Design of gravity light 2015

Abstract
Engineering design is the process of applying various techniques and the significance of
mechanism, scientific principles for the purpose of defining a device, processes or system
insufficient detail to permits physical and mechanical relations. Based on this concepts and
definitions we have prepare design and model electric power generation using gravity.

Gravity is an innovative device that generates light by using the gravitational force with some loads.
The main objective of the project is to solve the lighting problems of the people who live in the dark
villages, to keep the peoples safety.

The project also includes literature review, selection of material for each part and parts design such
as gears, chain, belt, sprocket, shafts, bars, flywheel, pulleys with v belt, the roller ball bearings and
selection of DC generator. We have also determined some parameters like Bending moment, torque,
force, and so on. The output power, duration of lighting service, and select more efficient type of
lump are included on this design.

Model of electric power generation using gravity is design provides power for the dark villages
within the selected fluorescence lamp. The duration of lighting time is some minutes and its
installation consumed area is safe based on considered the height of house or use one meter depth in
underground.

Generally, this project is will be suitable for peoples in the developing country because it provides
safety and reduces hazards.
Keywords: Gravity, Light, LED Lamp, DC Generator, Power, gravity light

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Acknowledgment
Our deepest gratitude is to GOD for he is the one behind our entire learning process up to the
successful accomplishment of this project. We pray his guidance will continue in our future work as
we prepare to contribute our share in the ongoing reformation of Ethiopia.

Next we sincerely appreciate the knowledge and experience provided to us by the Mechanical
Engineering department of Wollo University Kombolcha Campus. A special thanks to our advisors
ins. G/Michal G/Medhn who is so willingly dedicated his time to give his valuable suggestions and
clarifications so that we accomplish this project.

We are extremely grateful for the invaluable life time assistance and encouragement given
by our families so that we reach this chapter of our life. If it was not for them we would not have
achieved this piece of work.
Amsalu Moges, Gashaw Sishagn, Getachew Abraham, Getasew Aklog
ITR/0120/03 ITR/0410/03 ITR/0453/03 ITR/1182/03
BSc, Mechanical Engineering
Kombolcha Institute of Technology, 2015

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Table of Contents
Abstract ................................................................................................................................................................I
Acknowledgment ................................................................................................................................................II
List of Figures .................................................................................................................................................... V
List of Table ...................................................................................................................................................... VI
List of Acronyms ............................................................................................................................................. VII
List of conversion ........................................................................................................................................... VIII
CHAPTER ONE: INTRODUCTION .................................................................................................................1
1.1Backgrounds of the project ........................................................................................................................1
1.2 Problem of statement ................................................................................................................................3
1.3 Objectives .................................................................................................................................................3
1.3.1 General Objectives .............................................................................................................................3
1.3.2 Specific objectives .............................................................................................................................3
1.4 Aim of the project .....................................................................................................................................4
1.5 Significance of the project ........................................................................................................................5
1.6 Specifications of the project ......................................................................................................................5
1.7 Methodology .............................................................................................................................................5
CHAPTER TWO: LITERATURE REVIEW .....................................................................................................6
2.1 Literature Review of the Project ...............................................................................................................6
2.1.1Lamps ..................................................................................................................................................7
2.1.2Weight .............................................................................................................................................. 11
2.1.3 Dc Generator ................................................................................................................................... 11
2.1.4 Flywheel mechanism....................................................................................................................... 12
2.2 Founding and developing ....................................................................................................................... 13
2.2.1 Design approach.............................................................................................................................. 14
2.2.2 Technology used ............................................................................................................................. 14
CHAPTER THREE: RESULT AND DISCUSSION ...................................................................................... 15
3.1General Considerations in Machine Design............................................................................................ 15
3.2 General Procedure in Machine Design .................................................................................................. 16
3.3Conceptual frame work and analysis ...................................................................................................... 17
3.5 Geometric analysis ................................................................................................................................. 21

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3.6 Force analysis......................................................................................................................................... 22

