Abstract
Now a day it is most acceptable that any new ideas/or designed model should be cost effective and space effective. We have such type new ideas to design a model in which we have single motor/or prime mover to run two driver shafts and by the way to run four driven shafts which are connected through electromagnetic clutch with driver shafts. As there is only single motor/or prime mover it is effective for their installation cost and maintenance cost. Also it is effective for space utilization and to reduce electricity cost/or fuel cost.
Table of contents
Title page
Certificate
Compliance certificate
Acknowledgment
Abstract
Chapter 1
Introduction
1.1
Problem of current mechanism
Chapter 2
Detail description of clutch
2.1
Definition of clutch
2.2
Purpose
2.3
Principal of operation
2.4
Requirement of clutch
2.5
Types of clutch
Chapter 3
Literature review
Chapter 4
Design of project
4.1
Design of sprocket
4.2
Design of chain
4.3
Design of shaft
4.4
Design of friction lining
4.5
Dimension of spring
4.6
Design of armature
Chapter 5
Detail and description of project
5.1
Introduction of electromagnetic clutch
5.2
Basic operation of electromagnetic clutch
5.3
Schematic diagram of project
5.4
How to work
5.5
Applications
5.6
Advantages
5.7
Limitations
Chapter 6
Work plan
Conclusion
References
Chapter 1: Introduction
PROBLEM OF CURRENT MECHANISM
1. Space problem for industries:-
• In these days in a clutch system different motors are connected with the different shafts so we required more space for this mechanism.
2. Maintenance problem:-
• We used more than one motor so risk of fire is increase in motor.
• Many motors are required so maintenance cost high.
3. Electricity problem:-
• In this system more than one motor is used so maximum power required.
• Power requirement is more so cost is maximum so this cost affecting the production cost.
Chapter 2: Detail description of Clutch
2.1 Definition of clutch
The clutch is an important part in the transmission system of automobiles. It transmits power from the engine to gear box at various speeds. No shock is caused during this transmission of power.
2.2 Purpose
The function of the clutch is to temporarily disconnect the engine from the gear box unit. When the gear has to be changed from the first to the second, it should be done after disconnecting the engine from the gear box. If this is not done, the gear teeth might break. The clutch is thus helpful when starting, shifting gears and idling.
2.3 Principle of operation
The clutch works on the principles of friction. When two friction surfaces are brought in contact with each other and pressed they are united due to the friction between them.
If no one is resolved, the other will also revolve. The friction between the two surfaces depends upon the area of the surfaces, pressure applied upon them and co-efficient of friction of the surface materials. The two surfaces can be separated and brought into contact when required.
The driving member is kept rotating. When the driven member is brought in contact with the driving member, it also starts rotating. When the driven member is separated from the driving member it does not revolve. This is the principle on which a clutch operates.
2.4 Requirement of clutch
1. Torque transmission: – The clutch should be able to transmit maximum torque of the engine.
2. Gradual engagement: – The clutch should engage gradually to avoid sudden jerks.
3. Heat dissipation: – The clutch should be able to dissipate large amount of heat which is generated during the clutch operation due to friction.
4. Dynamic balancing: – The clutch should be dynamically balanced. This is particularly required in the case of high speed engine clutches.
5. Vibrating damping: – The clutch should have suitable mechanism to damp vibrations and to eliminate noise produced during the power transmission.
6. Size: – The clutch should be as small as possible in size so that it will occupy minimum space.
7. Free pedal play: – The clutch should have free pedal play in order to reduce effective clamping load on the carbon thrust bearing and wear on it.
8. Easy in operation: – The clutch should be easy to operate requiring as little exertion as possible on the part of the driver.
9. Lightness: – The driven member of the clutch should be made as light as possible so that it will not continue to rotate for any length of time after the clutch has been disengaged.
