Final semester Project

Lukhdhirji Engineering College, Morbi (634)

Diploma Mechanical Engineering Department

Year: 2014-15

:WORK REPORT:

RANK KRUNAL M.-126340319027

YADAV PARAS J.-126340319033

SOLANKI VISHAL V.-126340319043

PATEL PIYUSH K.-126340319060

PATEL SACHIN M.-136348319008

:submission:

Submitted- Vth Sem. : / /2014

This is to certify that






Has satisfactorily completed his term work in the subject Project-I (3351908) within

the prescribed time limit and prescribed boundary.

Date: Student

Date: Industrial/Institute Guide

Date: Head Of Dept.

CERTIFICATE

I would like to thank Head of the Diploma Mechanical Engineering Department, Prof. P.V.

JETHVA for giving Mechanical Department students the opportunity to prepare a project on a topic

relevant to mechanical engineering, thereby making possible for us to get a great insight on a topic

chosen by us.

I would like to sincerely thank to MR. K.C.PARMAR, my batch in charge and guide, for

guiding me wonderfully guidance on my topic, thereby making possible for me to learn a great deal

on the topic and making a very systematic project report.

Yours Faithfully,






TOPIC

NO. TITLE OF CHAPTER PAGE NO.

1. Abstract 4

2. Introduction 5

3. Literature review 6

4. Methodology 8

5. Constable idea 10

6. Various type and speed parameters 18

7. Classification of coupling 21

8. Future work 26

9. Conclusion 27

10. Reference 28

11. Day To day log book 29

INDEX

ABSTRACT

In present world there is a lots of coupling which required laser alignment which is very costly so

magnetic disc coupling provide a best way to couple driving shaft of motor to pump driven shaft without any

physical contact.

There is a no any requirement of laser alignment so magnetic disc coupling have advantage to work

with angular and linear misalignment so it is very useful in various industries easily. This deal with design

and development of magnetic disc coupling. Because of various industrial problems on alignment of driving

shaft to driven shaft magnetic disc coupling provide best way to connect them without any physical contact.

This project is about to construct the magnetic disc coupling that can transmit high torque. This project

involves the process of sketching and drawing. After design had completed next step is fabrication of

attachment to transform the paperwork into real work. This project is mainly about a generating a new

concept for transforming torque

INTRODUCTION

Because of enhance application of transmitting torque in industries and inherent limitation of non-

flexible coupling in terms of inaccuracy and non-optimum operation need felt for an attachment or a system

which can at least minimize inaccuracy for transmitting torque by minimizing backlash.

To study and understand further this replacement of magnetic coupling we have selected to work

upon design and development of magnetic coupling as final year project for Diploma in mechanical semester

5th examination to be held by GTU.

Magnetic Disc Coupling

Magnetic disc coupling which connect shafts without any direct mechanical contact. Good for

system processing highly volatile liquids or for transferring motion with in vacuum chambers without the

need for expensive and vulnerable shaft seals.

This coupling is simple construction and better flexibility than other coupling. It can work easily in

angular and linear misalignment areas.

PROBLEM STATEMENT

In industries there is lot of problem about misalignment while transmitting torque from driving shaft

to the driven shaft. To overcome this problem and obtaining maximum efficiency of system we are working

on,

“Modification of magnetic coupling”

Which can transmit up to 8 Nm torque in no load condition using 1 hp motor running at 960 rpm?

PROJECT OBJECTIVES:-

Design an attachment for magnetic coupling which can increase torque transmission efficiency.

Develop the magnetic disc coupling which can transmit torque without any physical contact.

Design and development of magnetic disc coupling which transmit torque from 7 Nm to 8 Nm.

ADVANTAGES:-

Smooth running.

Overload protection to 110%.

High torsion rigidity.

Maintenance and wear free

Maximum torque transmitted is 53.1 NM

Use in application with high operation temperature greater than 423 K

It can work with angular misalignment up to 3 degree and parallel misalignment up to ¼.

No Wearing Parts.

No wearing parts - wear free transmission of torque

Synchronous design

No slip at any speed

protecting mechanical components in the drive-line from damage

No physical contact between driving and driven parts

Disadvantages of magnetic coupling:-

Magnetic flux from the surroundings (such as other wires) may diminish or enhance the field the

Hall probe intends to detect, rendering the results inaccurate.

Also, as Hall voltage is often on the order of millivolts, the output from this type of sensor cannot be

used to directly drive actuators but instead must be amplified by a transits based circuit.

