LOVELY PROFESSIONAL UNIVERSITY

SCHOOL OF MECHANICAL ENGINEERING

DELHI- JALANDHAR (NH-1) PHAGWARA

A CAPSTONE PROJECT REPORT (MEC494)

ON

UNI-DIRECTIONAL MOTION MECHANISM TO

PRODUCE ELECTRICITY

(JANUARY– MAY 2016)

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

FOR THE AWARD FOR THE DEGREE OF

BACHELOR OF TECHNOLOGY

(Mechanical Engineering)

SUBMITTED TO

LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR

Under the guidance of:

Ravi Garg (UID: 18609)

Asst. Professor (CAD/CAM)

Lovely Professional University,

Jalandhar (Punjab)

Submitted by:

Bhupendra Kumar Shukla

Akash Pandey

Vidit Vishnoi

Nitish Kumar

B.Tech- Mechanical Engineering

Lovely Professional University,

Jalandhar (Punjab)

DECLARATION

We hereby declare that we selected the topic “UNI- DIRECTIONAL MECHANISM FOR

ELECTRICITY GENERATION” as our capstone project topic and we have worked under the

guidance of RAVI GARG: 18609. We have worked with full dedication during the semester on

our topic. We honestly referred the work previously done on this topic and related topics.

Bhupendra Kr Shukla (11205580)

Akash Pandey (11205577)

Vidit Vishnoi (11101912)

Nitish Kumar (11205614)

Date- April 29, 2016

CERTIFICATE

Certified that this CAPSTONE PROJECT titled “UNI- DIRECTIONAL MECHANISM FOR

ELECTRICITY GENERATION” being submitted by BHUPENDRA KUMAR SHUKLA,

AKASH PANDEY, VIDIT VISHNOI, NITISH KUMAR is a bona fide work carried by them

under my guidance from January- May 2016.

During this period, I found them very co-operative, sincere and hard working.

I wish to them good luck and success for all future projects.

………………………………

Ravi Garg (UID: 18609)

Asst. Professor

School of Mechanical Engineering

Lovely Professional University, Jalandhar

ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of the task would be incomplete

without the mention of the people whose ceaseless cooperation made it possible, whose constant

guidance and encouragement crown all efforts with success.

We are very thankful to Mr. RAVI GARG (UID:18609) Asst. Professor CAD/CAM of School

of Mechanical Engineering, Lovely Professional University, Jalandhar for his valuable

guidance and advice without which we could not have completed our capstan project.

He always encouraged and inspired us a lot to work hard and get through the problems. We extend

our gratitude to him for being the guiding force. His ever increasing helping nature needs a special

mention. We would also like to thank all the faculty of School of Mechanical Engineering, to

provide us all the helps that We need at the different stages of completion of my project work.

Lastly, we would like to thank our friends for their encouragement and help which they gave us to

overcome the difficulties at various stages of our project work.

LIST OF THE FIGURES

Figure Title Page

1.1 Uni-directional Mechanism 1

2.1 Scout moor gearbox, rotor shaft and brake assembly 4

2.2 Wind Mill 5

2.3 Axial Turbine Tidal Stream Generator Seagen in Stanford Lough 6

2.4 Distribution of Tidal Phase 6

2.5 Distribution of Tidal Phase 7

3.1 2-D diagram of Uni-directional drive with two shafts 9

3.2 2-D diagram of Uni-directional drive with three shafts 9

3.3 Sprocket 10

3.4 Sprocket Teeth 11

4.1 Spur Gear 17

4.2 Sprocket Hub on one side 18

4.3 Roller Chain 19

4.4 Dynamo Model 20

4.5 Spur Gear Rendered Model 22

4.6 Design of Spattered chain (Caused in design) 22

4.7 Tooth profile of the sprocket 24

4.8 Sprocket Deign 24

4.9 Roller Chai Profile 25

4.10 Roller Chain 26

4.11 Inner Roller Chain Link 28

4.12 Outer Chain Link 28

4.13 Rendered Model of Chain assembly 28

4.14 Input shaft 30

4.15 Intermediate Shaft Rendered Model 30

4.16 Output Shaft Rendered Model 30

4.17 Pillar Rendered Model 31

4.18 Bae Plate with stand 32

4.19 Dynamo Model 33

5.1 Indexing Plate 37

5.2 Indexing Plate 38

5.3 Manufacturing of the Shaft on Lathe Machine 38

5.4 Facing Operation performing 39

5.5 Power Hacksaw Machining Process 40

5.6 Electric Arc Welding Equipment 41

5.7 Flowchart of Electric Arc Welding 41

5.8 Assembly of the Model 43

5.9 Final Assembly of the Model 44

6.0 Final Mechanism 45

LIST OF TABLE

Table Title Page No

3.1 List of Component 10

4.1 Data Report of Gear 21

4.2 Dimension & Breaking Load of Roller Chain 27

4.3 Mechanical properties of steels for shaft 29

5 Cost Report 34

Contents of the Report

Topic Page No.

Declaration (ii)

Certificate (iii)

Acknowledgement (iv)

List of the Figure (v)

List of Table (vi)

Abstract .............................................................................................................................................x

CHAPTER-I

Introduction ........................................................................................................................1

Overview & Basic Idea ....................................................................................................1

Objective .........................................................................................................................1

Summary of the Project ..................................................................................................2

CHAPTER-II

Literature Review.................................................................................................................3

Renewable Energy Sources ..................................................................................................3

Types of Energy Sources .....................................................................................................3

Wind Power .............................................................................................................4

Tidal Power ..............................................................................................................5

Environmental Impact .........................................................................................................8

Challenges ...........................................................................................................................8

Conclusion ................................................................................................................................... 8

CHAPTER-III

Uni-Direction Motion Mechanism .......................................................................................9

Overview of the Machine Drawing ....................................................................................10

CHAPTER-IV

Research Mythology ..........................................................................................................12

Research .............................................................................................................................12

Market Survey ....................................................................................................................13

Material Selection ..............................................................................................................14

Selection Criteria ...............................................................................................................15

Selection of Material ..........................................................................................................15

Theory ......................................................................................................................................16

Designing of Components........................................................................................................20

Sprocket ........................................................................................................................................ 23

Chain ............................................................................................................................................. 25

Spur Gear ...................................................................................................................................... 20

Shaft .............................................................................................................................................. 29

Pillar ............................................................................................................................................... 31

CHAPTER-V

Complete Work plan with Timeline

Gantt Chart ..................................................................................................................................... 34

Cost Report .................................................................................................................................... 35

CHAPTER-VI

Manufacturing of Components ................................................................................................36

Gears ............................................................................................................................................. 36

Shaft/ Axel ................................................................................................................................... 39

Welding ..............................................................................................................................42

Assembly............................................................................................................................44

Material Purchase...............................................................................................................45

CHAPTER-VII

Result & Application ...............................................................................................................46

Future Scope ......................................................................................................................46

Conclusion .........................................................................................................................47

Reference & Bibliography .................................................................................................48

ABSTRACT

In several decades Technocrats used unidirectional mechanism in which many gear assemblies

were used, consequently which is very bulky and expensive to use in commercialization This paper

is based on advanced as well as economic implementation in unidirectional shaft by using ratchet

wheel and chain mechanism. This mechanical device is applicable to a mechanism, used especially

in energy generating devices and some hand tools, consisting of a metal wheel operating with a

catch that permits motion in only one direction and carrying spring loaded pawls on flanges to

engage with accompanied either of the main parts of a ratchet device i.e. the toothed wheel or bar,

or the pawl. One shaft is coupled to other shaft by aforesaid gearings, so that the rotary movement

performed either on clock wise or counter clockwise direction on input shaft will result

unidirectional motion applicable in power generation and power transmission. When the wobbling

movement of a floating body is connected to a rack of gears, this rack of gears will move up and

down. Resulting reciprocal movement could be taken up by a pinion to generate oscillatory

movement on a shaft. Such oscillatory movement is turned to unidirectional motion using this

invention. Harnessing the immense wave power in the world's oceans can be part of the solution

to word's energy needs. On the other hand, there are numerous applications in industry requiring

bidirectional motion to be converted to unidirectional motion.

