ĐẠI HỌC BÁCH KHOA HÀ NỘI

TRƯỜNG CƠ KHÍ
KHOA CTTT CƠ ĐIỆN TỬ

🙧🙥

ĐỒ ÁN THIẾT KẾ HỆ THỐNG CƠ
KHÍ-THIẾT BỊ TỰ ĐỘNG

ĐỀ TÀI: THIẾT KẾ HỆ THỐNG PHÂN LOẠI SẢN PHẨM

Mã học phần: ME3066

Mã lớp học: 729127
Sinh viên thực hiện: Nguyễn Duy Tùng Anh - 20195759
Giảng viên hướng dẫn: Trịnh Đồng Tính

Hà Nội, tháng 4 năm 2023

TRƯỜNG ĐẠI HỌC BÁCH KHOA HÀ NỘI SME.EDU –Mẫu 6.a
VIỆN CƠ KHÍ Học kỳ: 2022-2
Bộ môn Cơ điện tử Năm học: 2022-2023

ĐỒ ÁN MÔN HỌC: THIẾT KẾ HỆ THỐNG CƠ KHÍ Mã HP: ME3066

Thời gian thực hiện: 15 tuần; Mã đề: VCK01-19
Ngày giao nhiệm vụ: 10/04/2023; Ngày hoàn thành://2023
Họ và tên sv: Nguyễn Duy Tùng Anh MSSV: 20195759 Mã lớp:729127
Ngày …/…/2023 Ngày …/…/2023
BỘ MÔN CĐT CB Hướng dẫn
(ký, ghi rõ họ tên) (ký, ghi rõ họ tên)

I. Nhiệm vụ thiết kế: Thiết kế hệ thống phân loại sản phẩm

II. Số liệu cho trước:
1. Hệ thống cấp phôi tự động
2. Nguồn lực cấp phôi và đẩy phôi: Khí nén
3. Nguồn lực quay băng tải: Động cơ điện
4. Bộ truyền ngoài: Xích
5. Thông số hình học phôi:
 Hình lập phương : h1= 3cm, h2= 4cm, h3= 5cm
6. Trọng lượng phôi: Qmin = 0.5 kg; Qmax = 6.5 kg
7. Năng suất làm việc : N = 20 sp/ph
III. Nội dung thực hiện:
1. Phân tích nguyên lý và thông số kỹ thuật
- Tổng quan về hệ thống
- Nguyên lý hoạt động
- Phân tích tính chất, đặc điểm của phôi/sản phẩm để lựa chọn phương pháp cấp phôi phù hợp
- Xác định các thành phần cơ bản và thông số/yêu cầu kỹ thuật của hệ thống
2. Tính toán và thiết kế
1
 - Thiết kế các mô đun chức năng của hệ thống:
+ Mô đun cấp phôi tự động
+ Mô đun băng tải
+ Mô đun phân loại: pít tông khí nén, van từ, sensor, ...
3. Thiết kế chi tiết và xây dựng bản vẽ lắp
- Xây dựng bản vẽ lắp 2D/3D
- Xây dựng các bản vẽ chế tạo các chi tiết chính
4. Mô phỏng nguyên lý hoạt động (động học)

BẢNG SỐ LIỆU CÁC PHƯƠNG ÁN THIẾT KẾ

Năng suất
Trọng lượng phôi Kích thước hình học phôi (cm)
Đề số làm việc
[N,sp] [Qmin, kg] [Qmax, kg] [h1;d1] [h2;d2] [h3;d3] [h1] [h2] [h3]
VCK01-1 20 0,2 5 5;5 7;5 3;5 5 5 5
VCK01-2 18 0,3 5,5 10;6 5;6 3;6 5 5 10
VCK01-3 16 0,4 6 8;6 7;6 4;6 5 5 15
VCK01-4 14 0,5 6,5 15;5 10;5 5;5 3 3 5
VCK01-5 12 5,5 7 5;6 4;6 12;6 3 3 10
VCK01-6 10 0,2 5 10;4 5;4 4;4 3 3 15
VCK01-7 8 0,3 5,5 8;5 7;5 5;5 3 4 5
VCK01-8 6 0,4 6 15;5 10;5 3;5 3 4 10
VCK01-9 25 0,5 6,5 5;4 6;4 3;4 3 4 15
VCK01-10 20 5,5 7 10;4 5;4 4;4 4 6 5
VCK01-11 15 0,2 5 8;5 7;5 6;5 4 6 10
VCK01-12 10 0,3 5,5 15;5 10;5 4;5 4 6 15
VCK01-13 5 0,4 6 5;4 6;4 3;4 5 5 5
VCK01-14 30 0,5 6,5 10;6 5;6 6;6 5 5 10
VCK01-15 25 5,5 7 8;8 7;8 15;8 5 5 15
VCK01-16 20 0,2 5 15;4 10;4 3;4 3 3 5
VCK01-17 15 0,3 5,5 5;5 7;5 3;5 3 3 10
VCK01-18 10 0,4 6 10;6 5;6 3;6 3 3 15
VCK01-19 20 0,5 6,5 8;6 7;6 4;6 3 4 5
VCK01-20 15 5,5 7 15;5 10;5 5;5 3 4 10
VCK01-21 10 0,2 5 5;6 4;6 12;6 3 4 15
VCK01-22 5 0,3 5,5 10;4 5;4 4;4 4 6 5
VCK01-23 30 0,4 6 8;5 7;5 5;5 4 6 10
VCK01-24 25 0,5 6,5 15;5 10;5 3;5 4 6 15
VCK01-25 20 5,5 7 5;4 6;4 3;4 3 4 10
VCK01-26 16 0,4 6 10;4 5;4 4;4 3 4 15
VCK01-27 14 0,3 5 8;5 7;5 6;5 3 4 15
VCK01-28 12 0,4 5,5 15;5 10;5 4;5 4 6 5
VCK01-29 10 0,5 6 5;4 6;4 3;4 4 6 10
VCK01-30 8 5,5 6,5 10;6 5;6 6;6 4 6 15
VCK01-31 6 0,4 7 8;8 7;8 15;8 3 4 10
VCK01-32 12 5,5 6 15;4 10;4 3;4 3 4 15
VCK01-33 10 0,4 6 15;5 10;5 4;5 4 6 10

2
 ABSTRACT

Today, due to the constant development of technology, the need of a fast and
convenient application in industries is necessary. Automation is a practical
solution which helps increase the speed, accuracy and reduce labor price.