Magnetics are usually bulkier and more expensive.

Magnetics don't pass DC.

If you need to pass a low frequency signal, then you have to modulate it onto a carrier somehow.

LITERATURE REVIEW

Every industrial product has its own importance that is used for various purposes and to make the

industrial jobs easy and hassle-free. Industrial products can be in any form from a very small screw to large

and heavy machineries. High end couplings are also the most demanding industrial product used to connect

two different moving parts or connect two shafts together at their ends to transmit power for further use.

The most vital and demanding industrial products are used for a number of purposes in machineries to make

them more productive and workable.

As far as the use of innovative coupling is concerned, they are used to endow with the misalignment

of the shafts or to introduce mechanical flexibility. There are different types of couplings available in the

market and used for a number of purposes. Among a wide range of couplings, rigid coupling is one of the

main couplings available in the market that is utilized for the connection between two separate systems like

motor and generator.

A part from all this advantages, it has certain demerit also. It cannot work under overload condition.

It causes vibration problem while transmitting power at high speed also it has backlash problem.

To overcome this disadvantages magnetic coupling is invented by JOHN A. MACKEN. After this it is primary

examined by Ramon M. Barrera. In this they used stainless steel (SS) hub in which magnets are fixed.

This arrangement gives better running compare to rigid coupling. It can work under overload

condition and also overcome the vibration problem at high speed.

METHODOLOGY

PROJECT PLANNING:-

In process to develop magnetic coupling there is planning of overall project for completing project

on its schedule. Based on planning first we get the project title for final year project then make a literature

review. Made a lot of investigation about magnetic coupling. This investigation involves the advantages and

disadvantages of magnetic coupling in market. This task is done through the information got from the

internet, books and our guide.

After gathering all the information we started to select the best idea for it. To achieve this we

discussed with our guide about the design. After several design sketched design consideration was made

and we develop the one of the new design where this design called final concept. This all activity is

represented as a flow chart below.

CONCEPTUAL IDEA:-

There is a simple mechanism in magnetic coupling based on motion transmission from one

shaft to another shaft by magnets.

One shaft is driving shaft which is operated by motor while other one is idle shaft where the

rotating motion is transferred due to magnetic field produced between them. All this arrangement

is mounted on bed.

So main parts of magnetic coupling are:

1. Motor

2. Magnets

3. Driving shaft

4. Driven shaft

5. Hub

6. Bed

Component Material No. of component

Motor - 01

Magnets Rare earth magnet 08

Driving shaft Mild steel 01

Driven shaft Mild steel 01

Pulley Aluminum 02

Ball bearing Cast iron 02

Bed Cast iron 01

Following activities carried out in our project planning process for

development of hand power punching press :

1. Literature Review

2. Identification of Problem

3. Experimental Setup Preparation

4. Experimental Setup

5. Conclusion

ARRANGEMENT OF MAGNETS IN PULLEY:-

Magnetic coupling consists of two pulleys. These pulleys are fitted with permanent magnets,

hermetically sealed from the liquids, in a multiple arrangement. The inner and outer magnetic rotors are

locked together by magnetic forces and work as a synchronous coupling. The permanent-permanent

magnetic couplings create neither slippage nor induction current during rotation. When excessive torque is

applied, the magnets will decouple, they will not recouple.

These magnets are arranged in method called HALLBACH ARRAY. This method is as follows

A Halbach array is a special arrangement of permanent magnets that augments the magnetic field

on one side of the array while cancelling the field to near zero on the other side. This is achieved by having a

spatially rotating pattern of magnetization.

The rotating pattern of permanent magnets (on the front face; on the left, up, right, down) can be

continued indefinitely and have the same effect. The effect of this arrangement is roughly similar to many

horseshoe magnets placed adjacent to each other, with similar poles touching.

The effect was discovered by John C. Malison in 1973, and these "one-sided flux" structures were

initially described by him as a "curiosity", although he recognized at the time the potential for significant.

This is shown in figure.

DETAIL DESIGN:-

We are developing the magnetic disc coupling which uses 1 HP motor and the maximum amount of

the torque transmitted with the help of 8 rare earth magnet whose total magnetic field will be around 3.2

tesla around 7.93 Nm.

