VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI

Final Year Project Report on

FABRICATION OF WIRE TWISTING MACHINE

Submitted by

ADITYA SARATCHANDRA PADHIHARI 1BI18ME160

VINAY KUMAR JANGIR 1BI18ME151
VINEET PRAKASH 1BI18ME153
TANISHQ SHETTY 1BI18ME142
Under the guidance of
Dr.M.K PRASANNA KUMAR
Associate Professor

DEPARTMENT OF MECHANICAL ENGINEERING

BANGALORE INSTITUTE OF TECHNOLOGY
K.R .Road, V.V .Puram, Bengaluru – 560004
2021-2022
VISVESVARAYA TECHNOLOGICAL UNIVERSITY
Belagavi-590018, Karnataka, India

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 BANGALORE INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
K.R.Road, V.V. Puram, Bengaluru – 560 004

CERTIFICATE
Certify that the project work entitled “FABRICATION OF WIRE TWISTING
MACHINE” carried out by ADITYA SARATCHANDRA PADHIHARI (1BI18ME160),
VINAY KUMAR JANGIR (1BI18ME151), VINEET PRAKASH (1BI18ME153) &
TANISHQ SHETTY (1BI18ME142) the bonafide students of Bangalore Institute of
Technology in the partial fulfilment for the award of Bachelor of Engineering in Mechanical
Engineering of the Visvesvaraya Technological University, Belagavi during the year 2021-
2022. It is certified that all corrections/suggestions indicated for internal assessment have
been incorporated in the report deposited in the departmental library. The Project report has
been approved as it satisfies the academic Requirements in respect of project work prescribed
for the said degree.

Dr M.K Prasanna Kumar Dr T V Sreerama Reddy

Associate Professor Head of Department
Department of Mechanical Engineering Department of Mechanical Engineering
Bangalore Institute of Technology Bangalore Institute of Technology
Bangalore – 560004 Bangalore - 560004

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 * DECLARATION *

I declare that the project work report entitled “Fabrication of Wire Twisting
Machine” carried out by our project team, under the guidance of Dr.M.K
Prasanna Kumar., Associate Professor, Department of Mechanical Engineering,
Bangalore Institute of Technology, Bangalore-560004, during the academic
year 2021-2022. Further, we declare that this Technical Seminar report either in
part or in full is not submitted by us to any other university to the award of any
degree or diploma.

Date:

Place: Bangalore

Signature
ADITYA SARATCHANDRA PADHIHARI (1BI18ME160)

VINAY KUMAR JANGIR (1BI18ME151)

VINEET PRAKASH (1BI18ME153)

TANISHQ SHETTY (1BI18ME142)

Examiner 1 Examiner 2
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 ACKNOWLEDGEMENT
It is our privilege and duty to acknowledge the kind of help and guidance from several people
in preparation of this report. It would not have been possible to prepare this report in this
form without their valuable help, cooperation and guidance.

Our sincere thanks to guide Dr M.K PRASANNA KUMAR, Associate Professor, BIT for his
valuable suggestions and guidance throughout the period of this project.

We express gratitude to Dr. T V SREERAMA REDDY, Professor and Head, Department of

Mechanical Engineering, BIT for his valuable suggestions and guidance throughout the
period of this project.

We would like to express sincere gratitude to Dr ASHWATH. M. U, Principal, BIT for his
encouragement for the conduction of this project.

We take this opportunity to thank all the staff members of Mechanical Department for their
direct and indirect support throughout period of this project.

Last but not the least; we would like to thank our parents for their continuous support for
studies as well as for constantly encouraging learning engineering. Their personal sacrifice
for providing this opportunity to learn engineering is gratefully acknowledged.

Place: Bangalore

Date:

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 TABLE OF CONTENT

SL. NO. TOPIC PAGE NO.

1. CHAPTER 1- ABSTRACT 9

2. CHAPTER 2 – INTRODUCTION 10

3. CHAPTER 3 – LITRATURE SURVEY 11

4. CHAPTER 4 – OBJECTIVE 14

5. CHAPTER 5 – AIM OF PROJECT 15

6. CHAPTER 6 – COMPARISON 16

7. CHAPTER 7 – PROBLEM DEFINATION 19

8. CHAPTER 8 – CAD MODELLING 20

9. CHAPTER 9 – FABRICATION 22

10. CHAPTER 10 – COMPONENTS & 24

DESCRIPTION
26
10.1 Lead Acid Battery
10.2 D C Motor 28

11. CHAPTER 11 – WORKING PRINCIPLE 35

12. CHAPTER 12 – DESIGN, 36

CALCULATIONS & ANALYSIS
36
12.1 Design and Ball bearing
36
12.2 Wahl Stress Factor
37
12.3 Basic Shaft design Example
37
12.4 Design Procedure

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 12.5 Shaft Design Problem 37
12.6 Analysis 39
13. CHAPTER 13 – ADVANTAGES AND 43
DISADVANTAGES
43
13.1 Advantages
13.2 Disadvantages 43

14. CHAPTER 14 – EXPENDITURE 44

14.1 Labour Charge 45

14.2 Overhead Charge 45
14.3 Total Charge 45
15. CHAPTER 15 - CONCLUSION 46

16. CHAPTER 16 - PHOTOS 47

17. REFERENCE 48

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 LIST OF FIGURES
SL. NO. FIGURES PAGE NO.

