Category: Mechanical Projects

This project has the three main modules

Application of Practical Shop Processing – Applicable Products
Lighting System of an Automobile – Demonstration Model
Parallel Clamp – Applicable Equipment

OBJECTIVE:

The main aim of the project is to have set up experience on demonstration of a lighting system for a Motor vehicle by studying the basic components of the lighting system and the operation of the lighting circuit.

USEFULNESS:

Traffic regulations require every Motor vehicle to be fitted with a correct lighting system. The lighting system is also important for an automobile to drive safely at day or night.

Unless lighting system has been used or insufficient components being applied, it will be very dangerous for the vehicle. By demonstration set of a lighting system for an automobile may support much more knowledge of this system to the students who study the concerning engineering subjects.

APPARATUS:

Types of lamps required are;

Main components

• Headlamps
• Tail lamps
• Side or Parking lamps
• Stop lamp

Accessories

• Warning lamps
• Fog lamps
• Panel lamps and
• Interior illumination lamps

Types of switch constituted in the lighting system are:

• Light switch
• Dip switch
• Stoplight switch

CONSTRUCTION: (WORKING PROCEDURE)

Panelboard is made of wood which has a length (3 ½ ′), wide (2 ½ ′) and thickness (¼″).

The circuit diagram is drawn on the panel board.

Complete Circuit Diagram

• The set of apparatus is set up according to circuit on panel board.
• The apparatus is connected to wire. After the setting has been established, the circuit is connected to the battery.
• And then, the lighting system for an automobile which display on the panel board can be started for its demonstration.
• Some of the other components are not display on the demonstration model board due to cost factor.

The following are the components’ specifications:

Sr.No.	Components	No. Required	Specifications
1	Battery	1	12V
2	Head lamps	2	100 watt
3	Tail lamps	2	5 watt
4	Parking lamps	4	5 watt
5	Dip Switch	1

CHOOSING CABLE SIZE

CIRCUIT	CABLE SIZE	MAXIMUM CURRENT
	SWG (size of wire gage)	CARRYING CAPACITY
Battery and generator main feeds	44/0.012 28/0.012 14/0.010	27.5 amps 17.5 amps6 amps
Other main feeds Remaining circuits Starter circuits	37/0.036 61/0.036 61/0.044	According to circuit length and vehicle operating conditions

Firstly, it is calculated the current of headlamp and tail lamp. And the size of wire is selected from the table by comparing the result of current.

OPERATION:

THE LIGHTING CIRCUIT SYSTEM CONNECTION

• The battery is connected to the battery terminal of the light switch. The light switch is connected to the dip switch including full terminal and dip terminal connected to the head lamp’s each terminal respectively.
• Side terminal is connected to the side lamp or parking lamp.
• The tail terminal is connected to the tail lamp.
• The light switch control headlights, park sidelight, and tail lights.
• The dip switch enables the head light to be changed from dip to full beam, and vice versa, without affecting the park-light or the rear light.
• It should be noted that the stop lights will operate only when the ignition switch is on. Fuse is common practice to insert a fuse in the circuit of interior lights as on driving hazard is caused by the failure of the use in these circuits.

SWITCH OPERATION

• Naturally, during the right-driver, and in an emergency in the day-time, the full beam of the headlamp must be used and the number two-step of the light switches on. When faced with another vehicle, the dip beam is used so is not to dazzle the driver of that vehicle. Then the dip switch is used.
• When the number one step of the light switch is on, the parking lamps, the tail lamps and the number plate lamps all light up at the same time.
• As soon as the ignition switch is on, the brake lamps become operational and light up when the break is applied.

HEADLAMP ALIGNING AND FOCUSING

Headlamps must be correctly focused and aligned if the driver is to have good road illumination in the right place without dazzling another road user. They are the following.

• Front of vehicle to be square with screen.
• Vehicle to be loaded and standing on level ground.
• Recommended distance for setting at least 25 ft.
• For ease of setting one headlamp should be covered.

