Professional Documents
Culture Documents
Multipurpose Machines Using Scotch Yoke Mechanism
Multipurpose Machines Using Scotch Yoke Mechanism
CHAPTER-1
INTRODUCTION
Multi-operation machine as a research area is motivated by questions that arise in
industrial manufacturing, production planning, and computer control. Consider a large
automotive garage with specialized shops. A car may require the following work, replace
exhaust system, align wheels, and tune up. These three tasks may be carried out in any order.
However, since the exhaust system, alignment, and tune-up shops are in different buildings, it
is impossible to perform two tasks for a car simultaneously. When there are many cars
requiring services at the three shops, it is desirable to construct a service schedule that takes
the least amount of total time.
Page
1.2 Construction
The scotch yoke mechanism is constructed with iron bars. Here the crank is made
in some length and the yoke is also made using the same material. It is noted that the
minimum length of the yoke should be double the length of the crank. The crank and yoke is
connected with a pin. Iron bars are welded to both sides of the yoke to get the reciprocating
motion. The yoke with the iron bars is fixed on the display board with the help of c clamp.
Now the crank is welded to the end of the shaft of the motor. Now the pin on the crank is
connected to the yoke. The pin used to connect yoke and crank is a bolt.
to the initial position. For a complete rotation of crank the yoke moves through a length equal
to double the length of the crank. The displacement of the yoke can be controlled by varying
the length of the crank.
Page
CHAPTER-2
APPARATUS
2.1 Dc motors
At the most basic level, electric motors exist to convert electrical energy into
mechanical energy. This is done by way of two interacting magnetic fields - one stationary,
and another attached to a part that can move. A number of types of electric motors exist, but
most BEAM bots use DC motors 1 in some form or another. DC motors have the potential for
very high torque capabilities (although this is generally a function of the physical size of the
motor), are easy to miniaturize, and can be "throttled" via adjusting their supply voltage. DC
motors are also not only the simplest, but the oldest electric motors.
The basic principles of electromagnetic induction were discovered in the early 1800's
by Oersted, Gauss, and Faraday. By 1820, Hans Christian Oersted and Andre Marie Ampere
had discovered that an electric current produces a magnetic field. The next 15 years saw a
flurry of cross-Atlantic experimentation and innovation, leading finally to a simple DC rotary
motor. A number of men were involved in the work, so proper credit for the first DC motor is
really a function of just how broadly you choose to define the word "motor."
A DC motor is a mechanically commutated electric motor powered from direct
current (DC). The stator is stationary in space by definition and therefore so is its current. The
current in the rotor is switched by the commutator to also be stationary in space. This is how
the relative angle between the stator and rotor magnetic flux is maintained near 90 degrees,
which generates the maximum torque.
DC motors have a rotating armature winding but non-rotating armature magnetic field
and a static field winding or permanent magnet. Different connections of the field and
armature winding provide different inherent speed/torque regulation characteristics. The
speed of a DC motor can be controlled by changing the voltage applied to the armature or by
changing the field current. The introduction of variable resistance in the armature circuit or
field circuit allowed speed control. Modern DC motors are often controlled by power
electronics systems called DC drives.
The introduction of DC motors to run machinery eliminated the need for local steam
or internal combustion engines, and line shaft drive systems. DC motors can operate directly
Department of Mechanical Engineering, AMCEC, Bengaluru.
Page
Page
Brushed Motor - This type of motor produces a magnetic field in a wound rotor (the
part that rotates) by passing an electrical current through a commutator and carbon
brush assembly, hence the term "Brushed". The stators (the stationary part) magnetic
field is produced by using either a wound stator field winding or by permanent
ii.
magnets. Generally brushed DC motors are cheap, small and easily controlled
.
Brushless Motor - This type of motor produce a magnetic field in the rotor by using
permanent magnets attached to it and commutation is achieved electronically. They
are generally smaller but more expensive than conventional brushed type DC motors
because they use "Hall effect" switches in the stator to produce the required stator
field rotational sequence but they have better torque/speed characteristics, are more
efficient and have a longer operating life than equivalent brushed types.
iii.
Servo Motor - This type of motor is basically a brushed DC motor with some form of
positional feedback control connected to the rotor shaft. They are connected to and
controlled by a PWM type controller and are mainly used in positional control
systems and radio controlled models.
Normal DC motors have almost linear characteristics with their speed of rotation being
determined by the applied DC voltage and their output torque being determined by the
current flowing through the motor windings. The speed of rotation of any DC motor can be
Department of Mechanical Engineering, AMCEC, Bengaluru.
Page
Page
Page
Page
Since most small DC motors have 3 coils, the coils' current curves will overlay each other,
Department of Mechanical Engineering, AMCEC, Bengaluru.