1 Spinning Wheel 16

2 QC – 309E 17

3 GEW Automatic Twisting Machine 18

4 ISO Metric View 20

5 Top View 20

6 Side View 21

7 All View 21

8 Sizing of Square Steel frame 22

9 Arc Welding on Base Frame 23

10 Arc Welding Standing Legs 23

11 Wire Holding 24

12 Roller 24

13 MS Pipe 25

14 DC Motor 25

15 12V/7.2 Ah Battery 25

16 MS Flat Plate 25

17 Gear 25

18 Lead Acid Battery 26

19 Chemical Reactions in Batteries 28

20 Working DC Motor 29

21 Back EMF Circuit Diagram 30

22 DC Motor Principle 30

23 Electromagnet Relationship 32

24 Armature 32

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25 Commutator and Brushes 33

26 Combining all of them 33

27 Basic Design 36

28 Shaft Setup 37

29 Total Deformation of Ball Bearing 39

30 Equivalent Stress on Ball Bearing 39

31 Shear Stress on Ball Bearing 40

32 Factor of Safety in Ball Bearing 40

33 Ball Bearing Result Table 40

34 Total Deformation of Shaft Setup 41

35 Equivalent Stress of Shaft Setup 41

36 Shear Stress on Shaft Setup 42

37 Factor of Safety in Shaft Setup 42

38 Shaft Setup Result Table 42

39 Cost Table 44

40 Model Profile 1 47

41 Model Profile 2 47

42 Model Profile 3 47

43 Model Profile 4 47

44 Model Profile 5 47

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 CHAPTER 1 - ABSTRACT

The earliest twisting tool: In 1955, the spun wheel unearthed in the Banpo Museum in Xi'an,
Shaanxi, is the earliest twisting tool invented in ancient China, which is to insert a rod in the
middle of the spinning wheel, twisting the fibre together by spinning the spinning wheel, and
use the same method to synthesize the single strands of fibre to a more sturdy "line".

Wire twisting machine is machinery that twists many single wires into one strand. It includes
the body of the twisting machine and the circuit part. The spindle of the outer body of the
wire twisting machine is connected with the motor output shaft of the circuit part, and the
front end of the spindle is equipped with connecting pieces corresponding to the tap switch.
The wire twisting machine is suitable for twisting cotton yarn, cotton, chemical fibre,
embroidery thread, nylon, polyester, rayon, sewing thread, silk, glass fibre, etc. The function
of the electric wire twisting machine is to twist the core of the multi-core wire into one
strand.

A wire making machine is used for making wires according to utility. Thus fabrication
becomes the most valuable part in making of wire making machine as design needs to be use
in real making structure. The objective of the fabrication of wire making machine is to
develop a heavy structure and make a real life working model. Fabrication needs different
types of fabrication tools like cutting, welding, precision instruments, etc. tools for working
model to be fabricated. Today in every sector fabrication becomes the most important stage
of developing the ideas and design of engineer in real life. Which include every factory,
major and minor industry or else domestic purpose .Fabrication of rope wire making machine
includes cutting of metal rods, welding of metallic frames, adjust the proper alignment and
make a working model. In this machine bevel gears, rotating shafts are used for their different
uses and thus their proper alignment is necessary. In our machine we fabricated all this
assembly in a very fine manner so that it can be work properly. This paper includes the whole
process of assembly and work process of machine which comes under consideration. Other
things like rope and raw materials need not to be fabricated they are just designed.

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 CHAPTER 2 - INTRODUCTION

The twisted pair of electrical wires is a cabling technique used in audio and network
technology, among many others. Wires are twisted together to accomplish two main
goals: reduce outgoing noise and reduce incoming noise related to electromagnetic
interference.

Any time an alternating electric current is passed through a wire, a magnetic field is created
around that wire. The opposite is also true. Whenever a magnetic field interacts with an
electrical circuit, an electric current will be generated within the circuit. This means that a
signal in one circuit can “jump” to another nearby circuit, through a phenomenon called
induction. However, placing the wires near one another isn’t nearly as effective as twisting
them, and here’s why.

Destructive interference and common mode rejection only result in complete cancellation
when the two opposite energies are perfectly aligned. When the wires are simply next to one
another, they don’t truly occupy the same position. This means that a nearby circuit will
almost always be closer to one wire than the other. Likewise, a magnetic field passing by will
almost always interact with one wire before the other.

When the term fabrication gets used as an industrial term, it especially gets applied to the
structure and building by shaping, cutting and making assembly of components. Machine
fabrication is a process of creation of metal cutting, bending and assembling of various parts
of machine. In this project, the whole machine parts are gone through the different process of
fabrication. The metal used for the chassis is cast iron and for rotating parts stainless steel is
used. For the chassis making a long metal rod is passed through cutting process. A cutting is
an operation where the metal rods are fixed in chuck and fixed tightly, then a cutting tool is
contacted perpendicularly and metal rod is cut down. Assembly of these parts includes the
welding process. This is a process of fixing two metals permanently with the application of
heat between them.

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 CHAPTER 3 - LITERATURE SURVEY

Twisted pair cabling is a type of wiring in which two conductors of a single circuit are
twisted together for the purposes of improving electromagnetic compatibility. Compared to
a single conductor or an untwisted balanced pair, a twisted pair reduces electromagnetic
radiation from the pair and crosstalk between neighbouring pairs and improves rejection of
external electromagnetic interference. It was invented by Alexander Graham Bell.

The earliest telephones used telegraph lines which were single-wire earth return circuits. In
the 1880s electric trams were installed in many cities, which induced noise into these circuits.
In some countries, the tram companies were held responsible for disruption to existing
telegraph lines and had to pay for remedial work. For new installations, however, it was
necessary to protect against existing trams from the outset. Interference on telephone lines is
even more disruptive than it is on telegraph lines. Telephone companies converted
to balanced circuits, which had the incidental benefit of reducing attenuation, hence
increasing range.

