CEP MEEN201101007

Theory of Machines

COMPLEX ENGINEERING PROBLEM

Assigned date: 02/05/2023
Submission date: 02/06/2023

This is an individual assignment. Each student must solve this Complex

Engineering Problem according to the given unique parameters and solution
will be based upon proper justification and literature review.
Problem statement: A steam power plant is installed at the campus. In summers
when the load is increased the voltages are low and in winters it’s vice versa.
Design a Mechanical Regulating Device to address the given problem.
Parameters:
 Choose any Centrifugal Type Governor
 The length of each arm is 300 mm and all the arms are pivoted on
the axis ofrotation
 The mass of each ball is 7.5 kg and the mass of the sleeve is 45 kg.
 The extreme radii of rotation are 150 mm and 225 mm.
Required:
 Draw the controlling force curve and set-off a speed scale along
the ordinatecorresponding to a radius (assume any value b/w
200mm to 300mm)
 Complete engineering design
 2D and 3D CAD models of your design
Rubrics:
Sr
Criteria/ Marks 01 03 05
#
Ability to judge question Not able to identify Few variables are All factors / variables
1 Variables identified are mentioned

Evidence of thought
No thought found Found but Incomplete Used information
2 Process and
Correctly
Completeness of answer
Formatting Formatting Well
3 Not suitable Few mistakes in
presented
Modern tool
4 Not good good Excellent
usage/software skills
Total 05+05+05+05=20
marks

CLO-3, PLO-3
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Governor:
A governor is a complex mechanical or electronic device designed to automatically regulate
the speed or position of a system in response to varying load conditions, maintaining a desired
level of stability, control, and efficiency. It accomplishes this by continuously monitoring the
system's parameters and adjusting the input or output variables accordingly, utilizing various
feedback mechanisms and control algorithms. The governor's intricate design incorporates
sensors to measure relevant variables, such as speed, position, or pressure, and transmits this
information to a control unit. The control unit then processes the data, compares it to the desired
setpoint, and initiates appropriate corrective actions, such as adjusting fuel flow, altering
mechanical linkages, or manipulating electronic signals to the actuator. This intricate interplay
of measurement, computation, and control allows the governor to dynamically adapt to
changing conditions and ensure optimal system performance, stability, and safety. Whether
employed in power plants, engines, turbines, or other complex systems, the governor represents
a sophisticated amalgamation of engineering principles, precision mechanics, and advanced
control theory, embodying the pursuit of fine-tuned regulation and efficient operation.

Types of Governors:
The governors are mainly divided into two types i.e.,

 Centrifugal Governor

 Inertia Governor

These are further divided into following types according to their design.

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1. Centrifugal Governor:
In centrifugal governor only centrifugal force and change in speed are responsible for
controlling the actions. It widely used due to the variety of applications and mostly preferred
when balance on the masses is needed in the operation. It consists of a set of rotating weights
called flyballs, which are connected to the engine's control mechanism through linkages.

Figure 01: Centrifugal Governor

Principle:
It works on the principle of balancing centrifugal force of the rotating balls.

Construction of Centrifugal Governor:

A centrifugal governor has a simple design. This type of governor has multiple masses known
as governor balls which rotate at the distance from the axis of a shaft and driven through
suitable gearing from the engine crankshaft. It has two balls of equal masses attached to the
arm. These balls are provided by the combination of dead weight or spring.

Spindle axis is connected to the sleeve and driven by bevel gear mechanism connected with
crankshaft. Throttle valve is connected to the sleeves and operate by the actual change of speed
of engine. As load increases speed got decreases and the speed of governor ball as well as
governor also decreases which is geared with the crankshaft.