Page
Added together, this ideal motor's current will then look something like this,
Reality is a bit more complex than this, as even a high-quality motor will display a
current transient at each commutation transition. Since each coil has inductance (by
definition) and some capacitance, there will be a surge of current as the commutator's brushes
first touch a coil's contact, and another as the brushes leave the contact (here, there's a slight
spark as the coil's magnetic field collapses).
As a good example, consider an oscilloscope trace of the current through a Mabuchi
FF-030PN motor supplied with 2 V (1ms per horizontal division, 0.05 mA per vertical
division)
In this case, the peak-to-peak current ripple is approximately 0.29 mA, while the
average motor current is just under 31 mA. So under these conditions, the motor puts about
less than 1% of current ripple onto its power lines (and as you can see from the "clean" traces,
it outputs essentially no high-frequency current noise). Note that since this is a 3-pole motor,
and each coil is energized in both directions over the course of a rotor rotation, one revolution
of the rotor will correspond to six of the above curves (here, 6 x 2.4 ms = 0.0144 sec,
corresponding to a motor rotation rate of just fewer than 4200 RPM).
Page
Where:
V = input voltage
Eb = back EMF
Ia = Armature current
R = total resistance
The total resistance R is equal to Armature Resistance (Ra) + External resistance (Rph).
Page
Page
Page
Page
Page
motors
transformers, power
can
be
protected
conditioning
from overvoltages or
surges
with
harmonic
solation
filters.
Environmental conditions, such as dust, explosive vapors, water, and high ambient
temperatures, can adversely affect the operation of a DC motor.
To protect a motor from these environmental conditions, the National Electrical
Manufacturers Association (NEMA) and the International Electro technical Commission
(IEC) have standardized motor enclosure designs based upon the environmental protection
they provide from contaminants.
Page
When electrical and DC motor technology was first developed, much of the
equipment was constantly tended by an operator trained in the management of motor systems.
The very first motor management systems were almost completely manual, with an attendant
starting and stopping the motors, cleaning the equipment, repairing any mechanical failures,
and so forth.
The first DC motor-starters were also completely manual, as shown in this image.
Normally it took the operator about ten seconds to slowly advance the rheostat across the
contacts to gradually increase input power up to operating speed. There were two different
classes of these rheostats, one used for starting only, and one for starting and speed
regulation. The starting rheostat was less expensive, but had smaller resistance elements that
would burn out if required to run a motor at a constant reduced speed.
This starter includes a no-voltage magnetic holding feature, which causes the rheostat
to spring to the off position if power is lost, so that the motor does not later attempt to restart
in the full-voltage position. It also has over current protection that trips the lever to the off
position if excessive current over a set amount is detected.
Page
On the first step of the arm, full line voltage is applied across the shunt field. Since the
field rheostat is normally set to minimum resistance, the speed of the motor will not be
excessive; additionally, the motor will develop a large starting torque.
ii.
The starter also connects an electromagnet in series with the shunt field. It will hold the
arm in position when the arm makes contact with the magnet.
iii.
Meanwhile that voltage is applied to the shunt field, and the starting resistance limits the
current to the armature.
iv.
As the motor picks up speed counter - EMF is built up; the arm is moved slowly to short.
2.7.3
Four-Point starter
The four-point starter eliminates the drawback of the three-point starter. In addition to the
same three points that were in use with the three-point starter, the other side of the line, L1, is
the fourth point brought to the starter when the arm is moved from the "Off" position. The
coil of the holding magnet is connected across the line. The holding magnet and starting
resistors function identical as in the three-point starter.
Page
Page
Speed control over a wide range both above and below the rated speed: The
attractive feature of the dc motor is that it offers the wide range of speed control both
above and below the rated speeds. This can be achieved in dc shunt motors by
methods such as armature control method and field control method. This is one of the
main applications in which dc motors are widely used in fine speed applications such
ii.
iii.
cranes.
Accurate steep less speed with constant torque: Constant torque drives is one such
the drives will have motor shaft torque constant over a given speed range. In such
iv.
v.
Page
Page
Page
Page
Page
Page
2.9.4 Recommended Teeth per 25mm (tpi) for each material type
Page
Page
Blade Width:
Blade Thickness:
The kerf produced by the blades is somewhat wider than the blade thickness due to
the set of the teeth. It commonly varies between 0.030 and 0.063 inches / 0.75 and 1.6 mm
depending on the pitch and set of the teeth. The 10 inch blade is also fairly common and all
the above dimensions apply except for the following:
Hole to Hole:
A panel hacksaw eliminates the frame, so that the saw can cut into panels of sheet
metal without the length of cut being restricted by the frame. Junior hacksaws are the small
variant, while larger mechanical hacksaws are used to cut working pieces from bulk metal.