2.5 Types of clutch
Different types of clutches are as follows:
Friction clutch
Single plate clutch
Multi plate clutch
Wet clutch
Dry clutch
Cone Clutch
Internal clutch
External clutch
Centrifugal clutch
Diaphragm clutch
Positive clutch
Hydraulic clutch
Electromagnetic clutch
Vacuum clutch
Chapter 3: Literature Survey
Paper no.1
ELECTRO MAGNETIC CLUTCH
Jeyakkannan,shankar vignesh,prakash
The clutch is an important part in the transmission system of automobiles. It transmits power from the engine to gear box at various speeds. No shock is caused during this transmission of power.The function of the clutch is to temporarily disconnect the engine from the gear box unit. When the gear has to be changed from the first to the second it should be done after disconnecting the engine from the gear box. If this is not done the gear teeth might break. The clutch is thus helpful when starting, shifting gears and idling
This project work titled “ELECTRO MAGNETIC CLUTCH” has been conceived having studied the automatic clutch mechanism in vehicles. Now the project has mainly concentrated on a suitable control unit has been designed for automatic clutch. The fabrication part of it has been considered with almost case for its simplicity and economy, such that this can be accommodated as one of the essential tools on automobile garages. In our project, the switch is fixed below the braking pedal of the four wheeler.
The design and fabrication of electromagnetic clutch was carried out successfully meeting the required design standard. The magnetic clutch can be design for easy driving and safety of the driver. Hence its wide application in automobile. So it can be recommend for engineering industry and for commercial application.
Paper no.2
Design and Working of Electromagnetic Clutch to Reduce Wear and Slip
Lokesh rama naik,Anjanakumar H.M,Durgesh shridhar naik
The electromagnetic clutch is very important in vehicles and machinery to transmit the power from driving member to driven member by using clutch linkage. Already the electromagnetic clutch exists, but that clutch has number of problems like wear problem, slipping problem and complicated linkages. Hence for avoiding these problems we have designed a new electromagnetic clutch. In this new electromagnetic clutch the splines are used instead of clutch material (Friction plate & Clutch plate).
A clutch axle is provided with the splines on it, which is engaged with the spur gear and in sliding will disengage with spur gear. Here in this electromagnetic clutch, when clutch is actuated, current flows through the electromagnetic coil producing a magnetic field. The rotor portion of clutch becomes magnetized and sets up a magnetic loop that attracts the armature. The armature is pulled next to the rotor and a frictional force is generated. When current is removed from clutch, the armature is free to rotate the shaft, springs hold the armature away from the rotor surface when power is released, hence creating a small air gap. The new electromagnetic clutch which is free from slipping and hence it produce the smooth power, so there is no wear problem occur in newly generated electromagnetic clutch. In this electromagnetic clutch less number of linkages have used and takes less space in the vehicles.
Paper no.3
Design and Fabrication of Regenerative Clutch Assembly Model
Sanjulal T S, Ajith kurikn baby
Electromagnetic clutches are made to operate electrically and transmit torque mechanically. This is why they used to be referred to as electro-mechanical clutches. Over the years, EM became known as electromagnetic versus electro mechanical, referring more about their actuation method versus physical operation. Since the clutches started becoming popular over 60 years ago, the variety of applications and clutch designs has increased dramatically, but the basic operation remains the same. Single face clutches make up approximately 90% of all electromagnetic clutch sales.
This paper aims at introducing a regenerating clutching system model. A regenerative braking system is a common now a days, but this concept is different. Here electromagnetic clutches are used for power generation. A model was developed for utilizing the energy during clutch operation in four wheelers or two wheelers.
Electrical power is generated through clutch system while clutch is in disengaged position. By this arrangement we can generate excess electrical power which can be used to function additional electrical accessories fitted to vehicles in the recent days. Effective recovery of waste energy is successfully attained with the help of electromagnetic clutch and limit switch assembly.
In this work a small conceptual model is created and a motor is used as a substitute of an IC engine for delivering power. This project made up of the following parts; dynamo, battery, wheel, Alternating Current motor and electromagnetic clutch.
Paper no. 4
Fabrication of Electromagnetic Clutches & Braking System
Kunal Saurabh, Ayush Gupta
The electromagnetic clutch is a device which is used for engagement and disengagement electromagnetically with the help of electromagnet and a relay with provides better usage of an electromagnet to stop and apply different clutch and brakes. Therefore activating the unit with electric current, the coil gets energized and current running through coil generates a magnetic field. Magnetic flux overcomes air gap between armature and field, thus causing magnetic attraction to pull armature and connect to hub. Armature and hub are accelerated to match rotor speed. In brakes magnetic field acts directly between field and armature field acts on magnetic frame or on torque arm that handles brake torque. As armature contacts field, braking torque gets transferred into field housing, decelerated load.