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CHAPTER-I

1. INTRODUCTION

1.1 Overview & Basic Idea

As we know we need energy and our fossil fuels decreasing day by day so we have worked on

solution an unconventional way through which we can set up a mechanism which can produce

energy and not only that it should be efficient enough to be used in real time. So we worked up

upon mechanism which will produce electricity in both directions. Our basic need to build up

mechanical prototype which we used on bigger scale could give fruitful result.

Aim of our project is to design a mechanism that will produce Uni-directional output for bi-

directional rotation of input shaft. main motive behind this idea is to produce unidirectional

motion of shaft in wind mills, where turbine can rotate in both directions due to wind direction.

This mechanism will allow us to rotate the shaft of dynamo in single direction for continuous

generation of energy, independent of the direction of wind or independent of direction of

turbine blade.

1.2 Objective

1. To design a mechanism for converting the non-uniform and reciprocatory motion of wind

to uniform unidirectional motion for constant generation of electricity.

2. To design a mechanism for converting the non-uniform and bidirectional motion of wind to

uniform unidirectional motion for constant generation of electricity.

3. To study about elctricity generation mechanisms installed in most of the windmills and hydro

power plants.

Fig: 1.1 Uni-directional Mechanism

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Summary of the Project

The method of the present invention converts bi-directional torque to unidirectional torque.

The bi-directional torque comprises a first rotational drive in one direction alternating with a

second rotational drive in the other direction along a drive axis which is converted to become

unidirectional torque along a driven axis. At least a first and a second unidirectional element

are provided at any one or combination of said drive or driven axes. In particular, the method

comprises the steps wherein the first rotational drive engages first unidirectional element to

turn at least one axis in the first rotational direction and allows at least one axis to slip at the

second unidirectional element; - the second rotational drive engages at the second

unidirectional element to turn at least one axis in the second rotational direction and allows at

least one axis to slip at the first unidirectional element; the first rotational direction of the drive

axis is transmitted in the same direction to the driven axis; the second rotational direction of

the drive axis is transmitted in the reverse direction to the driven axis; thereby resulting in said

driven axis being rotated in a single direction by both rotational drives.

In one preferred embodiment of the invention, the drive axis is an axle and the driven axis is a

transmission shaft. The unidirectional elements may be any one or a combination of freewheel,

unidirectional clutch means, pawl-and-ratchet, and the like. Preferably still, the first rotational

drive of the drive axle is transmitted via a sprocket chain to the transmission shaft and the

second rotational drive is transmitted via a gear pair.

Alternatively, the first and second rotational directions of the drive axle may be transmitted to

the transmission shaft in the same rotational direction by an appropriate gear train. Preferably,

the gear train includes a bevel gears arrangement.

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CHAPTER II

2. LITRETURE REVIEW

2.1 Renewable Source of Energy

Renewable energy is energy which comes from natural resources such

as sunlight, wind, rain, tides, and geothermal heat, which are renewable (naturally

replenished). In 2006, about 18% of global final energy consumption came from renewable,

with 13% coming from traditional biomass, which is mainly used for heating, and 3%

from hydroelectricity. New renewable (small hydro, modern biomass, wind, solar, geothermal,

and bio fuels) accounted for another 2.4% and are growing very rapidly. The share of renewable

in electricity generation is around 18%, with 15% of global electricity coming from

hydroelectricity and 3.4% from new renewable.

Wind power is growing at the rate of 30% annually, with a worldwide installed capacity of

157,900 megawatts (MW) in 2009, and is widely used in Europe, Asia, and the United

States. The annual manufacturing output of the photovoltaics’ industry reached 6,900 MW in

2008, and photovoltaic (PV) power stations are popular in Germany and Spain. Solar thermal

power stations operate in the USA and Spain, and the largest of these is the 354

MW SEGS power plant in the Mojave Desert. The world's largest geothermal

power installation is The Geysers in California, with a rated capacity of 750 MW. Brazil has

one of the largest renewable energy programs in the world, involving production of ethanol

fuel from sugar cane, and ethanol now provides 18% of the country's automotive fuel. Ethanol

fuel is also widely available in the USA.

While most renewable energy projects and production is large-scale, renewable technologies

are also suited to small off-grid applications, sometimes in rural and remote areas, where

energy is often crucial in human development. Kenya has the world's highest household solar

ownership rate with roughly 30,000 small (20–100 watt) solar power systems sold per year.

2.2 Types of Source of Energy

Wind Power

Tidal Power

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2.2.1 Wind Power

Airflows can be used to run wind turbines. Modern wind turbines range from around 600 kW

to 5 MW of rated power, although turbines with rated output of 1.5–3 MW have become the

most common for commercial use; the power output of a turbine is a function of the cube of

the wind speed, so as wind speed increases, power output increases dramatically. Areas where

winds are stronger and more constant, such as offshore and high altitude sites are preferred

locations for wind farms. Typical capacity factors are 20-40%, with values at the upper end of

the range in particularly favorable sites.

Globally, the long-term technical potential of wind energy is believed to be five times total

current global energy production, or 40 times current electricity demand. This could require

large amounts of land to be used for wind turbines, particularly in areas of higher wind

resources. Offshore resources experience means wind speeds of ~90% greater than that of land,

so offshore resources could contribute substantially more energy. This number could also

increase with higher altitude ground-based or airborne wind turbines. Wind power is renewable

and produces no greenhouse gases during operation, such as carbon dioxide and methane.

Fig: 2.1 (Scout moor gearbox, rotor shaft and brake assembly)

Page 5 of 47

2.2.2 Tidal Power

Tidal power, sometimes also called tidal energy, is a form of hydropower that converts the

energy of tides into electricity or other useful forms of power. The first large-scale tidal power

plant (the Rance Tidal Power Station) started operation in 1966.

l although not yet widely used, tidal power has potential for future electricity generation. Tides

are more predictable than wind energy and solar power.

Among sources of renewable energy, tidal power has traditionally suffered from relatively high

cost and limited availability of sites with sufficiently high tidal ranges or flow velocities, thus

constricting its total availability. However, many recent technological developments and

improvements, both in design (e.g. dynamic tidal power, tidal lagoons) and turbine technology

(e.g. new axial turbines, crossflow turbines), are suggesting that the total availability of tidal

power may be much higher than previously assumed, and that economic and environmental

costs may be brought down to competitive levels.

