machine design assignment

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machine design assignment

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You are on page 1of 35

Introduction......................................................................................................................................3

Objective..........................................................................................................................................3

Hand Sketches.................................................................................................................................5

Design 1.......................................................................................................................................5

Design 2.......................................................................................................................................6

3D Design........................................................................................................................................8

Calculation.....................................................................................................................................15

Crank Shaft................................................................................................................................15

Hydraulic...................................................................................................................................17

Power Screw..............................................................................................................................18

Conveyor Belt............................................................................................................................21

Rack and Pinion.........................................................................................................................25

Material Selection..........................................................................................................................27

Crank shaft.................................................................................................................................27

Hydraulic...................................................................................................................................28

Power Screw..............................................................................................................................29

Conveyor Belt............................................................................................................................30

Rack and Pinion.........................................................................................................................31

Discussion......................................................................................................................................32

Conclusion.....................................................................................................................................33

Reference.......................................................................................................................................33

Page 1 of 35

Figure 2: Design 2...........................................................................................................................7

Figure 3: The crank shaft.................................................................................................................9

Figure 4: The Hydraulic Cylinder..................................................................................................10

Figure 5: The Power Screw............................................................................................................10

Figure 6: The Conveyor Belt.........................................................................................................11

Figure 7: The rack and pinion........................................................................................................11

Figure 8: The chosen design..........................................................................................................12

Figure 9: Step 1..............................................................................................................................13

Figure 10: Step 2............................................................................................................................13

Figure 11: Step 3............................................................................................................................14

Figure 12: Step 4............................................................................................................................14

Figure 13: Step 5............................................................................................................................15

Figure 14: Step 6............................................................................................................................15

Figure 15: Crank Shaft...................................................................................................................16

Figure 16: The table of the standard size.......................................................................................20

Figure 17: The density of the material belt....................................................................................22

Figure 18: The standard table of the belt width.............................................................................24

Figure 19: Data sheet of motor......................................................................................................28

Figure 20: Data sheet of cylinder...................................................................................................29

Figure 21: Data sheet of motor......................................................................................................30

Figure 22: Data sheet of motor......................................................................................................31

Figure 23: Data sheet mf motor.....................................................................................................32

Page 2 of 35

Introduction

Technology has become an essential part of our daily life wherever we go we can notice the great

impact that technology has in our life such as , computers elevators and numerous of inventions

that made our life easier. One of the greatest technological inventions is load carrying

mechanisms which are used to convert one type of motion to another and it being used in a wide

range of applications for example ,cranes ,ASRS ,AGVs, robots and many more. Using

mechanism to carry loads is much more efficient and fast as compared to the manual way of

doing it. An efficient load carrying system can be designed by using the right mechanism.

Objective

In this assignment, a system to carry the load from one point to another will be developed. All

possible mechanisms can be using in developing my design. And all calculations in relation to

the mechanisms used will be shown. The system will be a fully automated system.

The system should be consist of three different types of motion conversions by using different

mechanical components.

such as a power screw, a bearing, pulleys, gears, belts, shafts and etc. The motion conversion

should be chosen from the following:

Rotary motion to rotary motion conversion.

Rotary motion to intermittent motion conversion.

Reciprocating motion to linear motion conversion.

Reciprocating motion to rotary motion conversion.

Linear motion to rotary motion conversion.

Rotary motion to linear motion conversion.

Page 3 of 35

The load carrying system has to move linearly and also in rotation. The specification of the load

and the distance it has to be carried is given below:

3 cm

3 cm

0.03 m

W

= 6 kg

12 cm

W

7 cm

Position 1

Pick

0.06 m

0.5m

0.03m

0.2 m

W

15

0.1 m

0.5 m

Page 4 of 35

Position 2

Place

cm

Hand Sketches

Design 1

The first design consists of five parts which are a Crank-shaft, a hydraulic cylinder, a pwer

screw, a conveyor belt and a rack and pinion. And it has 3 different mechanisms to move the

component from position A to B.

Figure 1: Design 1.

The operation of the whole design is that the Crank-shaft mechanism at the beginning pushes the

load that has to be carried along till it reach the Hydraulic then the Power screw will push the

load till it reach the conveyor belt and the conveyor belt will deliver it to the surface of the Rack

and Pinion. After that the Rack and Pinion will take the load to the position place.