For obtaining all these specification the design and specification of all the components which are

used in magnetic disc coupling are below:

HUB:-

Sectional View of hub

Where,

D1 Internal diameter of working hub

D2 Internal diameter of idle hub

D External diameter of hub

L Distance between working and idle hub

S Overall diameter of hub

Gap Air gap between two hubs

PULLEY:-

Here we are using disc aluminum pulleys which have a disc for connecting rim to the shaft instant of

arms as a hub in magnetic disc coupling. This is shown in figure below, Magnets are arranged inside

of this pulley

Motor:-

An electric motor is an electric machine that converts electrical energy into mechanical energy. The reverse conversion of mechanical energy into electrical energy is done by an electric generator.

In normal motoring mode, most electric motors operate through the interaction between an electric motor's magnetic field and winding currents to generate force within the motor. In certain applications, such as in the transportation industry with traction motors, electric motors can operate in both motoring and generating or braking modes to also produce electrical energy from mechanical energy.

Electric motors are used to produce linear or rotary force (torque), and should be distinguished from devices such as magnetic solenoids and loudspeakers that convert electricity into motion but do not generate usable mechanical powers, which are respectively referred to as actuators and transducers.

Magnet:-

A magnet (from Greek "Magnesian stone") is a material or object that produces a magnetic field. This magnetic field is invisible but is responsible for the most notable property of a magnet: a force that pulls on other ferromagnetic materials, such as iron, and attracts or repels other magnets.

A permanent magnet is an object made from a material that is magnetized and creates its own persistent magnetic field. An everyday example is a refrigerator magnet used to hold notes on a refrigerator door. Materials that can be magnetized, which are also the ones that are strongly attracted to a magnet, are called ferromagnetic (or ferrimagnetic). These include iron, nickel, cobalt, some alloys of rare earth metals, and some naturally occurring minerals such as lodestone. Although ferromagnetic (and ferrimagnetic) materials are the only ones attracted to a magnet strongly enough to be commonly considered magnetic, all other substances respond weakly to a magnetic field, by one of several other types of magnetism.

Drive shaft:-

A drive shaft, driveshaft, driving shaft, propeller shaft (prop shaft), or Card an shaft is a mechanical

component for transmitting torque and rotation, usually used to connect other components of a drive train

that cannot be connected directly because of distance or the need to allow for relative movement between

them.

As torque carriers, drive shafts are subject to torsion and shear stress, equivalent to the difference

between the input torque and the load. They must therefore be strong enough to bear the stress, whilst

avoiding too much additional weight as that would in turn increase their inertia.

To allow for variations in the alignment and distance between the driving and driven components,

drive shafts frequently incorporate one or more universal joints, jaw couplings, or rag joints, and sometimes

a splined joint or prismatic joint.

VARIOUS TORQUE AND SPEED PARAMETER:-

KW

@960

RPM

Max.

Speed

Weight

per hub

Torque

Normal

Torque

PEAK A B D E G

HP RPM Kg Nm Nm Mm mm mm mm Mm

0.02 42500 0.05 0.12 0.16 26.9 21 15.9 15.9 3.2

0.05 26000 0.1 0.5 0.6 43.7 21 15.0 15.0 4.80

0.10 23000 0.1 0.7 0.9 50.3 28 15.0 15.0 4.80

0.15 19000 0.3 1.0 1.4 60.0 38 19.1 19.1 4.80

0.28 15500 0.6 1.7 2.3 72.6 51 25.4 25.4 4.80

0.62 12000 1.0 4.1 4.5 93.5 70 25.4 25.4 6.35

1.23 10500 1.2 8.1 9.0 107 70 25.4 25.4 6.35

1.85 9000 2.0 12.2 13.5 130 76 38.1 31.8 6.35

3.08 9200 2.2 20.3 22.6 125 70 38.1 31.8 6.35

4.63 9200 3.1 30.5 34.0 125 108 47.5 41.4 6.35

6.17 7800 4.1 40.6 45.2 147 108 52.6 46.0 6.35

8.02 7800 3.2 53.1 61.0 147 60 41.7 31.8 6.35

Various torque and speed

HOW IT’S WORK:-

Magnetic couplings consist of an outer and an inner drive. The two drives do not touch each other – the coupling works via the non-contact transfer of power, which means that the magnetic solution – in contrast to traditional solutions – does not experience any wear. The magnetic coupling is thus maintenance-free.

Between the two rotating units it is possible to place a can such that two different media can be kept separate. With the hermetic enclosure of the coupling in a stainless steel housing, corrosion is avoided and the coupling can operate directly as a wet runner in different liquids and aggressive environments.