Historically, tide mills have been used, both in Europe and on the Atlantic coast of North

America. The earliest occurrences date from the Middle Ages, or even from Roman times.

Fig. 2.2 Wind Mill

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Fig: 2.3 Axial Turbine Tidal Stream Generator Seagen in Stanford Lough

Tidal power is the only form of energy which derives directly from the relative motions of

the Earth–Moon system, and to a lesser extent from the Earth–Sun system. Action with

Earth's rotation, are responsible for the generation of the tides. Other sources of energy

originate directly or indirectly from the Sun, including fossil fuels, conventional

hydroelectric, wind, bio-fuels, wave power and solar. Nuclear is derived

using radioactive material from the Earth, geothermal power uses the Earth's internal

heat which comes from a combination of residual heat from planetary accretion (about 20%)

and heat produced through radioactive decay (80%).

Fig: 2.4 Distribution of Tidal Phase

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Fig: 2.5 Distribution of Tidal Phase

Tidal energy is generated by the

relative motion of the water which

interacts via gravitational forces.

Periodic changes of water levels, and

associated tidal currents, are due to

the gravitational attraction by the

Sun and Moon. The magnitude of the

tide at a location is the result of the

changing positions of the Moon and

Sun relative to the Earth, the effects

of Earth rotation, and the local shape

of the sea floor and coastlines.

Because the Earth's tides are caused

by the tidal forces due to

gravitational interaction with the

Moon and Sun, and the Earth's

rotation, tidal power is practically

inexhaustible and classified as are

renewable energy source.

A tidal generator uses this phenomenon to generate electricity. The stronger the tide, either in

water level height or tidal current velocities, the greater the potential for tidal electricity

generation. Tidal movement causes a continual loss of mechanical energy in the Earth–Moon

system due to pumping of water through the natural restrictions around coastlines, and due

to viscous dissipation at the seabed and in turbulence. This loss of energy has caused the

rotation of the Earth to slow in the 4.5 billion years since formation. During the last 620 million

years the period of rotation has increased from 21.9 hours to the 24 hours. we see now; in this

period the Earth has lost 17% of its rotational energy. While tidal power may take additional

energy from the system, increasing the rate of slowdown, the effect would be noticeable over

millions of years only, thus being negligible.

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2.3 Environmental Impact

Very little direct research or observation of tidal stream systems exists. Most direct

observations consist of releasing tagged fish upstream of the device(s) and direct observation

of mortality or impact on the fish. One study of the Roosevelt Island Tidal Energy (RITE,

Verdant Power) project in the East River (New York City), utilized 24 split beam hydro

acoustic sensors (scientific echo sounder) to detect and track the movement of fish both

upstream and downstream of each of six turbines.

The results suggested:

1. Very few fish using this portion of the river,

2. Those fish which did use this area were not using the portion of the river which would subject

them to blade strikes

3. No evidence of fish traveling through blade areas.

A tidal power scheme is a long-term source of electricity. A proposal for the Severn Barrage,

if built, has been projected to save 18 million tons of coal per year of operation. This decreases

the output of greenhouse gases into the atmosphere.

2.4 Challenges

1. The major challenges is that this project should not disturbed the marine ecology. It should

work even with accommodation of sediments.

2. It should not disturb the ship route.

3. It should yield as much power without damage the component.

2.5 Conclusion

Taking the idea from all research paper and studying their adverse effect and seeing where they

fail. We have made our model so that it can be used as in wind and tidal wave energy so that it

can generate electricity in both directions which are included in the literature review. We came

to a point that by using gear-train with sprocket and chain mechanism we can make a system

which is used to produce the Uni-directional mechanism and further generated electricity by

using dynamo. In this we used the basic model of dynamo that produces 2V maximum. For the

more amount of electricity, we can replace the dynamo with the bigger dynamo. In all research

paper idea is given that how gear train works, and how the power transmission take place.

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CHAPTER-III

UNI-DIRECTIOAL MECHANISM

Fig: 3.1 2D Figure of Uni-directional Mechanism

Firstly, we decided to make model of unidirectional motion using two shafts i.e. one

output and one input but then, for the point of view of innovation and generating more power

we designed and came up a new model consisting of an intermediate shaft which is more

efficient.

Fig: 3.2 2D Figure of Uni-directional Mechanism

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List of the components

Table 3.1 List of Component

In this project basically we have an input shaft and an intermediate shaft on both

of which one gear and one-way type sprocket is welded.

Principle of Sprocket: -

A ratchet consists of a round gear or linear rack with

teeth, and a pivoting, spring-loaded finger called a pawl

that engages the teeth. The teeth are uniform

but asymmetrical, with each tooth having a moderate

slope on one edge and a much steeper slope on the

other edge. When the teeth are moving in the

unrestricted

Fig: 3.3 Figure of Sprocket

Page 11 of 47

(i.e., forward) direction, the pawl easily

slides up and over the gently sloped edges

of the teeth, with a spring forcing it into the

depression between the teeth as it passes the

tip of each tooth. When the teeth move in

the opposite (backward) direction, however,

the pawl will catch against the steeply

sloped edge of the first tooth it encounters, thereby locking it against the tooth and preventing

any further motion in that direction.

Process: -

The third shaft which is the output shaft consist of the fixed type sprocket welded and pinned

in the center with flywheel at one end which is further with the help of a belt connected to

dynamo and further to LED.

So when we rotate the handle in clockwise direction the input shaft and the gear mounted on it

will also rotate in clockwise direction which then meshes with the gear of gear of intermediate

shaft resulting the transfer of motion in anti-clockwise direction.

But, the major role of motion transfer is played by the sprocket and chain mechanism.

As the one-way type sprocket when the input shaft is in clockwise direction will be locked and

the one on the intermediate shaft will be free to rotate. Hence, the chain moves in clockwise

direction thus, the output and the flywheel rotate in clockwise direction.

In another scenario, when we rotate the handle of input shaft in anti-clockwise direction the

sprocket or the input shaft will be free and the one on the intermediate shaft will be locked so

when the intermediate shaft rotates clockwise against with it the chain will move clockwise.

So the output shaft will move clockwise and the dynamo will generate electricity.

Further for higher generation we can use bigger dynamo. Also, we have used two LEDs with

switch as a safety measure so that if one malfunctions, the other one can be used.

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CHAPTER-IV

RESEARCH MYTHOLOGY

1. Research

There are a number of energy sources that are in the form of alternating up-and-down driving

motions including rise-and- fall, push-and-pull, see-saw lever movement, inflate and deflate

and the like. To harness such alternating motion to become useful mechanical work, usually it

has to be translated into a unidirectional motion to drive, for example, a crankshaft, slider crank,

bevel gear differential, compound gear train, etc. We used unidirectional mechanism as our

capstone project because today scenario is to generate the electricity with the less input and

here we have water a main source to make the project possible. As 76% area covered with

water that’s a big advantage for us to select as our project, main important is its pollution free

production of electricity and biggest advantage of using this project that it can work in both the

directions where other mechanism is fail to do so. Numerous attempts have been made on

methods and machines for harnessing unidirectional flow of kinetic energy, particularly that of

moving water.