In the era of industrialization and modernization of Vietnam, the automatic control

of production and product processing has been increased. This results in the
forming of flexible production systems, allowing a high degree of automation for
small and medium batch production on the basis of CNC machines and
industrial robots. Automation is also utilized in the product category system,
which is an important stage affecting the quality of commercial goods.

The project " Designing an automatic product classification system " was
conducted in order to reinforce students' knowledge and at the same time help
them recognize the connection between the theoretical knowledge and the
practical applications and use. The topic has many important applications in
fields such as product transportation, counting and classification. With this
automation system labor and production cost can be reduced.

Given the broad range of general knowledge, there are multiple areas of
knowledge that I have not mastered despite having consulted technical documents.
Hence, when implementing the project " DESIGN OF MECHANICAL
ELECTRICAL SYSTEMS ", it is unavoidable that limitations and shortcomings
exist. We look forward to receiving constructive advice and the support of
lecturers and peers.

We sincerely thank the lecturers in the Department of Technology mechanical

and especially …, who has enthusiastically guided, created favorable conditions
and given us valuable knowledge for the completion of this subject project.

Thank you sincerely

3
 TABLE OF CONTENTS
FIGURE LIST.............................................................................................................6
CHAPTER 1:..............................................................................................................7
OVERVIEW OF THE PRODUCT CLASSIFICATION SYSTEM...................7
1.1 Definition and Application...........................................................................7
1.2 Working principle.........................................................................................7
CHAPTER 2:...........................................................................................................8
BASIC COMPONENTS OF THE SYSTEM........................................................8
2.1 Conveyor........................................................................................................8
2.3 Piston............................................................................................................14
2.4 Sensor...........................................................................................................15
2.5 Motor............................................................................................................16
2.5.1 Definition...............................................................................................17
2.5.2 Working Principle................................................................................17
CHAPTER 3:.........................................................................................................18
CALCULATION AND DESIGN OF THE SYSTEM COMPONENT............18
3.1 Conveyor system..........................................................................................19
3.1.1. Calculate the parameters of the conveyor geometric and kinetics. 19
3.1.2. Calculate the tensile force...................................................................21
3.1.3 Choose the roller (Active/Passive).......................................................23
3.1.4 Test strength of the belt.......................................................................27
3.1.5 Choose the motor..................................................................................27
3.1.6. Choose the external transmission......................................................30
3.2 Choose automatic work-piece feeding system...........................................35
3.3 Pneumatic system and cylinder calculation..............................................36
3.3.1 Introduction of compressed air system and components..................36
3.3.2 Calculate the piston..............................................................................38
3.3.3 Calculate the air compressor...............................................................39
4
 3.4 Choose sensor...........................................................................................41
CHAPTER 4:.........................................................................................................43
DESIGNING SYSTEM MODEL ON SOFTWARE..........................................43
4.1 Overview of SOLIDWORKS software......................................................43
4.2 Basic components of the system.................................................................44
4.2.1 Main frame............................................................................................44
4.2.2 Conveyor belt........................................................................................45
4.2.3 Feeding box...........................................................................................45
4.2.4 Roller.....................................................................................................45
4.2.5 Chain transmission...............................................................................46
4.3 Model of product.........................................................................................47

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 FIGURE LIST

Figure 2.1 Conveyor model in real life................................................................................8

Figure 2.2 Belt conveyor.....................................................................................................9
Figure 2.3 Chute conveyor.................................................................................................10
Figure 2.4 Gravity conveyor..............................................................................................10
Figure 2.5 Powered roller conveyor..................................................................................11
Figure 2.6 Bucket conveyor...............................................................................................11
Figure 2.7 Ball transfer conveyor......................................................................................12
Figure 2.8 Slat conveyor....................................................................................................12
Figure 2.9 Train conveyor.................................................................................................13
Figure 2.10 Trolley conveyor............................................................................................13
Figure 2.11 Structure of the piston....................................................................................15
Figure 2.12 How sensor works..........................................................................................16
Figure 2.13 Types of motor...............................................................................................16

Figure 3.1 Length of conveyor, distance between products..............................................19

Figure 3.2 Forces acting on conveyor................................................................................22
Figure 3.3 Active roller......................................................................................................23
Figure 3.4 Forces acting on roller......................................................................................24
Figure 3.5 Moment chart Oy..............................................................................................25
Figure 3.6 Moment chart Ox..............................................................................................26
Figure 3.7 TAILI-MINHMOTOR Speed control motor...................................................29
Figure 3.8 Forces acting on piston.....................................................................................38
Figure 3.9 DSNU piston catalog........................................................................................39
Figure 3.10 Piston’s journey..............................................................................................39
Figure 3.11 Air compressor Wing TW-OF750-25l -1HP..................................................40
Figure 3.12 Infrared sensor E18-D80NK..........................................................................41

Figure 4.1 Main frame.......................................................................................................44

Figure 4.2 Conveyor belt...................................................................................................45
Figure 4.3 Feeder...............................................................................................................45
Figure 4.4 Roller................................................................................................................46
Figure 4.5 Chain transmission...........................................................................................46
Figure 4.6 Large Sprocket.................................................................................................47
Figure 4.7 Small Sprocket.................................................................................................47
Figure 4.8 Model................................................................................................................48

6
 CHAPTER 1:
OVERVIEW OF THE PRODUCT CLASSIFICATION SYSTEM

1.1 Definition and Application

A product classification system is an automatic or semi-automatic control system
which categories products with similar feature for packaging or discarding flawed
products.
These types of systems include for example:
 Based on the control method: automatic or semi-automatic systems, without or
with human participation to a certain extent, controlled by PLC and microprocessor.
 By color: the color sensor will recognize the color and convert it to electrical
signal and then through an ADC converter to the processor.
 According to the weight, shape and size.