As electrical power distribution became more commonplace, this measure proved inadequate.
Two wires, strung on either side of cross bars on utility poles, shared the route with
electrical power lines. Within a few years, the growing use of electricity again brought an
increase of interference, so engineers devised a method called wire transposition, to cancel
out the interference.

In wire transposition, the wires exchange position once every several poles. In this way, the
two wires would receive similar EMI from power lines. This represented an early
implementation of twisting, with a twist rate of about four twists per kilometre, or six
per mile. Such open-wire balanced lines with periodic transpositions still survive today in
some rural areas.

Twisted-pair cabling was invented by Alexander Graham Bell in 1881. By 1900, the entire
American telephone network was either twisted pair or open wire with transposition to guard
against interference. Today, most of the millions of kilometres of twisted pairs in the world
are outdoor landlines, owned and maintained by telephone companies, used for voice service.

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This process provides for twisting continuously supplied wires in one of preset directions
with an essentially uniform pitch of twist ensuring the maximum number of lays in the zone
of preliminary twisting, while simultaneously twisting the wires in the opposite direction in
the zone of final twisting of wires to form an article.

The machine for accomplishing the process comprises, sequentially mounted on a bed, an
unwinding device, a twisting mechanism, a pull-out mechanism and a take-up mechanism.
Arranged between the unwinding device and the twisting mechanism are guides
accommodating a carriage having a reciprocation drive. According to the invention, the
machine is provided with an auxiliary twisting head mounted on the carriage and provided
with a drive for rotating the head synchronously with the twisting head of the twisting
mechanism.

Herein disclosed is an arrangement of strand twisting apparatuses, comprising a plurality of

strand twisting apparatuses which are side-by-side and vertically installed in a row on floor,
and each of which comprises a fore portion of a frame including a flyer unit vertically
disposed for supplying and twisting strands into a cable, a take-up unit disposed in side-by-
side relation with the flyer unit to wind the cable, a direction change roll unit disposed
immediately above the flyer unit for changing the cable vertically fed from the flyer unit to a
horizontal direction, a capstan roll unit disposed immediately above the take-up unit for
smooth feed of the cable fed from the direction change roll unit to the take-up unit, and an
over-twister unit disposed between the direction change roll unit and the capstan roll unit to
stabilize twisting of the cable during travelling between the direction change roll unit and the
capstan roll unit; and a rear portion of the frame including a driving the flyer unit, the take-up
unit, the direction change roll unit, the capstan roll unit and the over-twister unit.

• Y. Yang, G. Li, M. Susner, M. Sumption, M. Rindfleisch, M. Tomsic,

and E. Collings(June 2015) [1] :-
The invention concerns a method of SZ stranding into one strand a bundle of two or more
flexible micro modules, each micro-module comprising one or more optical fibres. A first
pulley is located with its winding surface adjacent to a longitudinal axis of a cabling line.
The bundle of micro-modules is guided over the winding surface of the first pulley, the

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first pulley being rotating around the longitudinal axis of the cabling line. The rotational
speed, or the rotational direction of the first pulley, is alternating.

• P. V. Real, R. Cazeli, L. S. da Silva, A. Santiago, and P. Piloto(April

2004)[2] :-
A corrosion resistant rope in which the individual strands are sealed with a plastic
foam impregnate and surrounded with a dense unformed plastic material is made by
applying a foam able plastic to the individual wires of a series of wire strands, or,
alternatively, to the individual strands as a whole, and closing the strands into a rope
in a closing die while passing a non-foam able plastic material into the closing die.
Sealed plastic foam impregnated wire strands can be made in the same manner by
passing non foam able plastic material into the stranding die during fabrication of the
strand.

• Tekstil Ve Konfeksiyon(April 2016)[3] :-

Production methods of metal wire reinforced composite yarn were investigated and
tungsten wire reinforced composite yarn was produced in the twisting machine. In the
literature, commonly copper, chromium/nickel, steel were used as core but tungsten
wire was used in core of yarn differently in this study and nylon 6.6 yarns were used
as sheath. Two 1400 dtex and one 2100 dtex% 100 nylon 6.6 yarns were plied in the
'S' direction and produced plied yarn is wrapped around the tungsten wire in the 'Z'
direction so especially voluminous sheath yarns were preferred to cover around the
tungsten wire completely. Performance of produced tungsten wire reinforced
composite yarn was tested by measuring yarn count, twist, and tensile properties. Also
surface temperature of composite yarn was measured, depending on electrical current
and compared with surface temperature of bare tungsten wire.

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 CHAPTER 4 – OBJECTIVE

The wire twisting Machine fabricated here is very low, when compared with cost of
conventional automatic wire twisting machine is 70%. The operation of the machine is very
simple; the machine does not require any maintenance cost; there is least wear and tear. This
machine can satisfy a wide range of general requirement of wire in majority of industries.

The mechanical transmission structure of the stripper is composed of flyer wheel, reel and a
DC motor. The Motors powers the cable-making machine, called a flyer, that both twists and
winds the conductors on a reel. Whereas a guide roller is also used which is laterally offset
with respect to the axis of rotation and supplies the strand material to the supply point of the
at least one further deflection roller, which is offset from the axis of rotation.