The torque may be used to generate distributable useful energy, e.g. to turn a generator to

produce electricity.

Market Survey

Selection of Material

Design and Calculation

Manufacturing Process & Assembly

Theory

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There is a need of a unidirectional gear drive applicable as a unique apparatus applicable in

variety of applications, for the purpose of turning swings of a shaft in to continues Uni-

directional rotation of an output shaft.

2. Market Survey

We have gone through the market to see and select different type of component available or

not.

1. Firstly, we started with the main component of our project that is gear. The bigger

question to us was which gear to use? so we selected spur gear through market survey

because: -

It is used for parallel shaft and we are using parallel shaft in our project.

Also spur gear can be produced easily and with numerous processes

Also they produce less noise

2. Then we have searched for a suitable shaft that can be used efficiently and will not

destroy easily.

3. Then we searched for chain different types of chain available and which type we want

and which will be efficient in our project.

4. For the base plate we found a shop which can give us loose pieces.

5. For dynamo we searched for a special kind of dynamo setup which is less in cost and

is efficient enough to work on 2 LEDs so that if one malfunctions we have another work

working.

6. Then we searched for the key component of our project i.e. sprocket we searched for

special type of sprocket i.e. that will work one side (one-way type)

Visited shop for this: - For mechanical Components- Mahajan & Company- Jalandhar,

Virendra Industries- Jalandhar, Gupta Iron & Hardware Store, Nakodar Road-

Jalandhar, Krishna Iron & Hardware Store, Rama- Mandi Jalandhar, Sardar Bajinder

Singh Industries, Jalandhar

For electronics component: Riscin LPU

Page 14 of 47

3. MATERIAL SELECTION

3.1 Selection Criteria

The designer selects the materials of construction for his product based on several criteria such

as its cost, the desirable properties that it should possess, its availability, the preferred

manufacturing processes that are to be employed, etc. The overall economy is influenced by

all these factors. In special cases, essentiality and /or urgency of the need for the product can

supersede the economic considerations. The main criteria for material selection are discussed

below:

3.1.1 Cost of The Material

The amount of raw materials, their composition, quality, any special heat-treatment that is

required, etc. influence the unit cost of materials. The unit cost generally depends also on the

quantity of raw material that is purchased in a single lot. Special steel materials, for example,

cost much more in the market when purchased in small quantities from a retailer than in bulk

directly from the steel mill/stockyard.

3.1.2 Availability

The material should be readily available in adequate quantities. Material availability is closely

linked with the variety and level of technology obtained in a given geographic location.

Procuring materials from far and wide can be expensive, due to the additional cost for transport,

for transporter taxes and duties etc.

3.1.3 Manufacturing Process

Facilities for shaping and treating the selected material into the finished product or component

must be available for economic production. Otherwise, the production cost goes up. For

example, the selection of forged alloy steel for a connecting rod design necessarily assumes

that a suitable forging facility is available along with the necessary dies and other accessories.

If the alloy is of a rare quality, then facilities for its heat treatment might not be available.

3.1.4 Properties of The Material

The desired function and performance of any product depends to a great extent on the use of

materials with the right physical and chemical properties. In general mechanical engineering

these properties can be classified into different categories depending on how a particular

property affects the function and life of a component. The main property groups are: -

Page 15 of 47

Chemical Composition, specifying the contents of all the different elements

contained.

Properties of state, such as solid, liquid or gas, density, porosity, temperature.

Strength related properties, such as ultimate strengths in tension, compression and

shear, yield strength/ 0.2% strength, fatigue strength, notch sensitive, hardness, impact

strength, effect of high/low temperatures on strength, etc.

Strain related properties, such as elongation at fracture, elastic moduli, ductility,

malleability etc. these help to ensure the desired rigidity/ elasticity, formability etc.

Wear related properties, that determine the erosion, abrasion, friction etc. between

components in contact/ relative motion.

3.2 Selection of Material

3.2.1 Stainless Steels

Stainless steel is iron base alloy that has a great resistance to corrosion. It is observed that a

thin, transparent and very tough film forms on the surface of stainless steel which is inert or

passive and does not react with many corrosive materials within a temp range of 2350C to

9800C, it exhibits strength, toughness and corrosion resistance superior to other metals. It is

just ideally suited for handling and storage of liquid helium, hydrogen, nitrogen and oxygen

that exist at cryogenic temp. The property of corrosion resistance is obtained by adding

chromium only or by adding chromium and nickel together. Stainless steel is manufactured in

electric furnaces.

3.2.2 Cast Iron

Cast iron is a general term applied to wide range of iron carbon alloys. Their carbon contents

are such as to cause some liquid of eutectic composition (called ledeburite) to solidify. The

minimum carbon contents are therefore about 2% while the maximum is about 4.3%.

Cast iron should not be thought of as a metal having single element. It, at least, possesses six

elements. These are iron, carbon, silicon, manganese, 30 phosphorus and sulphur. Alloy cast

iron has still other elements, which have important effect on its physical properties.

Page 16 of 47

3.2.3 Mild Steel

Plain carbon steel in which carbon contents ranges from 0.08 to below 0.3 are known as mild

steel. Those mild steel in carbon contents is less than 0.15% are known as dead mild steel. Mild

steel is not such effected by heat treatment processes, especially hardening process. A decrease

in carbon content improves the ductility of mild steel. These steels possess good machinability

and weldability. They are mainly used for making wires, rivets, nut, bolt, screw, sheets, plates,

tube, roads, shafts, structural steel section and for general workshop purposes etc.

So, we used: -

1.spur gear – for this we used cast iron because it absorbs vibration.

2.Base plate & stands- we used mild steel

3.chain-roller chain of plain carbon steel

4.shafts- all the 3 shafts are made of mild steel

5.sprocket- Stainless steel

4. THEORY

1. Gear:

A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with

another toothed part to transmit torque. Geared devices can change the speed, torque, and

direction of a power source. Gears almost always produce a change in torque, creating

a mechanical advantage, through their gear ratio, and thus may be considered a simple

machine.

Types of Gear:

a) Spur Gear

b) Helical Gear

c) Herringbone Gear

d) Bevel Gear

e) Worm Gear

In our capstone project we spur gear because spur gear is the cheapest one and easy to

manufacture and also are used when the shafts are parallel.

Spur Gear:

Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or

disk, and with the teeth projecting radically, and although they are not straight-sided in

form (as viewed along the axis), the edge of each tooth (and thus the whole form) is straight

and aligned parallel to the axis of rotation. These gears can be meshed together correctly

Page 17 of 47

only if they are fitted to parallel axles. In our project we have used two spur gear meshed

with each other.

These geared are made from mild steel and we have purchased these set of gear as is it’s

from shop. There is no hard and fast rule for gear but the radius of gear should more than

sprocket used so that both can be used simultaneously in project.

Gear Tooth Failure

There are normally five types of failure:

o Abrasive Wear

Abrasive wear is the principal reason for the failure of open gearing and closed

gearing of machinery operating in media polluted by abrasive materials.

o Corrosive Wear

Corrosive wear is due to the chemical action of the lubricating oil or the additives.