3.7Part design............................................................................................................................................... 25
3.7.1Chain drive ....................................................................................................................................... 25
3.7.1.1 Design of chain Drive .................................................................................................................. 26
3.7.2 Design of sprocket .......................................................................................................................... 29
3.7.3 Design of gear train ......................................................................................................................... 33
3.7.4 Design of shaft ................................................................................................................................ 42
3.7.5 Design of v- belt with pulley........................................................................................................... 48
3.7.6 Return mechanism........................................................................................................................... 55
3.7.7 Roller ball bearing........................................................................................................................... 56
3.7.8 Key .................................................................................................................................................. 60
3.7.9 Steel Poles ....................................................................................................................................... 62
3.7.10 Flywheel design ............................................................................................................................ 62
3.8 DC Generator ......................................................................................................................................... 65
3.9 Lamp selection ....................................................................................................................................... 67
3.10 Cost analysis ........................................................................................................................................ 69
3.11 Assembly drawing ............................................................................................................................... 70
CHAPTER FOUR: CONCLUSION AND RECOMMENDATION ............................................................... 71
4.1 Conclusion ............................................................................................................................................. 71
4.2 Recommendation ................................................................................................................................... 72
Reference ......................................................................................................................................................... 73

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List of Figures
Fig (2a): model of gravity light ...........................................................................................................................6
Fig (2b): Picture of LED .................................................................................................................................. 11
Figure (3b): geometric analysis ....................................................................................................................... 21
Figure(3c):gravity light mechanism ................................................................................................................. 23
Figure(3d): simple roller chain ........................................................................................................................ 26
Fig (3e): terms used in chain drive................................................................................................................... 27
Figure (3f): tooth profile of sprocke ................................................................................................................ 30
Figure (3g): load acting on gears ..................................................................................................................... 43
Figure (3h): bending moment diagram ............................................................................................................ 47
Figure (3i): pulleys with v belt ......................................................................................................................... 48
Figure (3j): basic belt drive geometry .............................................................................................................. 50
Figure (3k): roller ball bearing ......................................................................................................................... 57
Fig (3L): assembly drawing ............................................................................................................................. 70

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List of Table
Table (3a): different steel grades ..................................................................................................................... 20
Table (3b): dimensions and breaking loads of roller chains ........................................................................... 26
Table (3c): service factor (ks) .......................................................................................................................... 27
Table (3d): tooth coercion factor (K2) ............................................................................................................ 27
Table (3e): the Properties sprocket wheel ....................................................................................................... 30
Table (3f): the value of endurance limit ( es) ................................................................................................... 39
Table (3g): value of deformation factor ........................................................................................................... 39
Table (3h): Values of flexural endurance limit. ............................................................................................... 40
Table (3i): density of belt material .................................................................................................................. 49
Table (3j): the principle dimensions for radial ball bearing ............................................................................. 59
Table (3k): dimensions of square and rectangular sunk key ............................................................................ 61
Table (3L): permissible value for coefficient of fluctuation of speed (cs) ....................................................... 63
Table (3m): Dc generator model type .............................................................................................................. 66
Table (3N): lamp types and their typical charcterstics................................................................................... 68
Table (3p): table of cost analysis ..................................................................................................................... 69

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List of Acronyms
ASME=American society of mechanical engineering
BHN=brinell hardness number
CFL=compact fluorescent lamp
LCCA=life cycle cost assessment
emf =electro motive force
DC=direct current
d = diameter of the shaft
FG350 = cast iron grade have a tensile strength of 350 N/mm2
FH = horizontal loading
FS = Safe load
fs= Friction coefficient
FV = vertical loading
G =shear modulus of elasticity of the shaft material in N/mm2
ISO=international standard organization
I = Moment of inertia
Kb = bending service factor
Mb = Bending Moment
T = Twisting moment acting upon the shaft or the applied torque in Nm

y= the yielding strength of cast iron

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List of conversion
1m=1000mm
1A =1000mA

1rev. = 2

1min = 60 sec
1KN =1000N
1Nm/sec =1watt
1MPa =1N/mm

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CHAPTER ONE: INTRODUCTION

1.1Backgrounds of the project

Now days due to the effect of pollution global warming there is a need for generating power from
renewable sources due to the availability of gravity all over the earth, a bound ant and consistent it
is varying suitable to generating power by using gravity. Energy demand is increasing day by day
with rapid growth in industrialization as well as modernization. But resources are gradually
decreasing at high extent. Within a few years the energy resource will be finished and hence these
will be lack of fuel (coal, wood, water etc.) for power generation. The other renewable sources such
as solar, wind, bio mass etc. are available only for a particular duration of time during the day and
night. Therefore the gravity light is one of the method to generate light which full fill energy
demands and requirements of present time for living in developing countries or dark villages.