CIRCUIT CONNECTION DIAGRAM

Parking Lamp & Stop and Tail lamps & Number Plate lamp

PROJECT PHOTOGRAPHS

REFERENCES 

1. J.A Dolan, AMSE, AMJED, 1996, Mortor Vehicle Technology and Practical Work Volume-1, lecture note in Mech. Eng: Dept., Ashton under Lyne College of Further Education Landon
2. R.E Owen, 1965, Electricity for Mortor Mechanics, Government Printer, Wellington, Newzeland.

Abstract:

• IC engine is the major component in any automobile
• IC engine is not just a single component, it is an assembly of various components
• It is very important to know how much pressure, load & stresses are acting on those parts and also the effect caused due to these parameters must be estimated
• So, we have selected 3 components of IC ENGINE
• The 3 components are PISTON,CRANK SHAFT & CONNECTING ROD
• IC Engine Components Designed those components in pro-e
• And finally we analyzed them in ANSYS so as to estimate the best material

Introduction:

• The internal combustion engine is an engine in which the combustion of a fuel (normally a fossil fuel) occurs with an oxidizer (usually air) in a combustion chamber
• In IC Engine chemical energy is converted into mechanical energy
• Internal combustion engines are most commonly used
• An IC Engine consists of hundreds of different parts, which are important for its proper working.
• However, the main components which are important are described below.
  1. Cylinder
  2. Cylinder head
  3. Piston
  4. Piston Ring
  5 . Connecting Rod
  6. Crank shaft
  7. Crank Case
  8. Fly wheel etc.
• Here we have considered 3 main parts namely,
  1.Piston
  2.Connecting rod
  3.Crank shaft

Result and conclusion :

Through the structural analysis of the parts individually it is clear that structural steel can withstand more stresses, then comes aluminum alloys when compared to normal cast iron parts.

And these results continued with assembly of the 3parts i.e. ; piston, connecting rod, crankshaft

With these results it can be concluded that the parts made with structural steels are better than that of aluminum, cast iron & aluminum is better than cast iron.

Analysis of Assembly:

Cast Iron Assembly:

Aluminum Assembly:

Structural Steel Assembly:

Future scope : 

The 3 components are PISTON,CRANK SHAFT & CONNECTING ROD which are designed in pro-e are finally going to be analyzed in ANSYS so as to estimate the effects caused due to pressure, load but thermal analysis can also be done to analyze temperature & its effects.

As there are some reasons for not completely implementing aluminum & other materials in IC engine parts, they must be overcome by extending the experiments.

Many crops especially rice, need stagnant and copious supply of water for a good yield and the river ayacuts in India have been well developed for a perennial flow of water atleast during the crop season. Irrigation plays a vital role in agriculture as a leading input both directly and indirectly because the cost of other inputs like fertilizer etc. largely depend on the availability of ensured water supply in the fields.

In the Indian context, capital intensive technologies like tubewells are usually beyond the purchasing capacity of the poor farmers. Labour intensive technologies such as pedal pumps, hand pumps, rower pumps, treadle pumps, Archimedean screw pump etc. are within the reach of the poor farmer due to their lower initial and operating cost.

A Bicycle Operated Low Head Water Pump designed, fabricated and tested in this project utilizes an improvised gear bicycle with chain and sprocket drive, a scooping mechanism, pipes and related pipelines.

The device is placed near a water source and the bicycle is pedalled. Due to this rotary motion, the scooping mechanism (connected to the wheel which is chain driven) scoops water from the water source and the collected water is sent to the farmlands through pipelines.

The whole device is non-polluting and totally independent of fuel, sunlight, wind etc.. Another attractive feature of this design is that the whole machine can be detached from the common bicycle, transported to the field and erected in situ.

Suitable modifications have been done to the bicycle to facilitate the transmission of motion from the rear wheel of the bicycle to the spiral scooping mechanism attached to a separate rim. A frame has been fabricated and fixed on the hub of the rear wheel so as to lift it off from the ground and thus avoid any hindrance when the bicycle is pedalled.