1.2 Working principle

 Based on sensors to classify types of products (cylinder and cube, its
height)
 Basic technical requirements of functional clusters in the system:
+ Conveyor speed is sufficient to achieve working productivity and engine with
enough capacity for stable operation of the transmission system.
+ The system of pushing work pieces with compressed air has low latency to
avoid affecting the product classification sensor.

7
 CHAPTER 2:
BASIC COMPONENTS OF THE SYSTEM

2.1 Conveyor

Figure 2.1 Conveyor model in real life

The main characteristics of conveyors for purposes of classification are the type
of traction and the load-carrying elements. A distinction is made between
conveyors with belt, chain, and cable drive elements and conveyors without a
drive element (gravitational, inertial, and screw conveyors). Conveyors with drive
elements can be differentiated by type of load-carrying elements into belt, apron,
cradle, flight, and bucket types. Such conveyors are characterized by movement of
the load together with the working element. The thrust is transmitted either by the
load-carrying element or by an element that pushes or pulls the material along a
fixed trough, tube, or bed. In conveyors without a drive element the movement
of the load is usually separate from the movement of the working elements, which
revolve in roller and screw conveyors or perform reciprocating motion in, for
example, inertial conveyors. Conveyors may have a machine drive (most often
electric; sometimes pneumatic), or the load may be moved by the force of gravity
(gravitational conveyors).

8
Advantages of conveyor belt:
- Simple structure, durable, capable of transporting separately and individually
in horizontal, inclined or a combination of horizontal and inclined.
- The investment capital is not very large, can be automated, simple operation,
easy maintenance, reliable work, high productivity and energy consumption
compared to other transport machines is not very large.
Types of conveyor belts on the market today
When designing a conveyor system to transport products to a sorting location, you
can choose from the following types of conveyors:

2.1 Belt Conveyor

Figure 2.2 Belt conveyor

This is probably what you picture when you think of a conveyor. They are simple
devices—a moving belt turned by pulleys—but are very useful. A motor is used to
turn the pulleys, thus moving the belt.

Chute Conveyor

9
 Figure 2.3 Chute conveyor

Picture a slide for your packages. Chute conveyors are metal slides used to
transport packages down to a lower level of your warehouse. They are cheap but
using them can increase the odds of packages bumping into each other and getting
damaged.

Gravity Roller Conveyor

Figure 2.4 Gravity roller conveyor

Instead of a belt, this device uses cylindrical rollers. It is built at a slight decline so
parts slide downward on their own.

10
Powered Roller Conveyor

Figure 2.5 Powered roller conveyor

This is like a gravity roller conveyor except a chain or belt is used to make the
rollers turn on their own, so they don’t have to be built on a decline. Sometimes
they can even go uphill.

Bucket Conveyor

Figure 2.6 Bucket conveyor

Grain elevators, which we discussed here, fall under this category. Bucket
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conveyor systems are used to move material vertically, by scooping it with a series
of buckets attached to a belt, chain, or cable. The conveyor moves the buckets
upward, scooping up the material, and carrying it to the top before dumping it out.
Ball Transfer Conveyor

Figure 2.7 Ball transfer conveyor

This type of conveyor system is described as: “Ball Transfer tables or conveyors
use a series of mounted ball casters to allow for unpowered, multi-directional
conveyance of the product.” Essentially, imagine rows of metal balls on a table
that can turn and rotate in any direction. This allows material to be pushed in
different directions (as opposed to rollers which can only go forwards and back).

Slat Conveyor

Figure 2.8 Slat conveyor

“A slat conveyor is basically a two-strand chain conveyor with slats connected

12
to the chain and a guiding system for the slats. This creates a smooth surface to
which tooling details or fixtures can be mounted to hold parts in the desired
position.”

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Chain Conveyor

Figure 2.9 Chain conveyor

These are exactly what they sound like. Instead of having rollers or a belt, they
have moving chains to carry products. They are usually low to the ground and are
used to carry larger items.

Trolley Conveyor

Figure 2.10 Trolley conveyor

There is a whole family of conveyors that carry their load beneath them instead of
on top of them. Sometimes the load is hung from an overhead beam and pushed
along. Other times they are motorized. Sometimes, as with the Power- and-Free
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Conveyor, they have two tracks—one motorized and one not motorized.

Because the conveyor is used in the system to transport products, in this project
I have chosen a belt conveyor for the following reasons:
- Conveyor load is not too large.
- The mechanical structure is not too complicated.
- Easy to design and manufacture.

However, this type of conveyor also has some disadvantages such as: the accuracy
when transporting is not high, sometimes the conveyor belts operate unstable due
to many factors: environmental temperature affects rollers, friction of the belt
drops through.

2.2 Piston
A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors, hydraulic cylinders and pneumatic cylinders, among other similar
mechanisms. It is the moving component that is contained by a cylinder and is
made gas-tight by piston rings. In an engine, its purpose is to transfer force from
expanding gas in the cylinder to the crank shaft via a piston rod and/or connecting
rod. In a pump, the function is reversed and force is transferred from the
crankshaft to the piston for the purpose of compressing or ejecting the
fluid in the cylinder. In some engines, the piston also acts as a valve by covering
and uncovering ports in the cylinder.