Gravity light: is an affordable lamp powered by gravity. With most of as living in countries where
running electricity and water is common place it would be hard for us to imagine what it might be
like living in countries where the supply of electricity might not be as stable which means getting
access to a descent right source at right could be

The gravity light basically an led build packed in a hall sing and by attaching a bag that comes with
the lamp all the user would have to do is fill the bag with about 20 kg of dirt or rocks and hung from
a cord bellow the right let gravity do its work.

Design and model electric power generation using gravity was built up for the purpose of supplying
cheap, effective lights to remote villages and areas in developing countries that often have to go
without reliable power sources. Low wages and expensive light sources means that once the sun
goes down everything goes dark or you have to rely on bio mass, fuel beading.

Gravity light offers a safe affordable alternative to kerosene lamps. The gravity light is shipped in a
heavy, durable bag that users fill with rocks or dirt to power a generator. Depending on how quickly
the weights are allowed to drop, the power it generates is somewhere between 30 and 500 mille
watts. Small out puts are used to charge a lamp during the hours. While larger out puts can power,
small electronic devices used.

In much of the world, kerosene lamps are used to provide necessary illumination, but kerosene does
a lot of damage to the people who use it. For instance kerosene in halation can do the equivalent
damage of two packs of cigarettes a day. While in India alone, over people are burned each year by
over turned kerosene lamps. Kerosene is also bad for the environment, eating up our limited
reserves of fossil fuels and contributing to global co2 missions. Was it of all though, kerosene is
quite expensive and can take up as much as 20% of an improving earn had family’s income since
the gravity light works to resolve many of the issues related to kerosene lamps. Providing a safe,

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cheap and clean light should eliminate the larger healthy and safety problems. While offering an
affordable light should allow farmers and students to continue their work offer dark.

Gravity light is an innovative device that generates light and power from gravity to replace
damaging, dangerous and expensive kerosene lamps. It takes only three seconds to lift. The weight
and that powers gravity light providing minutes of light on its descent. It is clean and
environmentally friendly. As gravity light does not have any operating costs after the initial
purchase cost it is more suitable for individuals with no big savings. Therefore this will be could
provide sustainable lighting for developing countries and replace the harm full kerosene lamps that
are currently being used in those types of nations.

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1.2 Problem of statement

The problem of bringing light to remote areas of the developing countries has been tackled in the
past and rural areas use kerosene lumps. This kerosene lumps will create more fire risks, since in
most third-world countries, kerosene lamps is a cheap source of light. However over the past year
there have been many reports of burns and deaths because of this unsafe solution of lighting, and
also will give of hazardous gases, such as carbon mono oxide. As general it is unhealthy (producing
toxic fume and poor quality light) and dangerous (fire).according to this problems we design gravity
light.

1.3 Objectives

1.3.1 General Objectives

The main objective of this project is to design and model electric power generation using gravity.

1.3.2 Specific objectives

 To develop proper material selection for each components model electric power generation
method design
 To select proper mini Dc generator to convert mechanical power to electrical power
 To design and select chain drive for use of high transmission efficiency and no slipping
 To design the transmission shafts that transmits power.
 Select proper type of lump
 To design pulleys with v-belt to transmit speed from one shaft to the other.
 To design simple gear train
 Select standard roller ball bearings
 To use flywheel to avoid vibration and used to perfect rotational motion

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1.4 Aim of the project

Mathematics in some form is the basis behind all technology in this world. In this particular case we
will be looking at the utilization of mathematics in the concept of gravity light, a lamp that allows
the generation of light and electricity through gravity. By means of reduced production of
greenhouse gases, this lamp also has a considerable social impact due to the fact that its price and
the requirements of usage make it possible to be used by many third-world countries, which may not
have direct access to electricity and as a result effective lighting.

Kerosene lumps has hazard gases, such as carbon monoxide (CO).Carbon monoxide is a gas, such
that we cannot see, small or taste. It bonds with haemoglobin in our red blood cells, allowing less
oxygen to be carried by the red blood cells. This can Cause carbon monoxide poisoning and will be
fatal if the person continuous to be exposed to the gas.

How the lamp works?

1. You are provided with two bags that you can fill with stones, sands and rocks etc. one big bag
(8- 20kg) one small bag (0.5-1kg)
2. You attach the bag to the weight hook and lift it up
3. As the previously lifted weight descends, it turns a series of gears within the lamp in to motion.