Page 5 of 35

Design 2

The second design consists of five parts which are a Cam, actuated linear guides, chain and

sprocket and a rotary table. And it has 4 different mechanisms to move the component from

position A to B.

Figure 2: Design 2.

The operation of the whole design is that the Cam mechanism at the beginning pushes the load

that has to be carried along till it reach the actuated linear guides than the quick return

mechanism will push the load till it reach the chain and sproket and the chain and sproket will

deliver it to the surface of the Rotary Table. After that the Rotary Table will take the load to the

position place.

Page 6 of 35

Design selected

Both designs are approved from the lecturer, I chose the first design due to the following reasons:

The number of conversion used was less.

Less power is used.

It would be easy to implement in the industry.

The components used in it are easily available in the market.

Crank (Rotary motion to Reciprocating motion conversion).

A crank is an arm attached at right angles to a rotating shaft by which reciprocating motion is

imparted to or received from the shaft. It is used to change circular into reciprocating motion, or

reciprocating into circular motion. The arm may be a bent portion of the shaft, or a separate arm

attached to it. Attached to the end of the crank by a pivot is a rod, usually called a connecting

rod. The end of the rod attached to the crank moves in a circular motion, while the other end is

usually constrained to move in a linear sliding motion, in and out.

Hydraulic cylinder (Linear motion to linear motion conversion)

It is a mechanical actuator that is used to give a unidirectional force through a unidirectional

stroke. It has many applications, notably in engineering vehicles. Hydraulic cylinders provide

very high mechanical advantage in lifting heavy loads by using only a small force on the smaller

cylinder. Also they are very rugged and economy.

Power screw (Rotary motion to linear motion conversion)

Power Screws are used for providing linear motion in a smooth uniform manner. They are linear

actuators that transform rotary motion into linear motion. Power screws are generally based on

Acme, Square, and Buttress threads.

Page 7 of 35

A belt is a loop of flexible material used to link two or more rotating shafts mechanically. Belts

may be used as a source of motion, to transmit power efficiently, or to track relative movement.

The belt drives permit large speed ratio and provides long life. They are easily installed and

removed and low maintenance.

Rack And Pinion (Rotary motion to linear motion conversion)

It is a type of linear actuator that comprises a pair of gears which convert rotational motion into

linear motion. A circular gear called "the pinion" engages teeth on a linear "gear" bar called "the

rack"; rotational motion applied to the pinion causes the rack to move, thereby translating the

rotational motion of the pinion into the linear motion of the rack.

3D Design

The system was drawn using Solidworks 2013 software.

Crank Shaft

Hydraulic Cylinder

Page 8 of 35

Power Screw

Conveyor Belt

Page 9 of 35

Complete Assembly

Page 10 of 35

The operation of the design as it was explained is that the Crank-shaft mechanism at the

beginning pushes the load that has to be carried along till it reach the Hydraulic then the Power

screw will push the load till it reach the conveyor belt and the conveyor belt will deliver it to the

surface of the Rack and Pinion. After that, the Rack and Pinion will take the load to the position

place. And here are the whole operation system is shown step by step.

Step 1

Page 11 of 35

The object load will be located in its position which as it mention before as it position A.

Figure 9: Step 1.

Step 2

Crank shaft will push the object load till the hydraulic cylinder (figure 10).

Step 3

The Hydraulic Cylinder will pull down the object load (figure 11).

Page 12 of 35

Step 4

The power screw will push the object load till the conveyor belt (figure 12).

Step 5

The conveyor belt will deliver the object load to the surface of the Rack and Pinion (figure 13).

Page 13 of 35

Step 6

The Rack and Pinion will take the load to the position B (figure 14).

Page 14 of 35

Calculation

Crank Shaft

Inertia Force -The displacement of the piston with respect to crank angle can be derived from

simple trigonometry. This can be differentiated to yield velocity and acceleration of the piston.

The expressions obtained tend to be very complicated and can be simplified into the expression

containing only first order (once per revolution), second order (twice per revolution), and a

negligible fourth order.

%20excitation%2mechanisms/source.html. Last accessed 4/10/2014.

Where:

= Crank angle ( degrees; zero at top dead centre).

N = Rotational speed [rpm].

R = Crankshaft radius [m].

L = Con rod length [m].

W is angular velocity(rad/s).

Page 15 of 35

The total torque acting on the crankshaft of a single cylinder engine results from the effect of the

forces on the crank slider mechanism. The torque resulting from piston motion is often called the

INERTIA torque.