Tooth is roughened.

o Initial Pitting

Initial pitting occurs during running-in period wherein oversized peaks on the

surface get dislodged and small pits of 25 to 50 μm deep are formed just below pitch

line region.

o Destructive Pitting

During initial pitting, if the loads are high and the corrective action of initial pitting

is unable to suppress the pitting progress, then destructive pitting sets in.

o Scoring

Fig: 4.1 Spur Gear

Page 18 of 47

Scoring is due to combination of two distinct activities: First, lubrication failure in

the contact region and second, establishment of metal to metal contact.

2. Sprocket

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain, track or other perforated or indented material. The

name 'sprocket' applies generally to any wheel upon which radial projections 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 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, tape etc. Perhaps the most common

form of sprocket may be found in the bicycle, in which the pedal shaft carries a large

sprocket-wheel, which drives a chain, which, in turn, drives a small sprocket on the axle

of the rear wheel. Early automobiles were also largely driven by sprocket and chain

mechanism, a practice largely copied from bicycles.

Sprockets are of various designs; a maximum of efficiency being claimed for each by

its originator. Sprockets typically do not have a flange. Some sprockets used

with timing belts have flanges to keep the timing belt centered. Sprockets and chains

are also used for power transmission from one shaft to another where slippage is not

Fig: 4.2 Sprocket Hub on one Side

Page 19 of 47

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 be noiseless even at high speed.

3. Chain

A chain is a series of connected links which are typically made of metal. A chain may consist

of two or more links.

Those designed for lifting, such as when used with a hoist; for pulling; or for securing, such

as with a bicycle lock, have links that are torus shaped, which make the chain flexible in

two dimensions (The fixed third dimension being a chain's length.)

Those designed for transferring power in machines have links designed to mesh with the

teeth of the sprockets of the machine, and are flexible in only one dimension. They are

known as roller chains, though there are also non-roller chains such as block chain.

Advantages of Chain As no slip takes place during chain drive, hence perfect velocity ratio is obtained.

Since the chains are made of metal, therefore they occupy less space in width than a

belt or rope drive.

It may be used for both long as well as short distances.

It gives a high transmission efficiency (up to 98 percent).

It gives less load on the shafts.

Fig: 4.3 Roller Chain

Page 20 of 47

4. Dynamo

A dynamo is an electrical generator that produces direct current with the use of

a commutator. Dynamos were the first electrical generators capable of delivering power

for industry, and the foundation upon which many other later electric-power conversion

devices were based, including the electric motor, the alternating-current alternator, and

the rotary converter. Today, the simpler alternator dominates large scale power generation,

for efficiency, reliability and cost reasons. A dynamo has the disadvantages of a mechanical

commutator. Also, converting alternating to direct current using power rectification

devices (vacuum tube or more recently solid state) is effective and usually economical.

Principle of Dynamo

The operating principle of electromagnetic generators was discovered in the years of 1831–

1832 by Michael Faraday. The principle, later called Faraday's law, is that an electromotive

force is generated in an electrical conductor which encircles a varying magnetic flux.

AC Dynamo is based on the phenomenon of electromagnetic induction. That is, when the

relative orientation between the coil and the magnetic field changes, the flux linked with

the coil changes and this induces a current in the coil.

5. DESIGN AND CALCULATION

1. Gear

Design Specification of Spur Gear:

There are three standards for the shape of the gear teeth.

a) 14.5º full depth involute system

b) 20º full depth involute system

c) Stub involute system

Fig: 4.4 Dynamo Model

Page 21 of 47

Pressure Angle 20º

Addendum M

Dedendum 1.25M

Clearance 0.25M

Working Depth 2M

Whole Depth 2.25M

Tooth Thickness 1.5708M

Fillet Radius 0.4M

(* Standard for 20º Involute Teeth- empirical relations)

Table 4.1 Date Report of Gear

Design Calculation:

Outer Diameter 127mm

Pitch Circle Diameter 123.5mm

Inner Diameter 24mm

Number of Teeth(T) 71

Material Cast Iron

Pitch Circle Diameter (d) = ���.���

Circular Pitch (p) =��

�=

�.��× ���.�

��= �.�����

Diametrical Pitch (P) =�

�=

��

�= ��.� (� = 5" ���ℎ)

Module (m) =�

�=

���.�

��= �.�����

Addendum Circle diamter = d + 2m = 123.5 + (2 × 1.739) =

���.����

Dededum Circle Diameter = d − 2m = 123.5 − (2 × 1.73) =

���.�����

Space Width = ���

Tooth Tickness= ���

Addendum = 126.98 − 123.5 = �.����

Dedendum = 123.5 − 121.18 = �.����

Full Depth = Addendum + Dedendum = 3.48 + 2.31 = �.����

Page 22 of 47

Backlash= ���

Pressure Angle = ��º

Center Distance(a) =�(�����)

�=

�.���× (�����)

�= ���.�����

As per the Standard 20º Involute Teeth-

�������� = 1.25� = �.������

�������� = � = �.�����

������� ����ℎ = 2� = �.�����

������ ����ℎ = 2.25� = �.�����

����ℎ �������� = 1.5708� = �.�����

Designed of Gear in Creo2.0

Problem Faced during Designing:

When we were design the

components we through to

design the components only for

input and output shaft means we

were going to use only two shafts

for the motion mechanism.

But after the analysis and

research project we got to know

if we were use an intermediate

shaft that increases the efficiency of the motion mechanism. And while designing the sprocket

Fig: 4.5 Spur Gear

Rendered Model

Fig: 4.6 Spattered Assembly

Page 23 of 47

we faced problem related to its free and locking motion mechanism that is the main factor to

convert the bi-directional motion to Uni-directional motion.

While we were assembling the component for the motion analysis the chain was not messing

correctly and when we analyze that chain is in under failure. So we got know the concept about

the center distance that’s make the perfect mesh. And we changed the center distance between

the pillar.

That was only problem we faced during designing & sorted out.

2. Sprocket

Dimension & Calculation/ Specification of Sprocket:

Chain Pitch (p) = 12.70mm, from the Table 08A (American Standared)

Pitch Circle Diamenter (D) =�

������

�

= 73.136mm

Rollar Diameter (d1) = 7.95mm from Table

Width between Inner Plate (b1) = 7.85mm from Table

Transuere Pitch (Pe) = 14.38mm

Top Diameter (Da), (Da)max = D + 1.25p− d

= 73.1364+ 1.25 × 12.70 − 7.95

= ��.������

(Da)min = D + p �1 −1.6

�� − d1

= 73.1364+ 12.70 �1 −1.6

18� − 7.95

= ��.�������

Root Diameter (Df) = D − 2ri

Rollaer Seating Radius(ri) = (��)��� = 0.505�1 + 0.069√�1�

= 0.505 × 7.95 + 0.069(7.95)

= �.������

(��)��� = 0.505�1

= 0.505 × 7.95

= �.�����

Roller Seating Angle (α) �(max) = �120 −��

��

�(���) = ���°

Page 24 of 47

�(min) = �140 −90

��

= ���°

Material Used= Mild Steel + HSS

Designed of Sprocket in Creo2.0

Fig: 4.7 Tooth Profile of Sprocket

Fig: 4.8 Sprocket

Design

Page 25 of 47

3. Chain

A Chain is classified in three categories to design it.