The main objective of fabrication of wire making machine is discussed in the upcoming lines.
To make a real life working model considering it as a prototype and showing real life
illustration. To understand the various processes which are included in the working principle
of design and fabrication of wire twisting machine also to understand the applied multiple
parts assembly approach and its techniques such as using arc welding to connect different
points and joints ensuring proper serviceability to a long period of time. Cutting, welding,
bending, machining process to understand. To make structure rigid and flexible so it can bear
forces along with it this paper include various analysis and part design problems. Firstly we
have made 3D parts in Computer Aided Design software that is CATIA. CATIA is a
commercial computer-aided design (CAD), computer-aided manufacturing (CAM),
computer-aided engineering (CAE) and printed circuit board (PCB) design software
application, developed by Autodesk. It is available for Windows and macOS, with simplified
applications available for Android and iOS. Secondly we have conducted Analysis on
different parts that previously we have made in CATIA. Analysis is done in Computer Aided
Engineering software namely ANSYS Workbench which appoints Finite Element Method as
its main working principle.

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 CHAPTER 5 – AIM OF PROJECT

This is an era of automation where it is broadly defined as replacement of manual effort by

mechanical power in all degrees of automation. The operation remains an essential part of the
system although with changing demands on physical input as the degree of mechanization is
increased.

Degrees of Automation are of two types

1) Full Automation
2) Semi Automation

In semi automation a combination of manual effort and mechanical power is required

whereas in full automation human participation is very negligible.

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of

these sources, pneumatics form an attractive medium for low cost automation. The main
advantages of all pneumatic systems are economy and simplicity. Automation plays an
important role in mass production.

• Reduction of lab our and material cost

• Reduction of overall cost
• Increased production
• Increased storage capacity
• Increased safety
• Reduction in fatigue
• Improved personnel comfort

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 CHAPTER 6 – COMPARISON

Spinning Wheel

Fig 1: Spinning Wheel

A spinning wheel is a device for spinning thread or yarn from fibres. It was fundamental to
the cotton textile industry prior to the Industrial Revolution. It laid the foundations for later
machinery such as the spinning jenny and spinning frame, which displaced the spinning
wheel during the Industrial Revolution.

The basic spinning of yarn involves taking a clump of fibers and teasing a bit of them out,
then twisting it into a basic string shape. The spinner continues pulling and twisting to make
it longer and longer, and to control the thickness. Thousands of years ago, people began
doing this onto a stick, called a spindle, which was a very lengthy process.

The actual wheel part of a spinning wheel does not take the place of the spindle, instead it
automates the twisting process, allowing one to "twist" the thread without having to
constantly do so manually, and also the size of the wheel lets one more finely control the
amount of twist. The thread still ends up on a spindle, just as it did before the invention of the
wheel.

The wheel itself was originally free-moving, spun by a hand or foot reaching out and turning
it directly. Eventually, simple mechanisms were created that let a person simply push at a
pedal and keep the wheel turning at an even more constant rate. This mechanism has been the
main source of technological progress for the spinning wheel, before the 18th century.

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Manual Wire Twisting Machine

Fig 2: QC – 309E

Cometech QC-309E Motor Twist Counter for yarn is used to twist ductile wire and bind two
to three strands together used mechanical energy transferred manually. This test machine uses
the characteristics of different length of yarn after twisting. Use the pointer or sensor to detect
changes in the yarn to figure the twist value of the measured object. This is a very important
reference data to the textile process. Electric twist measuring machine with the latest F1C
controller, built-in with rally pretension data for user queries, suggesting load for different
yarns. It can automatically determine the length of specimen and twister counter. The screen
will displays real-time data during the test to let the users to grasp the status of the test, to do
the statistical analysis through the test data after test. What’s more, when you test on yarns
with a high twist counter, the machine will reduce speed before the test starts to obtain a more
precise result.

In QC-309E, 7 inch TFT digital display is used as an indicator. Angular speed range between
50 RPM to 1500 RPM. Direction of Manual Control is in S and Z axis. Each set weighs
around 50g. Nominal Yield load is about 1.2g. Length is 81cm, breadth is 14cm and height is
32cm. It overall weighs around 11kg.

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Automatic Wire Twisting Machine

Fig 3: GEW Automatic Twisting Machine

This Twisting Machine Semi Automatic work on single operator and can produce half a
dozen machines simultaneously. The wires twisted by these machines are extensively used in
two-wheelers such as motorbikes, scooters, and bicycles. This Semi Automatic Twisting
Machine comes in horizontal and vertical dimensions.

Horizontal serial structure. Dual motor drive. Quick die change can be achieved. High-
precision grinding helical gear transmission. High efficiency, low noise. Drawing capstan
combined design. Fully immersed lubrication cooling to ensure the quality of the wire.

Modern day wire twisting machine and the project entitled wire twisting machine make
comparatively less noise than any other machine developed in the early 21st century. It
occupies less space than any other machine since it is using chain drive instead of belt drive.
Employing chain drive instead of belt drive also means that great slip could be avoided to a
larger extend hence wire twisting machine became more stable than usual machine. The
turning movement is reduced such that the machine will become steadier with every cycle.
Greater range of drives anything from 10 ft. to over 80 ft., and much greater distances when
carrier pulleys are used which results in increase in cost which also been reduced.

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 CHAPTER 7 – PROBLEM DEFINATION

While Designing and fabricating wire twisting machine certain problems were encountered
during its earlier days of its development which are as follows:

1) It is practically noisy.
2) It occupies more space than belt driving, and the slip is so great.
3) The turning movement is more; machines therefore it is not run steadily
4) Greater range of drives; anything from 10 ft. to over 80 ft., and much greater distances
when carrier pulleys are used which results in increase in cost.
5) Machine is very complex hence tough to operate and maintain.