Working of Centrifugal Governor:

A centrifugal governor is a device used to regulate the speed of an engine or machine by
controlling the flow of a working fluid, such as steam or fuel. It consists of several key
components, including a spindle, flyballs, linkages, and a control mechanism. When the engine
is running, the flyballs rotate with it. As the speed increases, the flyballs experience an outward
centrifugal force, causing them to move away from the spindle. This upward movement is
transmitted to the control mechanism through linkages. The control mechanism, which is
typically connected to the engine's throttle or fuel valve, responds by reducing the flow of
working fluid to the engine. This restriction in fluid flow leads to a decrease in the engine's
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speed. Conversely, as the speed decreases, the centrifugal force acting on the flyballs
diminishes, causing them to descend due to gravity. The control mechanism then adjusts the
throttle or fuel valve to allow for a higher flow of working fluid, compensating for the decrease
in speed. This cycle of flyball movement and control mechanism adjustment helps to maintain
a relatively stable speed for the engine.

Applications:
 It limits the rotation speed in the internal combustion engine of automobile and keep it
controlled according to desired speed.

 It is used to control the speed of turbine shaft in hydroelectric power plant.

 Centrifugal governors are also used to control the speed of mechanical music box.

2. Inertia governor:
Inertia governor is completely different from centrifugal governor. The combination of angular
and centrifugal force is used to control the position of the balls as well as operation of the
governor. Since it is not very popular, it is preferred when a rapid response is the main concern.
Principle: It works on the principal of movement of inertia due to both centrifugal and inertia
force.

Figure 02: Inertia Governor

Advantages:
• Highly sensitive to varying load
• Quick response due to fast reaction

Applications:
• It is used in steam turbine to control and maintain desired speed of the turbine when load
increase or decrease during work.
• It is used in a diesel engine to control speed of the engine at a particular set point.

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Porter Governor:
The Porter governor is a specific type of centrifugal governor that was invented by American
engineer Robert Porter in the mid-19th century. It is a mechanical device used to regulate the
speed of steam engines. The Porter governor consists of two rotating flyballs connected to the
governor assembly by arms. These flyballs are mounted on a spindle and rotate as the engine
speed changes.
As the engine's speed increases, the flyballs are pushed outward by centrifugal force. This
movement is transmitted to the governor assembly through the arms. The governor assembly
typically includes a sleeve that slides up and down on the spindle. The position of the sleeve is
connected to the engine's throttle or fuel valve.
When the flyballs move outward, the sleeve is pushed downward, reducing the opening of the
throttle or fuel valve, thus limiting the flow of steam or fuel to the engine. This reduction in
flow helps to stabilize the engine's speed. Conversely, if the engine's speed decreases, the
flyballs move inward, raising the sleeve and allowing for a greater flow of steam or fuel to
increase the engine speed.
The Porter governor utilizes a spring mechanism to provide a restoring force that opposes the
outward movement of the flyballs. This spring helps to maintain a balance between the
centrifugal force generated by the flyballs and the force exerted by the spring. By adjusting the
tension of the spring, the sensitivity and response of the governor can be fine-tuned to suit
specific engine requirements.
Overall, the Porter governor's design allows it to effectively regulate the speed of a steam
engine by continuously adjusting the throttle or fuel valve based on the rotational speed of the
flyballs. Its simplicity and robustness have made it a popular choice for steam power plants
and other applications where stable speed control is essential.

Construction of Porter Governor:

In porter governor two balls are located at the top and load is attached to the sleeves. The lower
link is connected to central sleeve and two stoppers are provided to control the movements of
sleeves. A mechanism is attached to the sleeves to operate the throttle valve.

Figure 03: Porter Governor

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Working:
The balls tend to moves up and down on the spindle due to the speed of revolution of the
spindle. As load at the engine decreases speed of the engine as well as spindle also tends to
increases. Centrifugal force is responsible for movement of balls in the upward direction while
lower arm pushes the sleeves upward to move the ball outward. These movements actuate the
throttle valve and fuel supply gets decreases through the mechanism connected to the sleeves.