1. Load Lifting Chain

2. Hauling Chain

3. Power Transmission Chain (we used this chain for the electricity generation)

The roller chains are standardized and manufactured on the basis of pitch. These chains are

available in single-row or multi-row roller chains such as simple, duplex or triplex strands.

& Power Transmission chain is also known as Roller Chain

Term Used in Chain:

1. Pitch of chain. It is the distance between the hinge center of a link and the

corresponding hinge center of the adjacent link. It is usually denoted by p.

2. Pitch circle diameter of chain sprocket. It is the diameter of the circle on which

the hinge centers of the chain lie, when the chain is wrapped round a sprocket. The

points A, B, C, and D are the hinge centers of the chain and the circle drawn through

these centers is called pitch circle and its diameter (D) is known as pitch circle

diameter.

Bush roller chain

A bush roller chain consists of outer plates or pin link plates, inner plates or roller link plates,

pins, bushes and rollers. A pin pass through the bush which is secured in the holes of the roller

between the two sides of the chain. The rollers are free to rotate on the bush which protect the

sprocket wheel teeth against wear. The pins, bushes and rollers are made of alloy steel. A bush

Fig: 4.9 Roller Chain

Page 26 of 47

roller chain is extremely strong and simple in construction. It gives good service under severe

conditions. There is a little noise with this chain which is due to impact of the rollers on the

sprocket wheel teeth. This chain may be used where there is a little lubrication. When one of

these chains elongates slightly due to wear and stretching of the parts, then the extended chain

is of greater pitch than the pitch of the sprocket wheel teeth. The rollers then fit unequally into

the cavities of the wheel. The result is that the total load falls on one teeth or on a few teeth.

The stretching of the parts increase wear of the surfaces of the roller and of the sprocket wheel

teeth.

It consists of five parts:

i) Pin ii) Roller iii) Bushing iv) Inner Link Plate v) Outer Link Plate

Fig: 4.10 Roller Chain

Page 27 of 47

Calculation:

Chain Number (ISO No) 08A/40

Pitch (mm) 12.70

Roller Diameter (mm) 7.95

Width (mm) 7.85

Transverse Pitch (mm) 14.38

Braking Load (N) 13800

Average Tensile Strength (Lb/KgF) 4299 / 1950

Maximum Working Load (Lb/KgF) 860 / 390

Weight (Lb/ft/Kg/m) 0.4930.66

Table: 4.2 Dimension & Breaking Load of Roller Chain

Page 28 of 47

Designed in Creo2.0

Fig 4.13: Rendered Model of Chain in Solid works

Fig: 4.11 Inner Roller Chain design

Fig: 4.12 Outer Roller Chain design

Page 29 of 47

4. Shaft

Properties of the Material that is used for the shaft.

The material used for shafts should have the following properties:

1. It should have high strength.

2. It should have good machinability.

3. It should have low notch sensitivity factor.

4. It should have good heat treatment properties.

5. It should have high wear resistant properties.

The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4

and 50 C 12.

Indian standard

designation

Ultimate tensile strength, MPa Yield strength,

MPa

40 C 8

45 C 8

50 C 4

50 C 12

560 – 670

610 - 700

640 – 760

700 Min.

320

350

370

390

Stresses in Shafts

The following stresses are induced in the shafts:

1. Shear stresses due to the transmission of torque (i.e. due to torsional load).

2. Bending stresses (tensile or compressive) due to the forces acting upon machine

elements like gears, pulleys etc. as well as due to the weight of the shaft itself.

3. Stresses due to combined torsional and bending loads.

Outer Diameter 24mm

Length Gear Shaft 254mm (10” Inch)

Length of Output Shaft 304.8mm (12” Inch)

Material Mild Steel

Cost

Designed in Creo 2.0

Table: 4.3 Mechanical properties of steels for shaft

Page 30 of 47

Fig: 4.14 Input Shaft Rendered Model

Fig: 4.16 Output Shaft Rendered Model

Fig: 4.15 Intermediate Shaft Rendered Model

Page 31 of 47

5. Pillar

In these pillar blocks, the material used is iron and a total of 6 pillar blocks are used

with a length of about 127mm for input shaft & for intermediate shaft, 172.80mm for

Output Shaft and 5mm diameter. They are not hollow and the weight of each pillar

block is around 250gms, in order to support the entire heavy structure.

Length of Input Pillar 127mm

Length of Intermediate Pillar 127mm

Diameter of Extended part 12mm

Length of Output Pillar 172.80mm

Material Mild Steel

6. Base Plate & Stands:

A 4mm thick metallic base plate made of mild steel of size 407.2 mm x 304.80 mm is used to

support the heavy assembly of all Ratchet gears, sprocket, chains links, pillars and all the stuff

needed for this project. This iron base plate is mounted on four stand made of cylindrical shaft

fitted with counter sink bolt. This stand will help us to handle project easily, and provide better

griping to hand due to heavy weight of this project.

Fig: 4.5.21 Pillar Rendered Model

Fig: 4.17 Pillar Rendered Model

Page 32 of 47

Due to large thickness it will hold the whole assembly with full stability even at high speed of

rotation. As shown in picture the four stands are mounted at four different corners by electric

arc welding. This plate was cut from large sheet of metal with the help of gas cutter and then it

is dimensioned by doing grinding and drilling operation was performed to attach stands.

Dimension of Base Plate:

Length 408.20mm

Breadth 304.80mm

Thickness of Plate 4mm

Material Used Mild Steel

Welding Electric-Arc Welding

Dimension of Stands:

Length 25.4mm

Breadth 25.4mm

Height 152.40mm

Material Used Mild Steel

Welding Electric-Arc Welding

Designed in Creo 2.0

1. Dynamo

Fig: 4.18 Base Plate with Pillar Rendered Model

Page 33 of 47

Component Name Dimension

Large Wheel (Red) 5” (inch)

Small wheel (Black) 10mm

Fig: 4.19 Dynamo Model

Page 34 of 47

CHAPTER-V

COMPLETE WORK PLAN WITH TIMELINE INCLUDING

COST REPORT

Cost Report

Components Quantity Cost

1. Gear 3 3000

2. Sprocket 3 1500

3. Shaft 3 700

4. Mild steel plate 2 600

5. Dynamo setup 1 500

6. chain 1 170

Total Cost 13 6470

Table 5- Cost Report

LOVELY PROFESSIONAL UNIVERSITYSCHOOL OF MECHANICAL ENGINEERINNG

CAPSTONE PROJECT TIMELINE ANALYSIS (FEB-MAY 2016) Plan Actual % Complete Actual (beyond plan) % Complete (beyond plan)

Period Highlight: 9

PLAN PLAN ACTUAL ACTUAL PERCENT *ACTIVITY START DURATION START DURATION COMPLETE PERIODS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Idea, Research on Research Paper and YouTube with Google 1 7 1 5 25%Market survey and visiting different shops 2 3 2 2 100%Designing of components using creo 2.0 2 7 2 5 35%Calculation related to various components 3 7 3 6 10%Design assembly and selection of best setup 4 7 4 10 85%Ordering of components according to design and measuring there dimensions4 10 4 14 85%Manufacturing of base plate, stands, pillers 6 10 6 14 50%Welding of all these with dimension according to design 8 5 8 7 60%Manufacturing of shaft using lathe machine 9 3 9 3 75%Assembly and welding of gear, sprocket and shaft 10 5 10 7 100%Final assembly with dynamo system and checking 11 4 11 4 60%

Uni-directional Mechanism

Page 35 of 47

CHAPTER- VI

MANUFACTURIN1G & ASSEMBLY PROCESS

5.1 Spur Gear

The commonly used generating processes used for the generation of gear teeth are: -

Gear Shaper Process

Rack Planning Process

Hobbing Process.