Here are some advantages of chain drives compared with gear and belt drives

• They can be used for both long and short distances

• A number of shafts and be driven from a single chain

• They are compact and have small overall dimensions

• They do not present fire hazard

• Temperature and environmental conditions do not affect their working

• They do not require initial tension

• They have very high efficiency (up to 96%)

• They do not slip

• They are easier to install

• They can withstand abrasive conditions

• They can operate in wet conditions

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CHAPTER 8 – CAD MODELLING

Fig 4: ISO Metric View

Fig 5: Top View

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Fig 6: Side View

Fig 7: All Views

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 CHAPTER 9 - FABRICATION

Fig 8: Sizing of Square Steel frame

1 inch square hollow frame is used to make the base of the machine whose length is 20 inches
and breadth is 12 inches along with it, an external support of length 9 inches is added in order
to support driven roller, DC motor and guide wheel. For cutting such hollow frame, Angle
grinder is used. An angle grinder, also known as a side grinder or disc grinder, is a handheld
power tool used for grinding (abrasive cutting) and polishing. Although developed originally
as tools for rigid abrasive discs, the availability of an interchangeable power source has
encouraged their use with a wide variety of cutters and attachments. Angle grinders can be
powered by an electric motor or compressed air. The motor drives a geared head at a right-
angle on which is mounted an abrasive disc or a thinner cut-off disc, either of which can be
replaced when worn. Angle grinders typically have an adjustable guard and a side-handle for
two-handed operation. Certain angle grinders, depending on their speed range, can be used
as sanders, employing a sanding disc with a backing pad or disc. The backing system is
typically made of hard plastic, phenol resin, or medium-hard rubber depending on the amount
of flexibility desired. Angle grinders are standard equipment in metal fabrication shops and
on construction sites. They are also common in machine shops, along with die
grinders and bench grinders.

22
 Fig 9: Arc Welding on Base Frame Fig 10: Arc Welding on standing Legs

All MS Steel Frame pieces are joined using arc welding method. Arc welding is a type
of welding process using an electric arc to create heat to melt and join metals. A power
supply creates an electric arc between a consumable or non-consumable electrode and the
base material using either direct (DC) or alternating (AC) currents.

Arc welding is a fusion welding process used to join metals. An electric arc from an AC or
DC power supply creates an intense heat of around 6500°F which melts the metal at the join
between two work pieces. The arc can be either manually or mechanically guided along the
line of the join, while the electrode either simply carries the current or conducts the current
and melts into the weld pool at the same time to supply filler metal to the join. Because the
metals react chemically to oxygen and nitrogen in the air when heated to high temperatures
by the arc, a protective shielding gas or slag is used to minimize the contact of the molten
metal with the air. Once cooled the molten metal then solidify to form a metallurgical bond.

23
 CHAPTER 10 – COMPONENT & DESCRIPTION

Component used:-
• MS Frame
• Fly Wheel
• Reel Wheel
• Shaft
• Bearing
• DC Motor
• Battery
• Pipes
• Roller

Fig 11: Wire Holding Fig 12: Roller

24
 Fig 13: MS Pipe Fig 14: DC Motor

Fig 15: 12V/7.2Ah Battery Fig 16: MS Flat Plate

Fig 17: Gear

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10.1 Lead Acid Battery

Where high values of load current are necessary, the lead-acid cell is the type most
commonly used. The electrolyte is a dilute solution of sulphuric acid (H₂SO₄). In the
application of battery power to start the engine in an auto mobile, for example, the load
current to the starter motor is typically 200 to 400A. One cell has a nominal output of 2.1V,
but lead-acid cells are often used in a series combination of three for a 6-V battery and six for
a 12-V battery.

The lead acid cell type is a secondary cell or storage cell, which can be recharged. The
charge and discharge cycle can be repeated many times to restore the output voltage, as long
as the cell is in good physical condition. However, heat with excessive charge and discharge
currents shortens the useful life to about 3 to 5 years for an automobile battery. Of the
different types of secondary cells, the lead-acid type has the highest output voltage, which
allows fewer cells for a specified battery voltage.

Inside a lead-acid battery, the positive and negative electrodes consist of a group of plates
welded to a connecting strap. The plates are immersed in the electrolyte, consisting of 8 parts
of water to 3 parts of concentrated sulphuric acid. Each plate is a grid or framework, made of
a lead-antimony alloy. This construction enables the active material, which is lead oxide, to
be pasted into the grid. In manufacture of the cell, a forming charge produces the positive and
negative electrodes. In the forming process, the active material in the positive plate is
changed to lead peroxide (PbO₂). The negative electrode is spongy lead (Pb).

Fig 18: Lead Acid Battery

26
Automobile batteries are usually shipped dry from the manufacturer. The electrolyte is put in
at the time of installation, and then the battery is charged to from the plates. With
maintenance-free batteries, little or no water need be added in normal service. Some types
are sealed, except for a pressure vent, without provision for adding water. The construction
parts of battery are shown in figure 12.

Chemical Action

Sulphuric acid is a combination of hydrogen and sulphate ions. When the cell discharges,
lead peroxide from the positive electrode combines with hydrogen ions to form water and
with sulphate ions to form lead sulphate. Combining lead on the negative plate with sulphate
ions also produces he sulphate. Therefore, the net result of discharge is to produce more
water, which dilutes the electrolyte, and to form lead sulphate on the plates.

As the discharge continues, the sulphate fills the pores of the grids, retarding circulation of
acid in the active material. Lead sulphate is the powder often seen on the outside terminals of
old batteries. When the combination of weak electrolyte and sulphating on the plate lowers
the output of the battery, charging is necessary.

