPRING

A Coil spring, also known as a helical spring, is a mechanical device, which is typically

used to store energy and subsequently release it, to absorb shock, or to maintain a force between

contacting surfaces. They are made of an elastic material formed into the shape of a helix which

returns to its natural length when unloaded.

Coil springs are a special type of torsion spring the material of the spring acts in torsion

when the spring is compressed or extended. Metal coil springs are made by winding a wire around

a shaped former - a cylinder is used to form cylindrical coil springs.

PRINCIPLE

When a spring is compressed or stretched, the force it exerts is proportional to its change in

length. The rate or spring constant of a spring is the change in the force it exerts, divided by the

change in deflection of the spring. That is, it is the gradient of the force versus deflection curve. An

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extension or compression spring has units of force divided by distance, for example N/m. Torsion

springs have units of force multiplied by distance divided by angle, such as Nm/rad or. The

inverse of spring rate is compliance, that is: if a spring has a rate of 10 N/mm, it has a compliance

of 0.1 mm/N. The stiffness ( k ) of springs in parallel is additive, as is the compliance of springs in

series. Compression springs are designed to become shorter when loaded. Their turns (loops) are

not touching in the unloaded position, and they need no attachment points.

Figure 2.1.6: Compression spring

USES

Springs are used in many purposes. And also one spring can be used for various purposes

simultaneously. There are some of functional purposes.

1. It can be used to store energy for a part of functioning cycles.

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2. Also it can be used to couple two different components i.e. to force, to engage, to maintain

contact with, to remain clear of some other components.

3. Springs, as an electrical device, are useful to maintain continuation in electrical circuit.

4. To counterbalance the weight or thrust, springs are used.

5. For a component, to regain its original position, springs can be used.

6. To decrease the shock or vibrations by observing the motion of moving weight.

ELECTRIC ARC WELDING

Electric Arc welding is a type of welding that uses a welding power supply to create an

electric arc between an electrode and the base material to melt the metals at the welding point.

They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable

electrodes. The welding region is usually protected by some type of shielding gas orslag.

ADVANTAGES

1. Flux Shielded Manual Metal Arc Welding is the simplest of all the arc welding processes.

2. The equipment can be portable and the cost is fairly low.

3. This process finds many applications, because of availability of wide variety of electrodes.

4. A big range of metals and their alloys can be welded.

5. Welding can be carried out in any position with highest weld quality.

6. The process can be very well employed for hard facing and metal deposition to reclaim parts

or to develop other characteristics like wear resistance etc.

APPLICATIONS28


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The process finds applications in :

(a) Air receiver, tank, boiler and pressure vessel fabrications;

(b) Ship building;

(c) Pipes and Penstock joining;

(d) Building and Bridge construction;

(e) Automotive and Aircraft industry, etc.

ELECTRIC WIRING

A system of wires providing electric circuits for a device. The pre-wiring of any automatic

gate system is critical. Generally all domestic and commercial systems will run off 230v mains

voltage. Most operators draw extremely low amounts of current making voltage drop minimal.

Proper insulation is provided such that Electrical wire insulation resists the flow of electrical

charge, thus preventing the loss of electric current and creating a safe vehicle for the flow of

electricity.

Generally at the same time as mains cable being installed, most installations will require

some sort of multi-core low voltage cabling to facilitate such things as audio intercom systems and

or the ability to activate gates via push-buttons within the dwelling. In all situations low voltage

cabling legally must be separate from mains power, preferably in their own high impact resistant

plastic conduit.

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ELECTRONIC SWITCH

A switch is an electrical component that can break an electrical circuit, interrupting the

current or diverting it from one conductor to another. A three way switch is used in this automatic

gate system where reverse, forward and idle positions are required in working of the swing gate

Figure 2.1.7: Reversing switch

Reversing switch is a type of DPDT switch. DPDT switches are available in 'toggle' type,

as shown in the picture above. The ideal switch for this application would have a momentary, or

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non-locking, action. It would automatically switch back to the centre-off position after the operator

has released the switch. These switches are normally a little more expensive.

PROJECT WORK

It consist of methodology adopted for doing the project. It also includes steps to system

fabrication, analyzing of system, working of system according to the various design considerations

of the project according to which the project is going to work out at appropriate conditions of

operation

FABRICATION OF SYSTEM

The whole system for opening the gate is fabricated in six finite steps which can be explained as

given below :

Step 1:

Firstly, the base metal plate is cut on which all others parts of the system are to be placed.

AC motor, gearbox, journal bearing and bent T-section metal plates are welded on it at

specified positions of the base metal plate.

Step 2:

After welding the main components on the base metal plate, they are interlinked with each

other for the power transmission. AC motor is linked with gearbox with the help of V-belt

drive to transmit power, where the gearbox is linked with the journal bearing with the help

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of the chain drive which offers zero slip. Journal bearing transfers the power to the tire with

its inside sliding mechanism.

Step 3:

Mechanical clamps are welded on to the base metal plate and on the side iron sheet. It is

welded on one of the base edge so as to make a opening mechanism of the system. Which

can be used for opening the system when required for maintenance or in case of repair.

Step 4:

Whole casing is covered with the iron sheet to provide a good aesthetic view and also to

prevent system from dirt and to provide safety from damage. Iron sheet is welded on the

other side opposite to the opening cover of the system with help of electric arc welding.

Step 5:

After that suspension link in T-shape metal piece is welded on the one side of the system

opposite to the opening mechanism by electric arc welding. Suspension springs are aligned

on the suspension link which are fitted and tightened on suspension link with help of the

hexagonal nut.