In this mechanism, the displacement should be 0.03 + 0.03=0.06m, illustrated in the parameters

given. The radius crank can be taken as 0.06m, as the radius will determine the displacement.

The con rod length has to be more than the radius of the crank. It can be assumed to be 0.09m.

We know the displacement is equal to 0.06m and the radius is 0.06m and the con red length is

0.09m and we know this formula displacement=(L+R) - X, where x is the position of piston pin

f from crank center. So X should be calculated first by the previous formula. After calculating X,

we got 0.09m.

From the triangle relation we can calculate the angle as follow:

l 2=x 2+ R 22 xR cos =cos1 ( 0.333 )=70.52

M ERC =6 kg factor of safaty ( 3 ) =18 kg

We

can

assumed

N =150 RPM =

an

RPM

2 N

=15.708 rad .

60

Page 16 of 35

of

150

as

velocity

doesnt

matter

i= M ERC R2 2 (

R

1

3 R

sin sin 2

sin 3 )

4L

2

4L

i=1.669 Nm

Hydraulic

P=gh

Above is the Pascals law which is used to find pressure that is exerted by the hydraulic cylinder.

Where :

= The density of the fluid used,(857kg/m^3).

g = The acceleration due to gravity (9.81m/s^2).

H = height (m).(0.5m)

P = 857 * 0.5 *9.81

P = 4203.585 Pa.

After that, the weight of the object load has to multiply with the factor of safety which is given

in the assignment 6 x 3 = 18kg. And the force should be calculated by the next formula.

F = ma

F = 18 * 9.81

F =176.58 N

After that, the area of the cylinder should be calculated by the next formulas A =

A=

Page 17 of 35

176.58

4203.585

= 0.042m2.

F

P

2

4 * D . And A is already

D2=

40.042

D=

0.0535 = 0.231m

= 0.0535

r = 0.231 / 2

r = 0.116m

Power Screw

The next equation is used because the power screw in our design was used horizontally.

[( ) ]

f

cos n

+ f c r c

f tan

1+

cos n

tan +

T =W r m

Where:

T = The torque applied to turn screw or nut, whichever is being rotated.

W = The load parallel to screw axis.

rm = The mean thread radius.

rc = The effective radius of rubbing surface against which load bears, called collar radius and it

will be neglect.

Page 18 of 35

n = Angle between tangent to tooth profile and radial line, measured in plane normal to thread

helix at mean radius.

The power screw was chosen with a single thread with ISO trapezoidal and it was made by the

steel. The coefficient friction of the steel is 0.12, and the pitch was assumed as 20 which is equal

to the lead according to the single thread. And the angle of the ISO trapezoidal thread is equal to

15. And from the standard thread size for Acme thread in inch as shown in figure 16, we chose

the diameter of 2.75in than the diameter in inch was converted to mm by multiply with 25.4, we

got the diameter 69.85mm.

by this formula

P

2

formula of rm , rm =

Page 19 of 35

dh

2

, so P is the pitch. After that, we got h 10mm and it was substituted in the

69.8510

=30 mm .

2

And for the load (W), the mass of the object is 6kg and it should be multiply with the factor

safety and the platform of the power screw was assumed as 10kg. So W = ((6*3) + 10) * 9.81=

274.68N.

The lead is the distance the screw would advance relative to the nut in one rotation. For a single

thread screw, lead is equal to the pitch as it mention before. Helix angle is related to the lead

tan =

Lead

2rm

20

2rm

= 0.106

= tan-1(0.106) = 6.057

The angle n measured the slope of the thread profile in the normal section. This is related to the

angle in the axial section and to the helix angle as follows:

Tan n = tan * cos

n = tan-1(tan * cos ) = 14.92

Now we can calculate the torque applied to turn screw from the following equation, after we got

all the values are required.

[( ) ]

f

cos n

+ f c r c

f tan

1+

cos n

tan +

T =W r m

0.12

0.966

30

+0

0.12 0.106

1+

0.966

T =274.68

0.106+

Page 20 of 35

T = 149.9722 Nmm.

T = 0.14997 Nm.

Page 21 of 35

Conveyor Belt

Fu = T . g . ( m+ mB ) +g . m. sin

Teery.

(2009).

Convoyer

Belt.

Available:

https://www.google.com.my/search?q=206-

Where:

g = It is gravity (g=9.81m/s^2).

m = The load to be conveyed (kg).

mb = (B:) the mass of the belt (kg).