Governor used in this problem:

Here we will user porter governor because it is best according to the application and problem
given. Its main advantage is that it can work at higher RPM due to dead weight attached on
sleeve.

Problem Solution
Given:

l = 300 mm = 0.3 m m = 7.5 kg

r1 = 150 mm = 0.15 m r2 = 225 mm = 0.225m

Let

FC = Controlling Force

𝑀. 𝑔 𝑀. 𝑔
( + 𝑚. 𝑔) tan 𝛼 = 𝐹𝐶 − × tan 𝛽
2 2
As

𝑀. 𝑔 𝑀. 𝑔
𝐹𝐶 = ( + 𝑚. 𝑔) tan 𝛼 + × tan 𝛽
2 2
𝑀. 𝑔 𝑀. 𝑔 tan 𝛽
𝐹𝐶 = ( + 𝑚. 𝑔 + × ) tan 𝛼
2 2 tan 𝛼
tan 𝛽 𝑟
Substituting tan 𝛼 = 𝑞, and tan 𝛼 = ℎ, we have

𝑀. 𝑔 𝑟
𝐹𝐶 = ( (1 + 𝑞) + 𝑚. 𝑔)
2 ℎ
Since 𝛼 = 𝛽 as shown in figure 02, therefore

q=1
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As

ℎ = √𝑙 2 − 𝑟 2

So FC will become
𝑟
𝐹𝐶 = (𝑚. 𝑔 + 𝑀. 𝑔) = 𝑔(𝑚 + 𝑀) ×
√𝑙 2 − 𝑟 2

Figure 04

The following table shows the values of FC for different values of r.

r (m) 0.12 0.13 0.14 0.16 0.19 0.2 0.26

h=

√𝑙 2 − 𝑟 2 0.2749 0.2703 0.2653 0.2537 0.2321 0.2236 0.1496

FC (N) 225 247 272 370 421 460 894

In order to set-off the speed scale along the ordinate through r = 267.8 mm = 0.268 m, we have

𝐹𝐶 = 𝑚. 𝜔2 . 𝑟

2𝜋𝑁 2
𝐹𝐶 = 7.5 ( ) 0.268
60

𝐹𝐶 = 0.02204𝑁 2

The values of FC for different values of N are given in the following table.

N
110 120 140 150 170 180 190 200
(r.p.m)

FC (N) 266.6 317.3 431.9 495.9 637 714.16 795.6 881.6

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r (m) FC (N)

0 0
0.12 225
0.13 247
0.14 272
0.16 370
0.19 421
0.2 460
0.26 894

Graph Between Radius and

Controlling Force
1000
900
800
700
600
FC (N)

500
400
300
200
100
0
0 0.05 0.1 0.15 0.2 0.25 0.3
Radius (m)

2D Model of Porter Governor:

A Porter governor is a type of centrifugal governor used in steam engines to regulate the speed
of the engine. It was invented by American engineer Robert Porter in the mid-19th century. A
2D model of a Porter governor can be represented as a schematic diagram illustrating its key
components and their relative positions.

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Figure 03: 2D Model of Porter Governor

3D Model of Porter Governor:

Figure 04: 3D Porter Governor

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Conclusion
In this problem, the Porter governor was chosen as the preferred option for the steam power
plant application due to its ability to operate at high rpm, making it well-suited for the task.
Although other governors like Proell or Hartnell governor could have been considered, they
were not selected due to their high sensitivity, which can result in a phenomenon known as
hunting.
Hunting refers to the continuous back-and-forth movement of the governor's control
mechanism in an attempt to stabilize the engine speed. This can lead to instability and
fluctuations in the power output. By contrast, the Porter governor is known for its robustness
and ability to provide stable control without excessive hunting.
To support the decision, graphs and 2D/3D models of the Porter governor were likely created.
These visual representations would have demonstrated how the Porter governor performs in
the specific context of the steam power plant, showcasing its suitability and effectiveness for
the intended purpose.

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