Step 6:

Finally, the system is joined with the mechanical gate by suspension link and T-shape metal

piece welded on base plate. The hexagonal nut and bolt in horizontal direction is used to

join the gate and gate opening system.

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DESIGN CONSIDERATIONS

Motor:

Type = AC

Power = 0.5 hp

Voltage = 230 V

Gearbox:

N2/N1 = T2/T1 ( Gear ratio )

N2/N1 = 1/70

Where,

N1 - Speed input to the gearbox.

N2 Speed available at tire.

Which means that for every 70 revolutions at gearbox input, there will be 1

revolution of the tire of the system. This is to overcome very high speed of motor and to achieve

desired low speed for opening and closing of gate.

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WORKING

When the 0.5 hp AC motor is given power supply, it comes into action. AC motor

produces 1400 rpm at its driver shaft, which are reduced to 1:1 or 1:2 at the entry of the gearbox.

Power is transmitted with help of the V-belt drive within motor and gearbox. Gearbox is used to

reduce the speed to very low value. It reduces the speed at journal bearing in the ratio of 1:70. This

reduced speed is delivered to journal bearing with help of roller chain drive.

After that, journal bearing delivers power to the tire with help of its sliding mechanism.

When the tire is set into rotary action by transferring motion and power, it moves the mechanical

gate in inward and outward direction with its motion. The direction can be changed in any direction

with help of the reversing switch linked with the main supply. The working in both direction can be

explained as below:

Opening the gate.

Closing the gate.

Opening the Gate

When the switch is pressed, the current will be sent to the motor to move in or out in swing

manner. Once the current reaches the motor will start to move and it will move the gate back and

forth. The gate reaches the end the gate touches the limit. When the gate touches the limit, a current

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is sent to the circuitry by pressing the switch by operator to stop the flow of current and stops the

motor.

Closing the Gate

To close the gate, same process is adopted. The switch in pressed in opposite manner which causes

the current to sent to motor, which in return close the gate by moving till the limit. When it almost

reaches the end the gate will touch limit position. Then switch in centre position is pressed, current

is sent to the circuit and a current sent to motor to make it stop.

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COMPLETE SYSTEM WITH PARTS NAME

Figure 3.4: Complete system with parts name

RESULTS AND DISCUSSIONS36


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The automatic gate system fabricated and tested. The result was what we expected that is,

the motor and circuit was compatible with each other with the gate. The motor was able to move

the gate from one end to the other and smoothly with the push of a button. We learned many skills

such as fabrication, wiring the circuit and other tools that we use for this project and was able to

work together as a team during this project. The main results obtained are given as following :-

Speed of opening:

the wheel system solution opens faster than any other automatic gate system around. This

makes it safer to use when entering or exiting a busy road and also gives less time for

animals to escape.

Size of gate:

we can swing gates up to over 20-feet, no problem; provided that the gate will swing on its

hinges this wheel system can open it.

Opens to 180 degrees:

there is no limit as to how far the gate will open during its operation, it can open up to 150

degree or beyond it.

Level of ground:

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up to 4 inches in normal format, but this can be increased to 6 inches with a few fine

adjustments

If the gate drops:

all wooden gates especially will move with the weather; no damage is done to the

mechanism due to suspension movement, unlike traditional systems that can be severely

damaged.

CONCLUSIONS AND FUTURE SCOPE38


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This project has demonstrated how to get a fully functional embedded product developed

from basic components. Comparing the advantages and disadvantages of the automatic gate

system, we found that it is advisable to use this kind system in our home and industrial area. In

other words, we found more good than bad from this system because it is simple safer and more

secure and it is able to keep the people who live in the house safely. In addition, it is also cheaper

in cost This project was a step towards this direction.

Looking at the current growth of automation, researchers will have to come up with new

advanced techniques of automation very soon. This project was a step towards this direction.

Though it did not cover the all aspects, but it was able to come out with an improved and simpler

design.

Advantages and Disadvantages39


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Advantages

1. The advantage of this most basic principle is that we can open bigger gates with far less power

than other systems

2. Needles to get down from the car or go out to open the gate (it could be raining or under the

hot sun)

3. Easy excess to the gate meaning with a push of a button, one is able to open & close the gate.

4. Automatic gate system is able to be connected to ones alarm security system.

5. No more stock or family pets disappearing down the road

6. No more risking your life to open your gate on the dangerous roads.

7. No more uninvited strangers on your door step.

Disadvantages

1. Power failure may cause the gate to stop opening and closing which might give chance for

uninvited stranger to come in easily).

2. Although the motor and circuit is proven to withstand all weather conditions, power overload

and any other problems but there is always a tendency that the circuit could malfunction or

motor could jam.

3. A cost for a good quality and reliable automatic gate are very expensive.

4. This system needs proper and constant maintenance from time to time.

REFERENCES

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The web sites that provided the information are:

www.autogates.com.

www.usautomatic.com

www.amazinggates.com

www.agriwheel.com

www.wikipedia.org

www.agriwheel.com

www.autogates.co.uk
http://www.autogates.com/http://www.usautomatic.com/http://www.amazinggates.com/http://www.agriwheel.com/http://www.wikipedia.org/http://www.agriwheel.com/http://www.autogates.co.uk/http://www.autogates.com/http://www.usautomatic.com/http://www.amazinggates.com/http://www.agriwheel.com/http://www.wikipedia.org/http://www.agriwheel.com/http://www.autogates.co.uk/

Documents

Automation of Swing Gate