The piston is usually cylindrical, divided into 3 parts including the pavilion,
head and body:
- In the piston nails, there are 3 types of convex, concave and equal. Each piston
peak receives high temperature gas pressure. The piston head section has oil ring
grooves and cement rings when used for mounting in the device. The grape
holes at the top of the oil capacity are opened into the bottom of the trench to
perform the task of supplying and escaping. The number of ring slots depends on
the engine type. On the piston body, there are horizontal holes, performing the
task of guiding the piston to move in the cylinder to transmit the force to rotate the
crankshaft when linked with the transmission rod to perform the function of
mounting the piston connecting pin and the transmission rod. The body of a diesel
engine's piston is usually longer than the piston body of a gasoline engine and the
base usually has an additional 1-2 rings of oil ring. In order to facilitate the air
conditioning when working from the carburetor to the engine crankcase, the piston
15
body of the two-stroke engine does not have a gas cylinder with a bottom hole or a
defect.

Working principle of the piston:

- The piston base is compressed at a certain temperature and pressure, the piston
operates automatically through the compressed air supply. Thanks to the
difference between the pressure at the outside school and the pressure level in
the piston act to supply the piston. The source of compressed air is the energy
that helps the piston work. Pistons can go all the way, requiring gas in the piston
to be discharged. When there is a type of pneumatic electronic valve in the
piston that causes the air to expand, the compressed air is converted into kinetic
energy. In the piston cavity, air will be compressed when supplying gas to the
piston. Energy is generated and transformation is performed. This amount of gas
generates work that helps the device work while taking up the space inside the
piston, causing the piston to move. Therefore, depending on the performance of
the device, the piston operates in a variety of methods to regulate intermediate
stops. At the same time control the amount of expansion or retraction of the
piston rod

Figure 2.11 Structure of a piston

2.3 Sensor
In general, sensor is known as a Detector. A sensor is an electronic equipment that is
used to detect and observe the physical activities and pass the notification/signal to other
electrical control devices. In other words, a sensor is an electronic device that can
transform energy from one form to another form. So, it is also called a
Transducer. The main function of the sensor is to identify and communicate with
physical quantities such as temperature, heat, pressure, distance, moisture, gas, and so
16
on. And it provides output in the form of electrical signal to connected control systems.

Figure 2.12 How sensor works

According to the principle of the sensor there are:

- Resistance sensor
- Electromagnetic sensors
- Electrostatic sensor
- Electrochemical sensor
- Thermoelectric sensor
- Electronic and ion sensors
According to the nature of the power source:
- Generator sensor
- Parameter sensor
According to the measuring method:
- Direct variable sensor
- Compensation sensor

2.4 Motor

17
Figure 2.13 Motor

2.5.1 Definition
Electric motors in general and DC motors in particular are rotating electromagnetic
devices, working according to the electromagnetic principle, when placed in a magnetic
field by a conductor and allowing current to flow through the conductor to make the coil
move. An electric motor converts electrical energy into mechanical energy.

2.5.2 Working Principle

The stator of a DC motor is usually one or more pairs of permanent magnets, or
electromagnets, the rotor has windings and is connected to a DC power source, another
important part of a DC motor is rectifier, it is responsible for changing the direction of
current while the rotation of the rotor is continuous. Usually this part consists of a
commutator and a set of brushes in contact with the commutator.

If the shaft of a DC motor is pulled by an external force, the motor will act as a
DC generator, and generate an induced Electromotive force (EMF). During
normal operation, the rotor when rotating will generate a voltage called counter-
EMF (CEMF), because it opposes the external voltage applied to the motor. This
electromotive force is similar to that generated when the motor is used as a
generator (like when we connect a load resistor to the motor output, and pull the
motor shaft by an external torque). Thus, the voltage applied to the motor consists
of two components: the electromotive force, and the voltage drop caused by the
internal resistance of the armature windings.

18
 CHAPTER 3: CALCULATION AND DESIGN OF THE
SYSTEM COMPONENT

*Overview of transmission system:

With: 1. Motor, 2. Clutch, 3. Gearbox, 4. Chain drive, 5. Conveyor

Electric motors usually have high rotation speed. So the rotation from the
motor will be reduced through the gearbox, then reduced again through the chain
drive and transmit to the conveyor in order to reach optimal working speed.

For my project, I choose motor with built in gear box, focus on designing the chain
drive system and the conveyor

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 3.1 Conveyor system
- Input parameters
+ Geometrical parameters of products:
Cubes: h1=3 (cm) h2=4 (cm) h3=5 (cm)
+ Weight of block: Qmin = 0.5kg Qmax = 6.5 kg
+ Working capacity: N = 20 block/min
+ Source of power: Electrical motor

Figure 3.1 Length of conveyor, distance between products

3.1.1 Calculate the parameters of the conveyor geometric and kinetics

- Find L:
• L = d + (n-1). Y
Where: n is the number of product on the conveyer at 1 time (n=4)
d is the diameter of products (d=0.05m)
Y is the distance between the center of 2 products (choose
Y=0.3m)
=> L = 0.05 + (4 - 1).0.3 = 0.95(m) Choose L=1.3m

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 - Find W:

Y 2(M + W )
- v > v1

With: Y is the distance between the center 2 products (choose Y=0.3m)

v is the speed of the conveyor
v 1 is the speed of the pistons (choose FESTO brand)

M is the distance from product’s edge to the conveyor’s edge

(choose M=0)
- Time to object go over the conveyor:
60 60
t= . nmax = .4=12 ( s )
N 20

- Conveyor’s speed:
L 1300
v= = =108.33 (mm/s)
t 12

Find v 1 by catalog from FESTO:

21
 Choose DSNU-20-200, v 1=0.5(m/s) at Qmax = 6.5 kg
0.3 2. ( 0+W )
=> > => W<0.69(m)
0.1083 0.5

Width of the conveyor should also longer than the diameter of product.
Choose W=0.15m
- Choose conveyor: PVC 3mm
 L = 1.3 m
 H = 3 mm
 W = 0.15 m
 Frame structure: Shaped aluminum
I choose PVC conveyor belt because of these advantages: Wear and scratch
resistant, Broad range in types, Easy the rework, Price friendly, Easy to clean, Oil
and grease resistant
3.1.2 Calculate tensile force
- Analysis forces applied on the conveyor belt
Primary tensile force:
+ Friction force between surface of belt and roller made by weight of blocks and
belt
+Initial belt tension