The whole setup is placed either in a stream or a stagnant water source like the village tank and the bicycle is pedalled. The scooping mechanism scoops the water which is now supplied to the fields with the help of delivery pipes. The designed model has a flow rate of 240 litres/hourand a head between 0.5metres and 1.5 metres. The stresses in the various members have been calculated and the factors of safety have been found to be satisfactory.

This flow rate can be increased with addition of more scoops and spirals and also by redesigning the scoop with an elliptical cross section instead of the present conical funnel. These twin changes will, in addition to increasing the flow rate by a factor of probably ten, will ensure a more uniform load torque and hence ease of operation for the worker.

The next prototype can be designed with a much larger wheel and/or a set of wheels than in the present model. One can also imagine a tandem bicycle operable by two or more workers at a time.

It is hoped that the present Bicycle Driven Low-Head Water Pump project is another step in today’s urgent search for an energy efficient, low cost, easily maintainable, non-polluting and affordable water pump to meet the irrigation needs of the small farmer in the developing world especially since agriculture all over the world is a loss making sector and depends heavily on government subsidy.

The current material handling processes includes complicated designs and the cost of the system is also high. Hence every industry is in need of a suitable material handling equipment which must be of low cost and also it must be flexible enough for the users.

This Pneumatic Six Axis Material Handling Equipment project serves as best for satisfying the above conditions. We used pneumatic application for the automation and it can be moved in six axis such that the entire material handling process can be automated.

WORKING PRINCIPLE

Our Pneumatic Six Axis Material Handling Equipment project consists of six pneumatic cylinders which are actuated with the help of the compressed air from the compressor. One pneumatic cylinder is attached at the bottom of the setup which is coupled with the rack and pinion arrangement and this cylinder is used to rotate the setup in 360°.

Another cylinder is placed vertically which is used to actuate the arm of the machine. The third cylinder is provided just above the vertical cylinder for achieving the raising and lowering action of the arm. The fourth cylinder is used to extend and retard the arm.

The fifth cylinder is used to raise and lower the gripper assembly. The last cylinder is used to actuate the gripper setup which is usually used to hold the work materials. Corresponding pneumatic cylinders are actuated with the help of the compressed air from the separate compressors and the material from one place in transferred to the other place with the help of this six axis material handling equipment.

This machine is highly useful since it can be moved in 360°.

2D DRAWING

ADVANTAGES

• Simple in construction.
• Easily available components are used.
• Can lift heavy objects that cannot be lifted with bare hands.
• Highly reliable.
• No need of skilled operators to operate this machine.
• The life of the machine is high.
• Maintenance free system.

DISADVANTAGES

• Semi automated machine.
• Need separate compressor for the effective operation of the system.
• If any one of the cylinders gets damaged, the entire operation if affected.

APPLICATIONS

These types of pneumatic six axis material handling equipment have a wide range of applications in the fields like,

• All industries,
• Highly suitable for assembly and packing industries.
• All manufacturing plants.

Abstract 

One of the crucial parts in wind turbine is Hub, which experience the loads from the blades and the loads were transmitted to the main shaft.

In this Design and Finite Element Analysis of Wind Turbine Hub project extreme loads and fatigue loads cases (IEC loads) were taken in to consideration and analysis are done for the two different materials viz cast iron and aluminum alloy.

Existing material is Cast Iron GGG 40.3 which has disadvantages like Very expensive Material for casting ,  Cost of Material is so High, Weight of the Hub is huge. In the Existing Material  we have so many disadvantages, so that to overcome we have chosen the  alternative material as Aluminum Alloy  6061.

Which has Advantages like Strength to weight ratio, Gradual  Reduction in cost,  Reduction in  the weight of the hub.

Finite element analysis is used to compare the above materials with extreme and fatigue load condition as per IEC load are discussed in this Design and Finite Element Analysis of Wind Turbine Hub project.