: the decline angle of conveyor (degrees).

Fu = the effective belt pull (N).

Material selection

The material used for belts must be strong, flexible, and durable. It must have a high coefficient

of friction. Though there are many type of belt material, we are going to use leather belt, one of

the most suitable materials used for many application. The densities of various belt materials are

given in the table below. So the density of the leather is 1000 kg/m3.

Page 22 of 35

The standard flat belt thicknesses are 5, 6.5, 8, 10 and 12 mm. The preferred values of

thicknesses are as follows:

6.5 mm for nominal belt widths of 50 to 140 mm.

8 mm for nominal belt widths of 90 to 224 mm.

10 mm for nominal belt widths of 125 to 400 mm.

12 mm for nominal belt widths of 250 to 600 mm.

The standard values of nominal belt widths are in R10 series, starting from 25 mm upto 63 mm

and in R 20 series starting from 71 mm up to 600 mm. Thus, the standard widths will be 25, 32,

40, 50, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250, 280, 315, 355, 400, 450, 500,

560 and 600 mm.

The thickness of the belt depends mainly on the material that needs to be transported and the

conveyor features such as the way of loading, the drop height, angle of the conveyor, etc. From

these various available choices of belt thickness, it is in our interest to choose the second one

which will make our belt 6.5mm (0.0065m) thick as our belt width will be around 125mm which

lies between 50 to 140mm.

As for the center distance, it is preferable to use 200mm (0.2m), which is illustrated in the given

parameters. We can calculate the belt length using the center distance and the diameters of the

pulleys for this formula:

belt lengt={

Let us first select a pulley material and characteristics then we can calculate the belt length.In

this mechanism, we are going to use aluminum for the pulleys because of its light weight and the

fact that it robs less energy to spin. They also have less rotational mass compared to other

materials. The density of aluminum is =2700 kg/m^3.

Page 23 of 35

The diameter of the pulley (D) may be obtained either from velocity ratio consideration or

centrifugal stress consideration. The following are the diameter of pulleys in mm for flat and

V-belts:

20, 22, 25, 28, 32, 36, 40, 45, 50, 56, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250,

280, 315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000, 1120, 1250, 1400, 1600,1800, 2000,

2240, 2500, 2800, 3150, 3550, 4000, 5000, 5400. The first six sizes (20 to 36 mm) are used for

V-belts only.

If the width of the belt is known, then width of the pulley or face of the pulley is taken 25%

greater than the width of belt. According to Indian Standards, IS: 2122 (Part I) 1973

(Reaffirmed 1990), the width of pulley is fixed as given in the following table:

In our case, our belt width is 125mm so the width of the pulley must be 13mm greater than the

belt width, so it is (125+13)mm = 0.138mm. As for the diameter of the roller, we can use

125mm, for both driver and driven pulleys, hence D = 125mm = 0.125m

Knowing the diameters and the center distance, belt length will be calculated in term of pulley

diameter.

Belt length =

Belt length =

Page 24 of 35

2 *(D1 + D2) + 2* X +

D 1+ D 2

4x

125+125

4200

Now we can calculate the mass of the belt m b by using this formula mb = b * t * l* . Where b is

the width of the belt which is 0.125. And t is the thickness of the belt which is 0.0065m. And l is

the length of the belt which is 0.79269m. And is the density of leather belt which is1000kgm-3.

mb = 0.125 * 0.0065 * 0.79269 * 1000 = 0.644kg

Now we can calculate the effective belt pull Fu from the following equation, after we got all the

values are required.

Fu = T . g . ( m+mB ) +g . m. sin

Fu =36.44 N

( V )=

N =0.0033

0.0033 m

.

s

60

=0.504 RPM 1

0.125

Power is given by

T =

0.2

dN

=0.0033 m/s

velocity ( V )=

,

we

also

know

that

60

60 ,

power ( p )=

2 NT

60

60 p 60 0.120

=

=1.145 Nm

2 N

2 1

Page 25 of 35

(Khurmi, R. S., and J. K. Gupta. A Textbook of Machine Design. New Delhi: Eurasia House,

2005. Print.)

From the table shown below we can see some formals it may use to calculate the torque.

Table 1: The formals of a rack and pinion.