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Tension at point S1 => S4: Si = Si−1 + W i−1 /i
With: W i−1 /i is the drag force from point (i-1) to point (i).
At special point S1:
+) S1 = S0 + W0/1 = S0 +q0Lw = S0 + 5.51 × 1.3 × 0.4 = S0 + 2.86 (N)
With: q 0 is the weight per 1m of belt
q0 = ρ.W.H.g = 1250*0.15*0.003*9.8 = 5.51 (N/m)
(ρ: Specific weight)
w=0.2÷0.4 (Choose w=0.4)
W 1 /2 = ξ. S1 = 0.06.( S0 + 2.86)

With: ξ = 0,03 ÷ 0,06 (Choose ξ =0.06)

+) S2 = S1 + W 12 = S0 + 2.86 + 0.06.( S0 + 2.86) = 1.06 S0 + 3.03 (N)

W 2 /3 = ¿L + Qt )w = (5.51*1.5 + 215.6)* 0.4 = 89.55 (N)

With: Qt is the total weight put on the belt (Qt = (6.5*4)*9.8 = 215.6 (N) )
max

+) S3 = S2 + W2/3 = 1.06S0 + 92.57(N)

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-Band drag force is the force transmitted from the guide drum to the belt
F = S3 – S0 = ΣW i−1 /i = 2.86 + 0.06 S0 + 0.172 + 89.55 = 0.06 S0 + 92.58 (N)
So to determine the drag force F we need to know the value of S0. The force S0
can be determined from the condition of sufficient frictional force to transmit
force at the path:
S3 ≤ S0.efα
F = S3 - S0 ≤ S0.(efα - 1)
With: α: angle of embrace of the tape on tang , α = π
f: coefficient of friction between the tape and the tang (0.2 ~ 0.4).
Choose f = 0.4
=> 0.06 S0 + 92.58 ≤ S0 .(e 0.4 π −1)
=> S0 ≥ 61.46 (N)
Choose S0 = 100(N) => S3 = 351.35(N) => F = 251.35 (N)
-Power required on tang axis:
F.v 251.35 .0.108
N yc = (KW) = = 0.0271 (KW) = 27.2 (W)
1000 1000
-Required moment on tang shaft:
M = F.d/2 =251.35x0.06/2 = 7.54 N/m

Conveyor’s parameter Symbol Value

Length L 1500 mm
Width W 150 mm
Thickness H 3 mm
Maximum number of products on tape at one n 4 products
time
Distance between workpieces Y 300 mm
Conveyor speed v 0.108 m/s
Active tang shaft diameter (follow the 60 mm

24
conveyor’s width)
Total weight on conveyor Qt 215.6 N
Conveyor traction F 251.35 N
Power on tang shaft Nyc 27.2 W

3.1.3 Test strength of the belt

Rubber belt thickness = 3mm. PVC belt
Maximum strength available = 8 (N/mm)
Mass of belt per m2 = 2.5kg/m2

3.1.4 Choose the motor

Calculate : Pct - required power of motor’s shaft
n sb - preliminary revolution (số vong quay sơ bộ)

P lv
We have: 𝑃𝑐𝑡 =
ŋ
With: Plv is the power of the transmission
ŋ is the efficiency of the transmission

F.v
Plv = =27.2 (W)
1000

ŋ = ŋol .ŋol . ŋol . ŋbr . ŋ x (Look up table 2.3)

25
 𝜼 = 𝜂𝑜𝑙 × 𝜂𝑥× 𝜂br = 0.99 × 0.93× 0.97 ≈ 𝟎. 89
27.2
 𝑃𝑐𝑡 = 0.89 = 30.56 (W)

26
 We have: 𝑛𝑠𝑏 = 𝑛𝑙𝑣. 𝑢𝑐
60.V 60 ×0.108
𝑛𝑙𝑣 = π . d (roller ) = π × 0.06 = 34.38 (rpm)

uc = ubr. ux =2×3 =6 with:ubr =3 :preliminary gear ratio of chain transmission

u x =2 :gear ratio of motor transmission

 n sb = 34.38×2×3 = 206.28 (rpm)

From the catalog above:

¿ Pct = 0.03 kW and n sb = 412.56 rpm. I motor DS-42RP7750247000-13K with:
Pmotor = 30.68 W

n motor = 199.3 rpm

27
 3.1.5 Choose the external transmission
-Transmission power: P1 = 30.68 W
ndc
- Transmission ratio: Ux = u ∗n = 1.93
br lv

ndc 199.3
- Number of driving sprocket revolutions: n1 = u = 3 = 66.43 rpm
br

n1
- Number of driven sprocket revolutions: n2 = U = 34.38 rpm
X

- Transmission chain’s power: P2 = P1* 𝜂𝑥 = 30.68 *0.93 = 28.53 W

- Select chain drive tilt angle: = 30°
- Select chain type: roller chain.
6
P 1 ×9.55 × 10
- Torque: Mz1 = n1 = 4411 (Nmm)

6
P 2 × 9.55× 10
Mz2 = n2 = 4101 (Nmm)

(*) Choose gear:

 Z1 ≥ 29 - 2Ux = 29-2×1.93 = 25.14 >19
¿> Z 1= 25

 Z 2= Z1 ×Ux = 23×1.93 = 48.25 ≤ (Zmax = 120)

¿> Z 2= 49

 Actual gear ratio:

Z2 49
ut = Z = 25 = 1.96
1

 ∆u ¿ | |
ut −u
u
× 100 %= |
1.96−1.93
1.93 |
×100 %=1.55 % <4 %

 Qualified
(*) Determine the chain step t:

28
 Pt = P1. k. kz. kn ≤ [P]
Choose experimental gear with Z01=25 and n01 =50 rpm
Z 01 25
Tooth form factor: kz = Z = 25 =1.0
1

n01 50
Revolution coefficient: kn = n = 66.43 =0.75
1

29
𝑘0 = 1 𝑏𝑒𝑐𝑎𝑢𝑠𝑒 𝛽 = 30°
𝑘𝑎 = 1 𝑏𝑒𝑐𝑎𝑢𝑠𝑒 𝑎 = (30÷50)p
k dc= 1.25 𝑖𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑖𝑠 𝑛𝑜𝑡 𝑎𝑑𝑗𝑢𝑠𝑡𝑎𝑏𝑙𝑒 𝑜𝑟 𝑑𝑜𝑒𝑠 𝑛𝑜𝑡 ℎ𝑎𝑣𝑒 𝑎 𝑐ℎ𝑎𝑖𝑛 𝑟𝑜𝑙𝑙𝑒𝑟

k bt = 1.3 𝑓𝑜𝑟 𝑝𝑒𝑟𝑖𝑜𝑑𝑖𝑐 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑖𝑜𝑛

k d = 1.2 𝑓𝑜𝑟 normal impact 𝑤𝑜𝑟𝑘𝑖𝑛𝑔

k c = 1 𝑓𝑜𝑟 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑜𝑛𝑙𝑦 1 𝑠ℎ𝑖𝑓𝑡

k = 1×1×1.25×1.3×1×1= 1.63
 Pt = P1.k.kz.kn =30.68×1.63×1×0.75 = 37.51 (W) = 0.037 (KW)

From table 5.5, we have: Pt < [ P ]=190W

• Chain pitch p = t =12.7 mm ; Pipe length B = 5.80mm
• Pin diameter dc = 3.66mm ; Allowable power [P] = 0.19 (kW)

30
(*) Determine the shaft distance and the number of links
 Preliminary axis selection:
a=40×t = 40×12.7=508 (mm)
 Number of links
2
2 a Z + Z (Z −Z ) t
x = + 1 2 + 2 2 1 =117.4
t 2 4π a
Choose x=118
 Recalculate a:

4
Z +Z
a* = t [ x− 1 2 +
2
= 512.05 (mm)
√( x−
2 ) (
Z1 + Z 2 2
−2
π )
Z 2−Z 1 2
]

In order for the chain not to be too tight, it is necessary to reduce by 𝑎 an

amount:
∆a = 0.003× a* = 1.54
a = a* - ∆a = 510.51(mm)

 Number of chain impact i:

z 1 × n1 25 ×66.43
i= = =0.94< [ i ] =60 => Satisfied
15 × x 15 × 118
Test chain durability:
Q
s= k . F + F + F ≥ [s]
đ t o v

With t = 12,7mm , d c =3,66mm , B=5.8mm. Search up table 5.2

- Q =18,200 (N)
- Weight of 1m of chain: q = 0.65 (kg)
- k đ =1
z 1 × n1 × t 25 ×66.43 ×12.7
- v chain= = =0.35(m/s)
60,000 60,000

31
 1000 P1 1000× 0.037
- Lực vòng: Ft = = = 105.71 (N)
v chain 0.35

- Lực căng do lực li tâm sinh ra: F v = q. v chain2 = 0.65 × 0.352 = 0.08 N

- Lực căng do trọng lượng nhánh xích bị động sinh ra

F o=9.81 × k f × q ×a = 9.81× 4× 0.65× 0.5105 = 13.02 N

- k f = 4 with β > 40o _

hệ số phụ thuộc độ võng của xích
- [s ] =7.8 with t=12,7 and n1=67.43 rpm from table 5.10

Q 18200
 s = k . F + F + F = 1× 105.71+ 13.02+ 0.08 = 153.18 ≥ [s] => Satisfied
đ t o v

Determine the parameter of the sprocket:

 Split chain links diameter:
t 12.7
d1 = π
sin ⁡( ) = sin ⁡( ) = 101.33 (mm)
π
Z1 25
t 12.7
d2 = π
sin ⁡( ) = sin ⁡( ) = 198.22 (mm)
π
Z2 49
 Tooth nail diameter:
π π
d a 1 = t. [0,5 + cotg( )] = 12.7× [0.5 + cotg( ) ] = 106.88 (mm)
Z1 25
π π
d a 2 = t. [0,5 + cotg( )] = 12.7× [0.5 + cotg( ) ] = 204.16 (mm)
Z2 49

 Tooth root dimeter:

d f 1= d 1 - 2.r = 101.33 – 2× 4.33 = 92.67 (mm)

d f 2= d 2 - 2.r = 198.22 – 2× 4.33 = 189.56(mm)

With r = 0.5025.d l + 0,05

d l = 8.51 from table 5.2

 r = 0.5025× 8.51 + 0.05 = 4.33 (mm)

32
  Test sprocket teeth for contact strength:

With: K đ = 1
√
σ H = 0.47. k r ( F t . K đ + F vđ ) . E
A . kd

A = 39,6mm2 with t= 12,7mm from Table 5.12

kr = 0.48 with z1 = 25
kd = 1 (only 1 chain)
𝐹𝑣đ = 13. 10−7𝑛1t3 = 13× 10−7× 66.43× 12.73 = 0.18 N
2 E 1 E2
E = E E = 2.1× 105 MPa because E1 = E2 = 2.1× 105 Mpa (steel)
1 2

Substituting we have:

√
5
σ H = 0.47 0.48 × ( 105.71 ×1+0.18 ) . 2.1 ×10 = 238.13 Mpa
39.6 ×1
Looking at Table 5.11 [1], we choose the sprocket material as gray cast iron,
with the characteristics of a passive disc with a large number of teeth (z > 50), with
a small chain speed (v < 3 m/s), [𝜎𝐻] = 650 𝑀𝑃𝑎 ≥ 𝜎𝐻 = 209.38 𝑀𝑃𝑎
 Determining the force acting on the shaft:
Fr = kx. Ft With: kx = 1.155 with β > 40°
 Fr = 1.15×105.71 = 122.09 N