On charge, the external D.C. source reverses the current in the battery. The reversed direction
of ions flows in the electrolyte result in a reversal of the chemical reactions. Now the lead
sulphates on the positive plate reactive with the water and sulphate ions to produce lead
peroxide and sulphuric acid. This action re-forms the positive plates and makes the
electrolyte stronger by adding sulphuric acid.

At the same time, charging enables the lead sulphate on the negative plate to react with
hydrogen ions; this also forms sulphuric acid while reforming lead on the negative plate to
react with hydrogen ions; this also forms currents can restore the cell to full output, with lead
peroxide on the positive plates, spongy lead on the negative plate, and the required
concentration of sulphuric acid in the electrolyte.

27
 Fig 19: Chemical Reaction in Batteries

On discharge, the Pb and PbO₂ combine with the SO₄ ions at the left side of the equation to
form lead sulphate (PbSO₄) and water (H₂O) at the right side of the equation. One battery
consists of 6 cells, each have an output voltage of 2.1V, which are connected in series to get a
voltage of 12V and the same 12V battery is connected in series, to get a 24 V battery. They
are placed in the water proof iron casing box.

10.2 D C Motor

An electric motor is a machine which converts electrical energy to mechanical energy. Its
action is based on the principle that when a current-carrying conductor is placed in a
magnetic field, it experiences a magnetic force whose direction is given by Fleming’s left
hand rule. When a motor is in operation, it develops torque. This torque can produce
mechanical rotation. DC motors are also like generators classified into shunt wound or series
wound or compound wound motors.

Fleming’s Left Hand Rule

Keep the force finger, middle finger and thumb of the left hand mutually perpendicular to one
another. If the fore finger indicates the direction of magnetic field and middle finger
indicates direction of current in the conductor, then the thumb indicates the direction of the
motion of conductor.

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Principle and Operation of DC Motor
A magnetic field arises in the air gap when the field coil of the DC motor is energized. The
created magnetic field is in the direction of the radii of the armature. The magnetic field
enters the armature from the North Pole side of the field coil and “exits” the armature from
the field coil’s South Pole side.

Fig 20: DC Motor Working

When kept in a magnetic field, a current-carrying conductor gains torque and develops a
tendency to move. In short, when electric fields and magnetic fields interact, a mechanical
force arises. This is the principle on which the DC motors work.

According to the fundamental law of nature, no energy conversion is possible until there is
something to oppose the conversion. In case of generators, magnetic drag provides this
opposition, but in the case of dc motors, there is back emf. Presence of the back emf makes a dc
motor ‘self-regulating’.

When the armature of a motor is rotating, the conductors are also cutting the magnetic flux
lines and hence according to the Faraday's law of electromagnetic induction, an emf induces in
the armature conductors.

29
The direction of this induced emf is such that it opposes the armature current (Ia). The circuit
diagram below illustrates the direction of the back emf and armature current.

Fig 21: Back EMF Circuit Diagram

Magnitude of back emf is directly proportional to speed of the motor. Consider the load on a dc
motor is suddenly reduced. In this case, required torque will be small as compared to the
current torque. Speed of the motor will start increasing due to the excess torque. Hence, being
proportional to the speed, magnitude of the back emf will also increase. With increasing back
emf armature current will start decreasing. Torque being proportional to the armature current, it
will also decrease until it becomes sufficient for the load. Thus, speed of the motor will
regulate.

On the other hand, if a dc motor is suddenly loaded, the load will cause decrease in the speed.
Due to decrease in speed, back emf will also decrease which allows more armature current.
Due to increase in armature current the torque will increase to fulfill the load requirement.

Fig 22: DC Motor Principle

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An electric motor is all about magnets and magnetism: a motor uses magnets to create
motion. If you have ever played with magnets you know about the fundamental law of all
magnets: Opposites attract and likes repel.

So if you have 2 bar magnets with their ends marked north and south, then the North end of
one magnet will attract the South end of the other. On the other hand, the North end of one
magnet will repel the North end of the other (and similarly south will repel south). Inside an
electric motor these attracting and repelling forces create rotational motion.

In the diagram above and below you can see two magnets in the motor, the armature (or
rotor) is an electromagnet, while the field magnet is a permanent magnet (the field magnet
could be an electromagnet as well, but in most small motors it is not to save power).

Electromagnet and Motor

To understand how an electric motor works, the key is to understand how the electromagnet
works. An electromagnet is the basis of an electric motor. You can understand how things
work in the motor by imagining the following scenario. Say that you created a simple
electromagnet by wrapping 100 loops of wire around a nail and connecting it to a battery.
The nail would become a magnet and have a North and South pole while the battery is
connected.

Now say that you take your nail electromagnet, run an axle through the middle of it, and you
suspended it in the middle of a horseshoe magnet as shown in the figure below. If you were
to attach a battery to the electromagnet so that the North end of the nail appeared as shown,
the basic law of magnetism tells you what would happen: The North end of the electromagnet
would be repelled from the north end of the horseshoe magnet and attracted to the south end
of the horseshoe magnet.

The South end of the electromagnet would be repelled in a similar way. The nail would move
about half a turn and then stop in the position shown.

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 Fig 23: Electromagnet Relationship

You can see that this half-turn of motion is simple and obvious because of the way magnets
naturally attract and repel one another. The key to an electric motor is to then go one step
further so that, at the moment that this half-turn of motion completes, the field of the
electromagnet flips. The flip causes the electromagnet to complete another half-turn of
motion.