The outer drive is normally connected to the drive unit and the inner drive is, for example, connected to a pump. If a can is placed between the two contact-free rotating units, a standard air-cooled norm motor can for example be connected to a pump without the use of gaskets and seals.

Magnetic couplings are also called torque couplings because they can transfer a certain maximum mechanical torque through the air. If the torque exceeds this maximum value, the coupling will “slip”, which means that the rotational speed between the two coupled units is no longer the same. This prevents wear and tear and the magnetic coupling provides a built-in safety feature that protects against damage.

There are two main types of couplings. One type has a radial design – similar to an ordinary electric motor – whilst the other is axially oriented such that it can transfer forces through a surface.

FOR MAXIMUM TORQUE:-

All important internal clearances are ground to tolerances of less than .001 in. (0.025 mm). Magnet

assemblies surround hysteresis assembly. When like poles face each other, they produce maximum

magnetic saturation of the hysteresis disc, forcing lines of flux to travel circumferentially through the

hysteresis disc.

FOR MINIMUM TORQUE:-

When opposite poles face each other they produce minimum saturation of the hysteresis disc. The

lines of flux travel through the hysteresis disc. Combinations of adjustment angles between the two

extremes give infinite adjustability. Because there are no contacting surfaces, the setting can be maintained

indefinitely.

TOOLS AND TECHNIQUES USED

Sketching: All the ideas for magnetic coupling are first sketched on paper to ensure that advantages

can be obtained.

Pro engineering software: the final design is drawn with the help of this software.

LIST OF MACHINE TOOLS:-

Lathe machine

Drilling machine

Grinding machine

Welding machine

MANUFACTURING PROCESSES INVOLVED:-

Measuring and marking

Cutting process

Grinding process

Turning

Classification of coupling

Rigid Coupling:-

A rigid coupling is a unit of hardware used to join two shafts within a motor or mechanical system. It

may be used to connect two separate systems, such as a motor and a generator, or to repair a connection

within a single system. A rigid coupling may also be added between shafts to reduce shock and wear at the

point where the shafts meet.

When joining shafts within a machine, mechanics can choose between flexible and rigid couplings.

While flexible units offer some movement and give between the shafts, rigid couplings are the most

effective choice for precise alignment and secure hold.

By precisely aligning the two shafts and holding them firmly in place, rigid couplings help to

maximize performance and increase the expected life of the machine. These rigid couplings are available in

two basic designs to fit the needs of different applications. Sleeve-style couplings are the most affordable

and easiest to use.

Flange coupling:-

This coupling has two separate cast iron flanges. Each flange is mounted on the shaft end and keyed

to it. The two flanges are coupled together with the help of bolts and nuts. The projected portion of one of

the flanges and corresponding recess on the other flange help to bring the shaft into line and to maintain

alignment. A flange which is provided with a shroud which shelters the bolts heads and nuts is called

protected type flange coupling

Clamp or split-muff coupling:-

In this coupling, the muff or sleeve is made into two halves parts of the cast iron and they are join

together by means of mild steel studs or bolts. The advantages of this coupling is that assembling or

disassembling of the coupling is possible without change the position of the shaft. This coupling is used for

heavy power transmission at moderate speed.

Magnetic coupling:-

A Magnetic Coupling is a means of transferring torque from one shaft to another without a

physical mechanical connection. Magnetic shaft couplings are most often used for liquid pumps and

propeller systems, since a static, physical barrier can be placed between the two shafts to separate the fluid

from the motor operating in air.

Magnetic shaft couplings preclude the use of shaft seals, which eventually wear out and fail from

the sliding of two surfaces against each another. Magnetic couplings are also used for ease of maintenance

on systems that typically require precision alignment, when physical shaft couplings are used, since they

allow a greater off axis error between the motor and driven shaft.

Requirements of Good Magnetic Coupling Setup:-

It should be easy to connect or disconnect the coupling.

It does allow some misalignment between the two adjacent shaft rotation axes.

Its goal should be to minimize the remaining misalignment in running operation so as to maximize

power transmission and to maximize machine runtime (coupling, bearing and sealing's lifetime).

It should have no projecting parts.

It is recommended to use manufacturer's alignment target values to set up the machine train to a

defined non-zero alignment, due to the fact that later, when the machine is at operation temperature,

the alignment condition is perfect

FUTURE WORK

In a next SEM we are going to present magnetic coupling. We will create proper design of magnetic

coupling in 2D AutoCAD drawing. After it we assemble all part of the model. After all we will run magnetic

coupling by joint electric supply.