A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by
its own electric motor or connected to a stationary engine. Most power hacksaws are
stationary machines but some portable models do exist. Stationary models usually have a
mechanism to lift up the saw blade on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.
While stationary electric hacksaws are reasonably uncommon they are still produced but saws
powered by stationary engines have gone out of fashion. The reason for using one is that they
provide a cleaner cut than an angle grinder or other types of saw. Large, power hacksaws are
sometimes used in place of a band saw for cutting metal stock to length.
Page
2.10.1 Types
Shapers are mainly classified as standard, draw-cut, horizontal, universal, vertical, geared,
crank, hydraulic, contour and traveling head. The horizontal arrangement is the most
common. Vertical shapers are generally fitted with a rotary table to enable curved surfaces to
be machined (same idea as in helical planning). The vertical shaper is essentially the same
thing as a slotter (slotting machine), although technically a distinction can be made if one
defines a true vertical shaper as a machine whose slide can be moved from the vertical. A
slotter is fixed in the vertical plane.
Small shapers have been successfully made to operate by hand power. As size
increases, the mass of the machine and its power requirements increase, and it becomes
necessary to use a motor or other supply of mechanical power. This motor drives a
mechanical arrangement (using a pinion gear, bull gear, and crank, or a chain over sprockets)
or a hydraulic motor that supplies the necessary movement via hydraulic cylinders.
2.10.2 Operation
A shaper operates by moving a hardened cutting tool backwards and forwards across
the work piece. On the return stroke of the ram the tool is lifted clear of the work piece,
reducing the cutting action to one direction only.
Page
CHAPTER-3
FABRICATION
3.1 Frame Work
68.5cm
Breadth:
18.5cm
Height:
71cm
Page
Specifications:
Table diameter:
Supporting link length:
Supporting link height:
7.5cm
18cm
13cm
Page
CHAPTER-4
4.1 Advantages
High torque output with a small cylinder size
Fewer moving parts
Smoother operation
Higher percentage of the time spent at top dead center (dwell) improving theoretical
engine
Page
4.3 Applications
This setup is most commonly used in control valve actuators in high pressure oil and
gas pipelines
It has been used in various internal combustion engines, such as the Bourke engine,
SyTech engine, and many hot air engines and steam engines.
It is also used in multipurpose machines and I.C engines.
CHAPTER-5
CONCLUSION
The scotch yoke mechanism is made and its advantages and disadvantages are
discussed. Its motion characteristics are studied. It is concluded that this mechanism is a good
choice to convert rotating motion into reciprocating motion because of fewer moving parts
and smoother operation. It can be used in direct injection engines like diesel engines, hot air
engines.
In this project report we provide an overview of the issues concerning different
aspects of multipurpose machine using scotch yoke mechanism .The project report focus on
the principle of scotch yoke mechanism, type of tooling and machining parameters and
process performance measure, which include cutting speed, depth of cut,material removal
rate with different type of equipments which can be run simultaneously and fabricate the
work piece In multipurpose machine has been presented . the presented results can help to
plan the machining of work piece with expected tolerance.
The following major conclusions may be drawn from the present project report.
Department of Mechanical Engineering, AMCEC, Bengaluru.
Page
established industrial processes offering attractive capabilities for handling work piece
of various length to be used at micro level.
We have explained the various parts and components of multipurpose machine using
scotch yoke mechanism.
The vital need for the fabrication of a multipurpose machine is significant in the much
delay and time as well as energy wasted in using simple hand tools to carry out jobs.
Moreover, the cost of a lathe machine is too high for an average user. Also, multipurpose
machine will helps to reduce the cost and consequently increase the rate of production and
craftsmans skill.
The general purpose for any project is to find solutions on a certain problems. Its also
gives main idea how the project to be completed. For this project, the problems that need to
be solved are:1) Any manufacturer wants to reduce cost and time taken to complete a product but gives
better quality products and increases the outputs.
2) Manufacturer tends to upgrade their machines to compete with the new machine with
new technology.
3) Lathe machine cutting tool can easily break and needs to enhance its tool life.
The continuous quest to have the problems of man and his growing needs solved has led
to the establishment of factories and other industries, which necessitates an intermediate
technology. However, simple hand tools that were in use before are no longer efficient for
Department of Mechanical Engineering, AMCEC, Bengaluru.
Page
REFERENCES
[1]
Mack. R., Mueller, R., Crotts, J., & Broderick, A. (2000). Perceptions, corrections and
[2]
[3]
[4]
[5]
[6]
[7]
Page
Project pictures
Page
Page