Summary of transmission parameter:

Specification Parameter Value
Chain type Roller hose
chain
Chain step t 12.7 mm
Number of links x 118
Shaft distance a 510.51 (mm)
Small sprocket tooth number z1 25
Large sprocket tooth number z2 49

33
 Sprocket material Grey cast iron
Small sprocket ring diameter d1 101.33 (mm)
Large sprocket ring diameter d2 198.22 (mm)
Small sprocket top ring diameter da1 106.88 (mm)
Large sprocket top ring diameter da2 204.16 (mm)
Bottom radious r 4.33 (mm)
Small sprocket tooth diameter df1 92.67 (mm)
Large sprocket tooth diameter df2 189.56 (mm)
Force acting on the shaft Fr 122.09 (N)
3.1.6. Determine tang shaft
Begined datas: 𝑃1 = 30.68𝑊
𝑛1 = 66.43 rpm
Select the material to make the shaft is C45 steel with stress σ b=600 MPa , allow
stress [τ ] = 12...30 Mpa
Preliminary determination of shaft diameter

dsb ≥
√
3 T
0.2 × [ τ ]

 T=Mz1: Torque on shaft

6 −3 6
P × 9.55 .10 30.68 ×10 × 9.55 ×10
T1 = = = 4410.68 Nmm
n 66.43
 [τ ] : allow stress. Choose [τ ] = 15 MPa

√
dsb ≥ 3 4410.68 =¿11.37 (mm)
0.2 ×15

Choose dsb = 20 mm

 Determine the forces acting

34
- Force from sprocket: Fr(chain)= Fr = 122.09 N
+ Frx = Fr× sin (30) = 61.05 (N)
+ Fry = Fr ×cos (30) = 105.73 (N)
- Force acting from the conveyor:
+ Conveyor belt traction: F =251.9 N
+ Weight of workpiece:
P1=M max × 9.8=6.5 × 9.8=63.7 ( N )

- Lead’s Weight:

() ( )
2 2
d 0.06
P2=W × π × × Dsteel × g=0.15 × π × × 7800× 9.81
2 2
¿ 32.45(N )
Where: d is the diameter of the previously selected tang d=60mm
Determine the diameter of the shaft segments

- Reactions at the drives:

−F rx . AC −F . AP −61.05 ×251.9−251.36 ×117
X B= = =−194.73 ( N )
AB 230
F ry . AC + ( P1 + P2 ) . AP 105.73× 251.9+ ( 63.7+ 32.45 ) .117
Y B= =
AB 230

= 164.71 (N)
XA = -F – F rx - XB = -251.36 – 61.05 +194.73= -117.68 (N)
YA = P1 + P2 + Fry – YB = 63.7 + 32.45 +105.73 – 164.71 = 37.17 (N)

35
From the moment diagram we see the most dangerous position at points P and B
M tđ =√ M x2 + M y 2 +0 ,75 M z2

Equivalent moments at positions are:

M tđP =√ 13768.562 +4348.892 +0.75 × 41012=14869 ( Nmm )

M tđB =√ 1337.282+ 2305.682 +0.75 × 41012=4440 ( Nmm )

36
Look up table 10.5 with 45 steel 60mm diameter we have [σ P]=50 MPa
20 mm diameter [σB]=63 Mpa

The shaft diameter at the cross section is determined by the formula:

d P≥
√
3 M tđP
0.1× [ σ P ]
=
√ 3 14869
0.1 ×50
=14.38 ( mm )

d B≥
√
3 M tđB
0.1 × [ σ B ] √
=
3 4440
0.1 ×63
=9.00 ( mm )

 Choosing the diameter for shafts

 Diameter of shaft B and shaft A are 20 mm.
 Diameter of shaft between shaft A and P is 25 mm
 Diameter of shaft P is 60 mm.
 Diameter of shaft C is 16 mm.

37
 3.1.7. Select and proof bearings
Select bearing type
Because the shaft does not bear the axial force, we choose a single row ball
bearing.
With advantages:
+ Low cost
+ Small friction loss, less dependent on lubrication
+ High interchangeability, convenient to replace, repair or maintain.

38
  Select bearing size

Look up table P2.7[1], with a shaft diameter of 20 mm, we get a bearing with:
+ Signboard 1000904
+ Inner diameter d = 20 mm
+ Outer diameter D = 37 mm
+ Thickness B = 9 mm
+ Dynamic load C = 5.14 kN
+ Static load C0 = 3.12 kN

39
 3.1.7 choosing key
With d=20 mm
→ Sprocket mayo length: lm = (1,2 1,5).d = 24 30 (mm)
Chọn lm = 27 mm

- Looking up table 9.1a, we can choose then with parameters:

+ Width: b = 6 mm
+ Thickness: h = 6 mm
+ Depth on shaft: t1 = 3.5 mm
+ Depth on hole: t2 = 2.8 mm
+ Then length l = (0.8 ~ 0.9). lm = (0.8 ~ 0.9). 27 = (21.6 ~ 24.3); Choose l = 23 mm

40
 Key and bearing parameters Symbols Value
Bearing inner diameter d 20 mm
Outer diameter of bearing D 37 mm
Thickness B 9 mm
Chain mayor length lm 27 mm
Key width b 6 mm
Key thickness h 6 mm
Key length l 23 mm

3.2. Choose automatic work-piece feeding system

At present, the production processes of products in the general industry
are developing in the direction of increasing automation. In order to
ensure a stable and fast production process, it is necessary to have an
accurate supply of work- pieces in space in accordance with the right
span (timed feeding) and continuously according to the operating cycle of
the line.
Therefore, the bar feeding process is one necessary requirement that need
to be studied and solved in automatic production systems in order to
improve labor productivity and product quality. The automatic bar
feeding system must provide the work-piece in a timely, accurate and
quantity manner.
As a bar feeding mechanism, the product enters the conveyor, the output
product is divided equally and the products come out a certain time apart
to suit the capacity and conveyor’s speed.
Comment: Each type of embryo level above has its own characteristics
and in each type also includes many different forms. Depending on the
production technology, people are arranged to supply the work-piece
continuously or paste the section according to the cycle or to supply the
work-piece according to the order.
In this project, I use a cyclical intermittent bar feeding system and work- pieces
are cylinders of equal diameter, the main difference is in height
3.3 Pneumatic and piston system