The electromagnetic clutches and brakes is a generic term used to refer to the functions such as transmission and interruption or deceleration and stoppage of torque by electromagnetic action.
A Clutch is a device used to make and break contact. Electromagnetic Clutch is a type of Clutch system which uses electromagnetic for engagement and disengagement of vehicle. When power is supplied through AC and DC source electromagnetic clutch gets intermeshed. And making axle or shaft to rotate which causes a dynamic motion of vehicle. A brake is opposite to clutch.
Chapter 4: Design of Project
4.1 Design of Sprocket
Let, Power of motor = 90 kw
R.P.M of motor = 1480 r.p.m
Here, both sprockets have same diameter (So, N1=N2)
Velocity Ratio= =1
Design Power= Rated Power Service Factor (ks)
But, from design data book ks for medium shock or vibrating load and for normal 8 to 10 Hour per day use the ks= 1.20
Design Power = 1.20 × 90 =108kw
Using DDB we select chain 12B using 2000 rpm and power.
We have value of following point,
P = 19.05mm
W = 11.68mm
Wb = 59kN
Check for suitability of pitch,
P ≤ 10 ×
Where, N1 = speed of sprocket, rev/sec
=1480/60 rps =24.67 rps
Hence, P must be less than 33.33mm
So, selected pitch is suitable.
Now, we know that pitch circle diameter of the sprocket
Here, d1 = p mm
= 19.05 mm
=188.214mm = 0.188m
Here, d1 = d2
Pitch line velocity of the sprocket,
V1 = (d1* n1) m/s
= 19.67 m/s
Design Of Chain
Load on the Chain,
W =rated power/pitch line velocity
=90/19.67
= 4.57kN
Factor Of Safety
= Wb/W
= (591000)/457
=89.39
This value is more than DDB
So, center distance between sprockets,
=30P =3019.5 =572mm
Design Of Shaft
Torque transmitted by shaft
T =
=
= 580Nm
For carbon steel τ1=42 N/mm2
580 = (π× τ1× D3)/16
580 = (3.14×42×106× D3)/16
D = 41.27mm
Standard diameter of shaft
D = 41.27mm
Design Of Friction Lining
Area of friction lining
A=2×3.14×R×b
Where, R=mean radius
b=width of lining=R/4
Normal force
W=A×P
W=2×3.14×R×b×p
Torque
T= u×W×R×n
Where u= coefficient of friction= 0.3
P=intensity of pressure= 0.2 – 0.3N/mm2
N= 2 for both sides of plate effective
T=u×2×3.14×R3 ×p×n
= (3.14×u×R3×p×n)/2
R=135 mm
b=135/4 = 33.75 =34mm
Design Of Clutch plate
Let, r1=outer radius of clutch plate
r2=inner radius of clutch plate
Radial width b= r1 – r2
r1 – r2 = 34 mm ……. (1)
For uniform wear,
Mean radius R= (r1 + r2)/2
r1 + r2=2R
r1 + r2 = 270 mm ……. (2)
From, Equations (1) & (2)
r1=152mm,
r2=118mm
Dimension Of Spring
Normal force
W=2×π×R×b×p
=7209.955 N
If the spring is designed for an overload of 25%
Total load on the spring = 1.25×W
= 1.25×7209.955 N
= 9012N
Assume, spring index is 6
Wahl’s stress factor
k = +
= 1.2525
Max. Shear stress induced in the wire 420N/mm2 assumed
Max. Load on each spring = 9012/4 =2253N
Here 4 spring are used
Max. Shear stress induced in the wire
420=k×8×Ws×c/ (3.14×d2)
d =10.16mm
As per standard wire size SWG 17
d = 10.16mm
Mean diameter D = C×d = 60mm
Assume the spring has 4 active turns
n = 4, G = 84×1000 N/ mm2
The compression of spring
δ =
δ = 17.398mm
For square and ground ends, total number of turns
n’ = n+2 =6
Free length Lf = n’×d + δ + 0.15×δ
= 80.9mm
Pitch =
= 16.18mm
Design Of Armature
No. Of phase= 3, pole= 4, slots= 16
Each slot contain 2 coil sides
Slots/pole = 16/4 = 4
Total num of coil sides = 2×16
= 32
Minimum diameter of armature = 0.001×P
= 0.001×90×1000
= 90 mm
Chapter 5: Detail and description of project
5.1 Introduction to electromagnetic clutch:-
•Electromagnetic clutches operate electrically, but transmit torque mechanically. This is why these are also called electro mechanical clutches.