First of all, we have to choose the face width and the number of teeth and the diameter will be

given. We chose the width of 40mm and the number of teeth is 20 so the diameter was 80mm as

it can be seen from the table below. Also the material selection was chosen for both rack and

pinion was steel. The coefficient friction of steel with steel is 0.62.

Table 2: Standard sizes of the rack and pinion.

Page 26 of 35

Last accessed 1/10/2014.

Where:

Tp = The torque at pinion.

S.f = The factor of safety.

Now we should find the torque at pinion, the factor of safety is given 3.

The torque at pinion = (Fr * d) 2000

Where:

Fr = The force at rack.

D = The diameter.

The force at rack can be gotten by this equation

The force at rack = T . m . g+ m. g

Where:

g= It is gravity (g=9.81m/s^2).

So the force will be 0.62 *(6*3)*9.81+(6*3)*9.81 is equal to 286.0596N. The force will be

substitute in the equation of the torque at pinion. The torque at pinion = (Fr * d) 2000. So

(286.0596*0.08) 2000 will be 0.0144Nm. Finally we can get the torque.

T = 0.0144 * 3 = 0.0342 Nm

Page 27 of 35

Material Selection

Crank shaft

Quantum Series Brushless Servo Motor Dimension Drawing DC Motor (QB03401) can be used

for the crank as it has a torque of 1.669Nm.

Page 28 of 35

Page 29 of 35

Hydraulic

Model number of the cylinder is RACL-2010 can be used for Hydraulic as it has a diameter of

231mm.

Page 30 of 35

Power Screw

DC Motor (BCI-42.25 B00-C/18) can be used for the power screw as it has a torque of

0.149Nm.

Page 31 of 35

Conveyor Belt

Quantum Series Brushless Servo Motor Dimension Drawing DC Motor (QB03400) can be

used for the conveyor belt as it has a torque of 1.145 Nm.

Page 32 of 35

Quantum NEMA 17 Brushless Servo Motor Dimension Drawing DC Motor (QB01700) can

be used for the rack and pinion as it has a torque of 0.0342 Nm.

Page 33 of 35

Discussion

The assignment idea was to carry the load from one point to another will be developed. Two

designs were sketched and both of them got the approval from the lecture. The first design was

chosen because it is comparatively easy to make and it would be easy to implement in the

industry. Power Screw, Hydraulic, Crank Shaft, Conveyor Belt and Rack and Pinion were the

mechanisms of the first design which is chosen to construct it. After that, the design was

implemented in SolidWork 2013 software. Than the calculation part of the five mechanisms

chosen were done. And from the calculations were gotten, the materials selection was done based

on the torque for power screw, conveyor belt, crank and rack & pinion, and for the hydraulic was

based on the diameter.

During the assignment, some problems were faced and they solved. One of this problems was in

the designs, in the first design was done easily. In the second design, it was complicated to find

because most of the motion conversion was used in the first design. And this problem was solved

by checking the internet and some books. Another problem was in implement the 3D design,

CREO software was the one which was usually using but in this design, the workable parts were

needed and this can be doing using CREW but it will be very difficult to implement it. So this

problem was solved by the lectures advice who recommended us to use Solidwork 2013 which

it was very easy to use and install it regarding to many videos in YOUTUBE. These videos were

very helpful to understand Solidwork 2013 and it was enough for students.

Page 34 of 35

Conclusion

Load carrying mechanisms which are used to convert one type of motion to another and being

used in a wide range of many applications and it is much more efficient and fast as compared to

the manual way of doing it.

This assignment was a very useful, interesting way to learning of designing the mechanical

components by Solidworks 2013. On the other hand, the design was an overall success, it was

designed following all the listed criteria and the calculations are done which it would function

efficiently. So engineers should now design more components of this type so that we can make

our daily works easier. And complete the tasks with maximum efficiency and minimum cost.

Reference

Frank. (2014). The density. Available: http://www.engineeringtoolbox.com/iso-grade-oild_1207.html. Last accessed 10/10/2014.

Than. (2014). Cylinders. Available: http://www.enerpac.com/en-us/industrial-toolsimperial/hydraulic-cylinders-jacks-lifting-products-and-systems/lightweight-aluminumcylinders/racl-series-aluminum-lock-nut-cylinders. Last accessed 10/10/2014.

CHAN.

(2014

).

Motors.

Available:

http://www.ebmpapst.com.au/en/products/motors/bcigearmotors/bcigearmotorsdetail.php

?pID=142258. Last accessed 9/10/2014.

Page 35 of 35

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