Milling Process (Gears we used in this project are made by Milling Process)

5.1.1 Gear Shaper Process

In this process a pinion shaped cutter is used which carries clearance on the tooth face and

sides. It carries a hole in the center for mounting on the stub arbor or spindle of the machine.

The cutter is mounted with the axis vertical and is reciprocated up and down by sliding the

spindle head along the vertical ways on the machine. In addition to the reciprocating motion,

the cutter and the gear blank both are rotated slowly their own axis. The relative speed of

rotation of the two is the same as the gear to be cut will have with a pinion of the same number

of teeth as the cutter. It is accomplished by providing a gear train between the cutter spindle

and the work spindle. The cutter in its rotation generates the tooth profile on the gear blank.

All gears cut by the same cutter will mesh correctly. This is a specific advantage of this process

over the forming process using rotary cutters. Also it is a much faster process than rotary

cutting.

5.1.2 Gear Planning

In this process rack type cutters for generating of spur. Involutes rack has straight edges and

sharp corners and hence can be manufactured easily and accurately. The cutters generate as

they are cut and as the name implies, the machine cuts the teeth by reciprocating planning

action of the cutter. This is a true generating process since it utilizes the principle that an

involute curve can be formed by a straight generator when a gear blank is made to roll without

slip relative to the generator.

Page 36 of 47

5.1.3 Gear Hobbing

In this process, the gear blank is rolled with a rotating cutter called the HOB. A majority of the

involute gears are produced by this method. A gear hob looks like a worm, but carries a number

of straight flutes (gashes), cut all around, parallel to its axis. This results in the production of

separate cutting teeth and cutting edges. In operation, the hob is rotated at as suitable speed and

fed into the gear blank. The blank also rotates simultaneously. The speeds of the two are so

synchronizes that the blank rotates through one pitch distance for each complete revolution of

the hob. There is no intermittent motion of the two and the generating continues steadily. The

hob teeth are just like screw threads, i.e. having a definite helix angle. The hob is, therefore

tilted to its own helix angle while cutting the gear so that its teeth are square with the blank and

produces a true involute shape.

5.1.4 Milling Process

Milling is one of the metal removal process best known for making gear. Here a firm cutter is

passed through the gear blank to affect the tooth gap, helical gear, worm & worm wheel and

bevel gear can be manufactured by milling. Gear milling is less costly and less accurate process

and it is employed for the following: -

Coarse pitch gear

Racks of all pitches

Worms

Toothed parts as sprockets and ratchets.

The production capacity in this method is low since each space is machined separately and the

time is lost in retuning the job to its initial position and in indexing for each tooth. In actual

practice a series of cutters are selected for a number of teeth to be milled. Out of all above

processes we select the Gear Shaping for the manufacturing of all the gears. The various

reasons for selection of this process are as following: -

This process of making gears is cheaper than hob cutter.

Gear shaping machines are easily available.

All gears can be made of same pitch by same cutter.

Page 37 of 47

Indexing

Indexing head also known as dividing head

or spiral head. It is a specialize tool that

allow a work piece to be circularly indexed.

i.e. easily and precisely rotated to preset

angle or circular division. Indexing head

usually used on the table of milling

machine. Index plate that are generally used

are:

a) Brown and Sharpe Milling

Plate No-1- 15 16 17 18 19 20 Holes

Plate No-2- 20 23 27 29 31 33 Holes

Plate No-3- 37 39 41 43 47 49 Holes

b) Cincinnati & Parkinson Dividing Head

Plate No-1

o Slide 1- 24 25 28 30 3 37 38 39 41 42 43 Holes

o Slide-2- 46 47 49 51 53 57 58 59 62 66 Holes

Plate No-2

o Slide No-1 34 46 79 93 109 123 139 153 167 181 197 Holes

o Slide No-2 32 44 77 89 107 121 137 151 163 179 Holes

Plate No-3

o Slide No-1 26 42 73 87 103 119 133 149 161 175 191

o Slide No-2 28 38 71 83 101 113 131 143 159 173 187

Indexing Formulae

�������� =��

�

�ℎ��� � = �� �� ����ℎ

Fig: 5.1 Indexing Plate

Page 38 of 47

5.2 Shaft

In the manufacturing of the axles following operations are used: -

Turning

Facing

Drilling

Assembly

5.2.1 Turning

It may be defined as the machining the operation for generating external surfaces of the

revolution by the action of the cutting tool on a rotating work piece. When the same action is

applied to internal surfaces of the revolution, the process is termed as boring.

Fig: 5.3 Manufacturing of the Shaft on Lathe Machine

Fig: 5.2 Indexing Plate

Page 39 of 47

5.2.2 Facing

Facing operation machines the ends of the work piece. It provides a surface which is square

with the axis of the work piece from which to start the job. Facing is done by feeding the cross

slide or compound in or out. In facing the cutting tool moves from the center of the job towards

its periphery and vice – versa. Facing is primarily used to smooth off a saw- cut end of a piece

of bar stock or to smooth the face of rough casting.

5.2.3 Drilling

Drilling is the process of making holes in a work piece. Either the work piece rotates or drill is

stationary or vice-versa. When drilling on the lathe is being done, generally the work piece

rotates in the chuck and the drill held in the tail stock is fed into the work piece by means of

Fig: 5.4

Facing Operation performing on Lathe Machine

Page 40 of 47

the hand wheel on the outer end of the tail-stock assembly. It is possible to do drill by holding

and rotating the drill in the lathe spindle while keeping the work stationary, supported by a

special pad mounted in tail-stock quill. Since drill feed is by hand, care must be taken,

particularly in drilling small holes. Coolant should be withdrawn occasionally to clear chips

from the hole and to aid in getting coolant to cutting edges of the drill.

5.2.4 Base Plate

Mild Steel Plate has been taken out from the IRON Sheet by the Power hacksaws. We used the

cutting operation to dimense the plate.

Cutting Process

Power Hacksaw: Power hacksaws are used to cut large sizes (sections) of metals such as steel.

Cutting diameters of more than 10/15mm is very hard work with a normal hand held hacksaw.

Therefore, power hacksaws have been developed to carry out the difficult and time consuming

work.

The heavy ‘arm’ moves backwards and forwards, cutting on the backwards stroke.

Fig: 5.5 Power Hacksaw Machining Process

Page 41 of 47

5.3 Welding

In assembly we used welding process to join the manufactured parts. There are many welding

processes available but we used ELECTRIC ARC WELDING to assemble the model.