•The electromagnetic clutch is most suitable for remote operations since no linkages are required to control its engagement.
•It has fast and smooth operation.
Types of electromagnetic clutch:-
•Friction plate clutch
•Multiple disk clutches
•Electromagnetic tooth clutches
•Electromagnetic particle clutches
•Hysteresis powered clutch
5.2 Basic operation of electromagnetic clutch:-
The clutch has four main parts: field, rotor, armature, and hub. When voltage is applied the stationary magnetic field generates the lines of flux that pass into the rotor.
The rotor is normally connected to the part that is always moving in the machine. The flux (magnetic attraction) pulls the armature in contact with the rotor (the armature is connected to the component that requires the acceleration), as the armature and the output start to accelerate.
Slipping between the rotor face and the armature face continues until the input and output speed is the same (100% lockup). The actual time for this is quite short, between 1/200th of a second and 1 second.
Disengagement is very simple. Once the field starts to degrade, flux falls rapidly and the armature separates. One or more springs hold the armature away from the rotor at a predetermined air gap.
5.3 Schematic diagram of project:-
5.4 How to work:-
This system worked on the mechanism of power transmission system and it convert electrical power to the mechanical power. In this system shaft is connected with motor with the help of gear. Different electromagnetic clutches mounted on this shaft. Controlling of this clutch arranged in one controller.
When we start the motor one part of clutch which is connect with shaft is rotate. When we supply the clutch from supplier then the clutch being electromagnetic and it rotate the shaft. With the help of this we stop or start shaft during motor is working.
With the help of this mechanism we connect different mechanism with the help of one motor. In this system only one motor is used so this system required small space and we decrease maintenance cost.
5.5 Applications:-
This mechanism is used where space is very less and power consumption is more.
Such type clutch mechanism is used to operate multiple machine like a belt conveyor, which are located nearer to each other on same line. Such kind of mechanism can be used at the place where material handling is required.
Other application of such mechanism can be done where power transmission required at lower speed.
5.6 Advantages:-
In present days, the space available in most industry is less i.e. the utilization of available space is most important. So this type mechanism employs only single motor so the space required for overall mechanism is less than that is separate motor mechanism.
The whole mechanism becomes compact due to nearer located machines. In this mechanism only one motor is used which reduce the maintenance & installation cost.
Only one motor is used so it reduces the electricity consumption.
5.7 Limitations:-
This type of mechanism can be used only when if the different machines which are to be operated should be closely placed.
Such type mechanism is suitable for limited no. of transmission because more no. of transmission system increase the length of mechanism.
Chapter 6: Work plan
REFRENCES
Jeyakkannan,shankar Vignesh,”Electromagnetic clutch” –ICEIET-2016
Lokesh rama naik,Anjanakumar H.M,Durgesh shridhar naik “Design and working of electromagnetic clutch to reduce wear and slip”- 2016.
Sanjulal T S, Ajith kurikn baby” Design and fabrication of regenerative clutch assembly model”- IRJET-2016
Kunal Saurabh, Ayush Gupta” Fabrication of electromagnetic clutch”- Noida 2017
V B Bhandari,”Design data book”– Mc Graw Hill. Professional Publication.2017
Conclusion
This project is very useful for small industries which required small spaces. By the use of this project we save more electricity and maintenance.
This project is based on how we can use one motor for different mechanism instead of every motor for every mechanism. In this mechanism electrical owner converted into mechanical power. In this mechanism the speed control is not possible. This mechanism is more successfully and better working than current mechanism.