CONCLUSION

After constructing and performing all required experiment on magnetic disc coupling we can say

that it is no slip coupling it transmits equal number of revolution as that of motor with minimum air

gap.

The torque transmitted has direct relation with the air gap as we increase the air gap the torque will

reduce and vice versa.

This is one best try to connect driving shaft to drive shaft without any physical contact. In various

industries there is a lots of time waste on alignment of pump shaft to motor shaft and there is no

possibilities of accuracy so by applying this technology one can get more benefit.

There is no any need of alignment instrument so this technology provide best way of time saving

and money plus man power saving

REFERENCES

Machine design by R.S.KHURMI.

Elements of machine design by BHANDARI.

www.wikipediya.com

www.ac-tech.com

http://www.wikipediya.com/

http://www.ac-tech.com/

Day to Day Log Book

ENROLLMENT NUMBER OF THE STUDENT : 126340319027

NAME OF THE STUDENT : RANK KRUNAL M.

INSTITUTE : L.E.COLLEGE

DATE DETAILS OF WORK CARRIED OUT INITIAL OF STUDENT INITIAL OF INDUSTRY/INSTITUTE

GUIDE & INSTRUCTOR/WORK

MAN

15/07/2014 SELECTION OF THE PROJECT V.V. SOLANKI

16/07/2014 COLLECTION OF INFORATION

V.V. SOLANKI

19/07/2014 START WORKING ON REPORT V.V. SOLANKI

20/07/2014 WORKING ON INDEX V.V. SOLANKI

21/07/2014 WORKING ON ACKNOWLEDGEMENT& CERTIFICATE

V.V. SOLANKI

22/07/2014 TYPING OF THE PROJECT V.V. SOLANKI

23/07/2014 INSERTING THE IMAGE OF AUTOMATIC LATHE

V.V. SOLANKI

26/07/2014 CONCLUSION OF THE PROJECT V.V. SOLANKI

2/08/2014 VISIT TO INDUSTRY

V.V. SOLANKI

14/11/2014 CORRECTION OF THE PROJECT V.V. SOLANKI






MAN

15/07/2014 SELECTION OF THE PROJECT S.M. PATEL


S.M. PATEL

19/07/2014 START WORKING ON REPORT S.M. PATEL

20/07/2014 WORKING ON INDEX S.M. PATEL


S.M. PATEL

22/07/2014 TYPING OF THE PROJECT S.M. PATEL


S.M. PATEL

26/07/2014 CONCLUSION OF THE PROJECT S.M. PATEL


S.M. PATEL

14/11/2014 CORRECTION OF THE PROJECT S.M. PATEL






MAN

15/07/2014 SELECTION OF THE PROJECT P.K. PATEL


P.K. PATEL

19/07/2014 START WORKING ON REPORT P.K. PATEL

20/07/2014 WORKING ON INDEX P.K. PATEL


P.K. PATEL

22/07/2014 TYPING OF THE PROJECT P.K. PATEL


P.K. PATEL

26/07/2014 CONCLUSION OF THE PROJECT P.K. PATEL


P.K. PATEL

14/11/2014 CORRECTION OF THE PROJECT P.K. PATEL






MAN

15/07/2014 SELECTION OF THE PROJECT P.J. YADAV

16/07/2014 COLLECTION OF INFORMATION

P.J. YADAV

19/07/2014 START WORKING ON REPORT P.J. YADAV

20/07/2014 WORKING ON INDEX P.J. YADAV


P.J. YADAV

22/07/2014 INDUSTRIAL VISIT P.J. YADAV


P.J. YADAV

26/07/2014 CONCLUSION OF THE PROJECT P.J. YADAV


P.J. YADAV

14/11/2014 CORRECTION OF THE PROJECT P.J. YADAV






MAN

15/07/2014 SELECTION OF THE PROJECT K. M. RANK

16/07/2014 INFORMATION COLLECTION

K. M. RANK

19/07/2014 START WORKING ON REPORT K. M. RANK

20/07/2014 WORKING ON INDEX K. M. RANK


K. M. RANK

22/07/2014 VISIT TO INDUSTRY K. M. RANK


K. M. RANK

26/07/2014 CONCLUSION OF THE PROJECT K. M. RANK


K. M. RANK

14/11/2014 CORRECTION OF THE PROJECT K. M. RANK

Final semester Project

Education

Transcript of Final semester Project