You flip the magnetic field simply by changing the direction of the electrons flowing in the
wire (you do that by flipping the battery over). If the field of the electromagnet flipped at just
the right moment at the end of each half-turn of motion, the electric motor would spin freely.

Armature
The armature takes the place of the nail in an electric motor. The armature is an
electromagnet made by coiling thin wire around two or more poles of a metal core. The
armature has an axle, and the commutator is attached to the axle. In the diagram above you
can see three different views of the same armature: front, side and end-on. In the end-on view
the winding is eliminated to make the commutator more obvious. You can see that the
commutator is simply a pair of plates attached to the axle. These plates provide the two
connections for the coil of the electromagnet.

Fig 24: Armature

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Commutator and Brushes

Fig 25: Commutator and Brushes

The "flipping the electric field" part of an electric motor is accomplished by two parts: the
commutator and the brushes. The diagram at the right shows how the commutator and
brushes work together to let current flow to the electromagnet, and also to flip the direction
that the electrons are flowing at just the right moment. The contacts of the commutator are
attached to the axle of the electromagnet, so they spin with the magnet. The brushes are just
two pieces of springy metal or carbon that make contact with the contacts of the commutator.

Combination

Fig 26: Combining all of them

In this figure, the armature winding has been left out so that it is easier to see the commutator
in action. The key thing to notice is that as the armature passes through the horizontal
position, the poles of the electromagnet flip. Because of the flip, the North Pole of the
electromagnet is always above the axle so it can repel the field magnet's North Pole and

33
attract the field magnet's South Pole. If you ever take apart an electric motor you will find
that it contains the same pieces described above: two small permanent magnets, a
commutator, two brushes and an electromagnet made by winding wire around a piece of
metal. Almost always, however, the rotor will have three poles rather than the two poles as
shown in this article. There are two good reasons for a motor to have three poles:

• It causes the motor to have better dynamics. In a two-pole motor, if the electromagnet
is at the balance point, perfectly horizontal between the two poles of the field magnet
when the motor starts; you can imagine the armature getting "stuck" there. That never
happens in a three-pole motor.
• Each time the commutator hits the point where it flips the field in a two-pole motor,
the commutator shorts out the battery (directly connects the positive and negative
terminals) for a moment. This shorting wastes energy and drains the battery without
needle. A three-pole motor solves this problem as well.
• It is possible to have any number of poles, depending on the size of the motor and the
specific application it is being used in.

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 CHAPTER 11 – WORKING PRINCIPLE

The mechanical transmission structure of the stripper is composed of flyer wheel, reel and a
DC motor. motors power the cable-making machine, called a flyer, that both twists and winds
the conductors on a reel, wherein a guide roller which is laterally offset with respect to the
axis of rotation and supplies the strand material to the supply point of the at least one further
deflection roller, which is offset from the axis of rotation. This object is achieved according
to the invention by the characteristics of a double-twist bunching machine for fabricating
bunched strand material having an inlet for individual strands which are supplied to a first
deflection point that has a first deflection roller, the first deflection roller being arranged so as
to be rotatable around an axis of rotation for forming a first twist, a bow rotating about the
axis of rotation and connecting the first deflection point with a second deflection point, the
second deflection point having at least one second deflection roller that is rotatable about the
axis of rotation for forming a second twist.

35
 CHAPTER 12 – DESIGN, CALCULATION AND ANALYSIS

Fig 27: Basic Design

12.1 DESIGN OF BALL BEARING

Bearing No. 6202
Outer Diameter of Bearing (D) = 40mm
Thickness of Bearing (B) = 12mm
Inner Diameter of the Bearing (d) = 15mm
r1 = Corner radii on shaft and housing = 1mm (From Data Handbook)
Maximum Speed = 14,000 rpm (From Data Handbook)
Mean Diameter (dm) = (D + d) / 2
= (40 + 15) / 2
dm = 27.5 mm

12.2 WAHL STRESS FACTOR

Ks = (4C – 1) + 0.65
(4C – 4)
Where C = 2.3
Ks = (4 × 2.3) – 1 + 0.65
(4 × 2.3) – 4
Ks = 1.85

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12.3 BASIC SHAFT DESIGN EXAMPLE
The drive shaft with multiple pulleys experience two kinds of stresses, bending stress and
shear stress. The maximum bending stress generated at the outer most fiber of the shaft. And
on the other hand, the shear stress is generated at the inner most fiber. Also, the value of
maximum bending stress is much more than the shear stress. So, the design of the shaft will
be based on the maximum bending stress and will be driven by the following formula:

Maximum bending stress, Tb = (M × r) / l -------- Eqn. 1.1

Where,
M is maximum bending moment on the shaft
r is the radius of the shaft
I is area moment of inertia of the shaft

12.4 DESIGN PROCEDURE

• Draw the bending moment diagram to find out the maximum bending moment (M) on
the shaft.
• Calculate the area moment of inertia (I) for the shaft.
• Replace the maximum bending stress (Tb) with the given allowable stress for the
shaft material.
• Calculate the radius of the shaft.

12.5 SHAFT DESIGN PROBLEM

Fig 28: Shaft Setup

37
Refer the above picture, where a steel shaft is supported by two bearings and a pulley is
placed in between the bearings. We have to design the shaft. Weight of the pulley is 1000 N.

Maximum allowable shear stress for the shaft material = 40 N/mm2

From the bending moment diagram, the maximum bending moment (M) is calculated as
66666.67 N/mm2.
Area moment of inertia (I) of the circular shaft is:
I = π × r4 × 0.25
= 0.785 × r4 ---------------- Eqn. 1.2
From Eqn 1.1 we can say:
40 = (66666.67 × r) / (0.785 × r4)
r = 7.04 mm
So, the minimum radius of the shaft should be 7.04.