41
 3.3.1 Introduction of compressed air system and components
Pneumatic Systems (Pneumatic Systems) are widely used in the
assembly and processing industry, especially in areas where hygiene,
explosion-proof or hazardous environments are required. For example,
the field of electronic assembly, food processing, product sorting and
packaging stages of automatic production lines; in the mechanical
processing industry…
+ Advantages:

- Because air is compressible (elastic), it can be compressed and

extracted into a container with favorable high pressure, as a store
of energy.
- Capable of transmitting long distances by pipeline system with
small loss, compressed air after mechanical work can be
discharged without causing harm to the environment;
- High drive speed, flexible, easy to control with reliability and accuracy;
- There are effective solutions and devices to prevent overload and
overpressure;
+ Disadvantages:

- Transmission power is not large. At the need of large transmission

power, the cost of pneumatic transmission will be 10-15 times
higher than electric drive of the same capacity, but the size and
weight are only 30% of that of electric drive;
- When the load changes, the transmission speed always tends to
change because the elasticity of the compressed air is quite large,
so the ability to maintain a straight or uniform motion is often
difficult to achieve.
- Compressed air is released into the environment which can cause noise.
+ The structure of the compressed air system (The structure of
Pneumatic Systems):
Usually includes the following device blocks:

- Power station: Air compressor, accumulator, safety devices,

42
 compressed air treatment equipment (dust filter, steam filter,
dryer, …)

- Control block: control signal processing elements and actuators

reversing control elements.

- Block of actuators: Cylinder, pneumatic engine, suction cup.

+ Components of the compressed air system:

Compressed air source: In industry, according to production scale,

people often build several compressed air stations for production with
different purposes. If the compressed air system wants to work stably,
continuously and reliably, the compressed air source must be stabilized
in pressure, sprayed with lubricating oil for the control elements,
actuators..., so it should be equipped with a series of elements in series
such as air compressor with constant stroke volume, accumulator, steam
filter, oiler, pressure regulating valve with overflow gate, ...

- Compressed air treatment equipment: Chemical drying

equipment, filters and physical drying equipment, service
conditioners.

- Compressed air distribution: Usually consists of a system of pipes

to distribute compressed air to the required place.
The actuators: have the function of converting the energy accumulated in the
compressed air into kinetic energy.

3.3.2 Selection of cylinder piston used in the system

Due to the characteristics of the fast acting cylinder, the stroke is not
large and fixed, so we choose the two-way acting cylinder used in the
system. The two-way acting cylinder helps the system to be controlled in
a fully automatic and precise manner.

43
 3.3.2 Calculate the piston

D d
F Pmsmax

p1 p2

Figure 3.8 Forces acting on piston

Input : Maximum work piece mass : 𝑚 = 6.5 𝑘𝑔

Friction coefficient 𝑓 = 0.3
Stroke S = 150 𝑚𝑚
2
p1 π D
Pressure create by the piston: F= .µ
4

With: D: Bore size

p1: Working pressure

µ: efficiency factor of the cylinder

Most pneumatic cylinders work under dynamic loads. Then due to friction
loss, due to the elasticity of compressed air under load changes, due to the inertia
of the piston before moving, so the efficiency factor 𝜇 = 0.5
Preliminary selection of working pressure of the system p =5 bar =5. 105 N/m2
In order for piston to move:
2
p1 π D
F= µ ≥ Fms max
4

44
 With: F ms max =f∗P max∗g=0.3∗6. 5∗10=19.5 N .

 D≥ 4×
√ Fms max
p µπ √
= 4× 5
19.5
5.10 ∗0.5∗3.14
=9.97 mm

Choose D = 25mm.
With D=25mm and S=150mm, I choose piston DSNU with specification:

Figure 3.9 DSNU piston catalog

Piston D=25mm
Stroke H = 150mm
3.3.3 Calculate air compressor
y 0.3
Time between activations of piston:∆ t= v = 0.108 =2.78 (s) = t1 +t2

Choose t1 = 1.78 s; t2 = 1 s.

Figure 3.10 Piston journey

S 0.15
v 1= =
t 1 1.78
= 0.08 (m/s)

45
 S 0.15
v 2= =
t2 1
= 0.15 (m/s)

The amount of air needed for 1 piston to work:

q = A. (v1 +v2) = 0.0005× (0.08 + 0.15) = 1.15× 10-4 (m3/s) = 0.01 (l/min)
2 2
πD π × 0.025
With: A = = = 0.0005 (m2)
4 4

The system uses 3 pistons => The tank size required for air compressor: V = 3.q =
0.05 liters
I choose Wing TW-OF750-25l -1HP air compressor with volume of 25l.

Figure 3.11 Air compressor Wing TW-OF750-25l -1HP

Figure 3.12 Infrared sensor E18-D80NK

 Power supply: 5VDC.

 Detection distance: 3~80cm.

46
  The distance through the rheostat can be adjusted.

 Output current: 300mA.

 Open-collector NPN output helps to customize the output voltage,

the higher the voltage, the higher the output voltage will be.

 Product material: plastic.

 There is led to display red output.

 Dimensions: 1.8cm (D) x 7.0cm (L).

REFERNCE DOCUMENT
[1] Tính toán thiết kế hệ dẫn động cơ khí tập 1, PGS. TS Trịnh Chất – TS Lê Văn
Uyển, NXB GD.
[2] Chi tiết máy (tập 1+2), Nguyễn Trọng Hiệp, NXB GD.

47