Electric Arc Welding:

Arc welding is one

of several fusion

processes for

joining metals. By

applying intense

heat, metal at the

joint between two

parts is melted and

caused to intermix -

directly, or more

commonly, with an

intermediate molten

filler metal. Upon

cooling and

solidification, a metallurgical bond is created.

Fig: 5.6

Electric Arc

Welding Equipment

Fig: 5.7

Electric Arc Welding

Page 42 of 47

Types of Arc Welding

There is a common misconception from people who are not welders. That misconception is

that all a welder has to do is grab the welding gun and pull the trigger. Many beginning welders

are surprised when they start training that there is so much more to the trade than that. They

are also surprised that there are so many different kinds of welding. For beginners, let's go over

the various kinds of welding that exist so that no one is caught by surprise when they start their

training and discover they have much more to learn than they thought.

Arc welding is one of the most common kinds of welding. The concentrated heat of an electric

arc joins metal by fusing the parent metal to a joint using a consumable electrode. Direct or

alternating current could be used, and which one depends on the welding material and the

electrode.

Flux-cored arc welding (FCAW) uses tubular electrodes that are filled with flux. It's much

less brittle than the coatings on SMAW electrodes and preserves most of the alloying benefits.

Gas metal arc welding (GMAW), also known as MIG welding, shields the welding arc with

a gas such as argon or helium or even a mixture. Deoxidizers in the electrodes can prevent

oxidation which makes it possible to weld multiple layers.

Gas tungsten arc welding (GTAW) is also known as TIG welding. It uses tungsten electrodes

as one pole of the arc in order to create the required heat.

Plasma arc welding (PAW) has ionized gases and electrodes that generate hot plasma jets that

are aimed at the welding area. These jets are extremely hot.

Shielded metal arc welding (SMAW) is one of the simplest, oldest, and most versatile

welding methods. The arc comes from a coated electrode tip being touched to the workpiece

and then withdrawn to maintain the arc.

Submerged arc welding (SAW) has a granular flux that is fed into the weld zone that forms

a thick layer, completely covering the molten zone and preventing sparks and spatter. It allows

for deeper heat penetration since it acts like a thermal insulator.

Page 43 of 47

ASSEMBLY

We welded the

mild steel plate

with the L-

angle stands

through electric

arc welding

process. After

that as per the

motion analysis

of the design

we welded the

pillar by the same process as per specific distance between them. Gears, Sprocket are fitted

on the respective shafts and welded with the arc process for the efficient motion. As per the

Fig: 5.8 Assembly of the Model

Page 44 of 47

motion ratio we make the alignment of the gears and the sprockets and welded the opposite

side pillars to fix them for a perfect motion.

Now output shaft is fitted on pillars.

Compound shaft is fitted in such a way so that

pinion of compound shaft correctly meshes

with output shaft’s gear. Adjustments are

made with the help of shim and packing. Now

input shaft is fitted on same. Sprockets and

gears are welded on their shafts. Now these

shafts are assembled on base plate with the

help of circlips.

Clearance is adjusted by the help of shim.

Center distance between the two pillars is

adjusted with the help of lock

nuts at all the corners.

Sprocket is assembled on

output shaft with the help of

welding. Roller chain is

mounted on all the three

sprockets and chain is locked

by chain lock.

5.2.6 Material Purchased

Rest of the part of Uni-directional mechanism are purchased from market. Which constitutes

the

different material of different parts according to our requirement. All these parts are

purchased by suggesting with mechanic. Material purchased are Gear, Sprocket, roller chain,

Dynamo-set.

Fig: 5.9 Final Assembly of the Model

Page 45 of 47

CHAPTER-VII

RESULT & CONCLUSION

6.1 Result

After complete designing & study about the Electricity generation mechanism using Natural

resources (wind power, tidal waves) we have finally designed a mechanism on which we have

further made number of experiments. We have also designed mechanism for generating

uniform unidirectional motion from non-uniform reciprocating motion that has wide

applications in electricity generation systems because in all the other methods only generation

through one side is possible so we have tried to modify it using two ways.

As per the experiment we got to know that the maximum generation of current is 2V. Further

we can increase the voltage by implementing the bigger dynamo.

6.2 Application

The major application of this mechanism was in Energy generation through Wind mills in those

areas where the direction of wind affects the rotational direction of wind turbine.

This idea will help us to generate continuous rotation motion of shaft from the non-continuous

rotation of shaft (to and fro motion of shaft) as in case of tidal waves. Tidal waves cause a

turbine to rotate clockwise and anticlockwise during their journey and we can convert this

motion for continuous shaft rotation for generation of Electricity using dynamo.

Fig: 6 Final Mechanism

Page 46 of 47

This mechanism can be used to convert the swinging motion of pendulum into the continuous

rotary motion of shaft into single direction without any jerk.

It can also be used in ships or small boats which move upstream as well as downstream and in

both the streams it will create power for the ship or boat.

Also if further improvement and research is done in this field it can also be used in field of

automobile because of advancement of hybrid technology.

6.3 Future Scopes

Various future scope of this “Uni-directional Motion Mechanism” system is: -

This project serves the purpose of explaining the student of technical institute and

college various energy generation concepts and mechanisms.

Useful for installation in electricity power plants.

6.4 Conclusions

Wind speed and direction indication by designing a further anemometer and show the

electricity generation on a large scale.

Further, the mechanical design installed in this system could be used in dams and other oceanic

areas to generate continuous electricity from high and low tides by just attaching a

dynamo/alternator, a fly-wheel and turbine assembly and could be used for Tidal energy

generation.

Further this mechanism can be used in many industries like Automobile sector and in ships.

That may change the scenario of the world.

6.5 References and Bibliography

Content has been taken from many sources as Research Paper, Books and Internet source

Research Paper

Patent WO2008096272A2 – “Unidirectional gear drive” - Google Patents Published on: Aug

14, 2008 by Leelananda Jayasuriya

Patent WO2002063185A1 – “Bi-directional to unidirectional torque conversion method and

apparatus” - Google Patents, Published on: Dec 14, 2008 by Leelananda Jayasuriya

Patent US20080295626 – “Unidirectional Gear Drive” - Google Patents, Published on: Dec 4,

2008 by Leelananda Jayasuriya

Page 47 of 47

Books

Design of Machine Element (Third edition) by Dr. V. B Bhandari

Theory of Machine by S. S Rattan

Manufacturing Technology by Mikell P. Grover & P.N Rao

Website

“Renewable Energy Sources” en.wikipedia.org/wiki/Renewable_energy

“Wind Power” en.wikipedia.org/wiki/Wind_power

“Tidal Power” en.wikipedia.org/wiki/Tidal_power

“Material Selection” en.wikipedia.org/wiki/Material_selection

“Spur Gears Terminology” en.wikipedia.org/wiki/Gear#Spur

“Shaft Design” en.wikipedia.org/wiki/Shaft_(mechanical_engineering)

“Machining Process” www.technologystudent.com/equip1/equipex1.htm

“Machining” www.twi-global.com/technical-knowledge/job-knowledge/cutting-processes-

plasma-arc-cutting-process-and-equipment-considerations-051/

“Cutting Process” mmu.ic.polyu.edu.hk/handout/0102/0102.htm

“Sprocket & Chain” www.gizmology.net/sprockets.htm