For a pulley system like this, the product of roller diameter d and RPM n is the same for both
driver and driven roller. It means that,
d₁ × n₁ = d₂ × n₂
We can use this formula to find any of these four values: driver roller diameter d₁, its angular
velocity n₁, the driven roller diameter d₂ or its angular velocity n₂.
d1 = 80mm, n1 = 30 rpm & d2 = 60mm
80 × 30 = 60 × n₂
n₂ = 40 rpm

The last values that can be found with this roller calculator are the drive torque (torque of the
driver roller) and the driven torque (of the driven roller). Use the following equation:
T = P /(2 * π * n / 60)
Where,
Angular velocity n of each pulley is expressed in revolutions per minute.
T = 60 / (2x3.14x30/60)
T = 19.108 N-m

38
12.6 ANALYSIS

12.6.1 Ball Bearing Analysis

Fig 29: Total Deformation of Ball Bearing

Fig 30: Equivalent Stress on Ball Bearing

39
 Fig 31: Shear Stress on Ball Bearing

Fig 32: Factor of Safety in Ball Bearing

Fig 33: Ball Bearing Result Table

40
12.6.2 Shaft Problem Analysis

Fig 34: Total Deformation of Shaft Setup

Fig 35: Equivalent Stress of Shaft Setup

41
 Fig 36: Shear Stress on Shaft Setup

Fig 37: Factor of Safety in Shaft Setup

Fig 38: Shaft Setup Result Table

42
 CHAPTER 13 – ADVANTAGES AND DISADVANTAGES

13.1 Advantages
1) Size: Size of the modified machine is very less as compared to conventional one
thereby facilitating its use in small scale industries also.
2) Simplified Mechanism: The number of gears in our modified design is very less in
number as compared to conventional machine. We are just using only five- six gear.
3) Less Maintenance: Since we are using fewer gears, and our mechanism is much
simpler so it doesn’t require any extra maintenance job, thus making profits in the
context of maintenance.
4) Power Consumption: Our proposed design, consumed a very low Electric power (as
compared to Conventional wire-rope making machine) because in our design twisting
& winding action is perform at one point so that only one power motor is sufficient
for the motion of both the assembly.
5) Degree of Freedom: The DC motors in our model has a property of rotating in both
the direction i.e. clockwise and anti-clockwise direction hence one can do debinding
also.

13.2 Disadvantages
1) Lack of Uniformity: Wire twisting machine has two DC motors hence its differential
speed can cause variable binding of single wire.
2) Speed: DC motors are running at slow RPM due to which the rate of wire producing
through our machine is quite slow.
3) Friction: Spindle in our wire twisting machine experience moderate amount of
friction while spinning hence minimal power loss occurs.
4) Types of Wires: Our machine is limited for producing only three single winding
wires.

43
CHAPTER 14 – EXPENDITURE

Fig 39: Cost Table

44
14.1 Labour Charges
Lathe, Drilling, Welding, Grinding, Power Hacksaw, Gas Cutting:
Cost = 2500/-

14.2 Overhead Charges

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 12350/- + 2500/-
= 14850/-

Overhead Charges = 20% of the manufacturing cost

= 2970/-
14.3 Total Cost
Total cost = Material Cost + Labour cost + Overhead Charges
= 12350/- + 2500/- + 2970/-
= 17820/-

45
 CHAPTER 15 – CONCLUSION

• Overall Factor of Safety is around 5 so the experimental setup is considered safe for
operation.
• All parts and different components of the machine are constructed and furnished.
• 12 V / 7.2 Ah battery is used hence sufficient amount of electricity is supplied.
• The calculated Value and the obtained result via analysis are found to be equal and
same.
• Our Project cost us around 17,820/-.
• We learned more about kinetics of machinery and closely studied the effective of
forces on different working bodies or parts.
• Gained Knowledge on the working of heavy wire making machines that are actually
used in large scale industries.
• Studied the nature of flow of current in different types of wires considering resistance,
impedance and permeability.

46
 CHAPTER 16 – PHOTOS

Fig 40: Model Profile 1 Fig 41: Model Profile 2

Fig 42: Model Profile 3 Fig 43: Model Profile 4

Fig 44: Model Profile 5

47
 REFERENCE

1) Production in twisting machine and examining physical and thermal properties of

tungsten wire reinforced composite yarn by Tekstil Ve Konfeksiyon.
2) P. V. Real, R. Cazeli, L. S. da Silva, A. Santiago, and P. Piloto.
3) Y. Yang, G. Li, M. Susner, M. Sumption, M. Rindfleisch, M. Tomsic, and E.
Collings.
4) Electrical Wire Manufacturing Plant Project Report: Industry Trends, Manufacturing
Process, Plant Setup, Machinery, Raw Materials, Investment Opportunities, Cost and
Revenue 2022-2027.
5) PVC Wire & Cables - Manufacturing Plant, Detailed Project Report, Profile, Business
Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery,
Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue.
6) GALVANISED M.S. WIRE ROPE by Dr. R. K. Bharti D.O. No.64 (24) / DI /
VCMATTERS / 2020-2021 / E DATED: 17.02.2021 OF AS & DC.
7) Copper Wire Manufacturing Project Report 2021: Plant Setup, Industry Trends, Business
Plan, Machinery Requirements, Raw Materials, Cost and Revenue in 2026.

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