4. The length of time depends on the weight of the bag and the brightness settings. The brighter the
lamp is the shortage the period of time.

5. There are external connectors that allow charging and powering various other devices such as
torches and radios.

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1.5 Significance of the project

This project provides many applications for various persons who work in different working area.
Such as;
 For small enterprises who are interested to be an entrepreneur, this is used as a business plan
for them.
 For the students who have been under graduation .It is used as an initial point to design the
project and modified it as well.
 For the company which manufacture the mechanism of the gravity light.
 For the whole people who live in the dark village by providing light and keeping their safety
and avoiding burning of fire.
 Ensure the safety of people
 Facilitate the performance of visual tasks
 Aid the creation of an appropriate visual environment (appearance & character)

1.6 Specifications of the project

 To satisfy the lightening demands of the people who live in one house.
 In our design the considered height is three meter; two meter is above the ground and one
meter is underground.
 The duration of lighting time is limited or specified such minutes.

1.7 Methodology

Methodology is a method that used how to do the project like data collection, data presentation.
Data collection: The data collection process conducted in to two perspectives of data types, which
includes;

Primary data: interview, observation of videos and manual data record.

Primary data collection sources: it is a type of data collection that can be obtained by observation,
questionnaire and interview with concerned people. For example we asked electrical department
teachers.

Secondary data: like different service reference, internet, books, handout, and previous designs
concept.

Data presentation: After the data have been collected and organized they are ready for presentation
data by: graphically, table and Auto cad drawing.

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CHAPTER TWO: LITERATURE REVIEW

2.1 Literature Review of the Project

Today over 1.5 people have no reliable access to mains electricity. Those people rely dominantly on
kerosene for light. However kerosene is not only extremely hazardous but the fumes are
carcinogenic and kill an estimated 1.5 million women and children in Africa every year. There is a
real need for a safer, sustainable and affordable alternative. Four years ago Brunel alumnus Jim
reeves and his colleagues martin rid ford of therefore design inspired by the potential of gravity,
created a radical new form of lighting by the concept of gravity phenomenon which had discovered
by Sir Isaac Newton near 400 years ago.
London researches Martin Radford and Jim Reeves who have spent four years for developing
gravity light as an off line project. They are using tried and tested manufacture that has the right
knowledge to make gravity light. Gravity light is the revolutionary new approach to storing energy
and creating illumination. With huge financial support via a crowd founding campaign they have
been able to develop gravity light and in October 2013 gifted the first 1000 trial units to Africa and
India. Gravity light is powered by a weighted bag that, when lifted by hand, drops slowly to the
ground providing up to some minutes of LED lighting. This process is free and can be repeated time
and time again.

From the dangers and cost of kerosene, the insights from the trial will enable further development
and in the future villagers in developing countries will be able to purchase gravity light for less than
5 dollar. London based designer’s martin Radford and Jim Reeves have created what they are
calling the gravity light, an LED lamp that runs off of nothing but gravity. [6]

Fig (2a): model of gravity light

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After Martin and Jim, chun-chao Wang and yuh-suiang Wang has success fully invents the concept
of gravity power generation mechanism. In this concept more simplified mechanism is used for the
generation of the electricity. The primary objective of this invention is to provide gravity power
generation mechanism which can provide a continuous and stable operation to continuously convert
the gravity potential energy in to kinetic energy and then to convert the kinetic energy in to
electrical energy so as to perform a long time, effective and stable energy output. Russian inventor,
Mikhail Dmitry to know about his gravity motor-he has apparently devised a mechanism whereby
static gravitational pull can be harness to generate use full energy. He has worked for many years
developing and testing gravity powered devise and he has been very success full in his work. His
various designs is based on the principle of having weights attached to a wheel and arranging for
those weights to be offset out wards when failing and offset in wards when rising. Because of the
different lever arms involved. That gives a force imbalance which cause the wheel to rotate
continuously and if the weights are of considerable size, then the rotational is power full and can be
used to generate electrical energy. [3]

2.1.1Lamps
Artificial lighting is being used more and more in the world. The usage is quite non homogeneous.
In developing countries, we can still find a widespread use of fuel based lighting but nowadays the
situation is changing and the demand for electric based lighting is growing. Electric lighting
consumes about 19% of the world total electricity use. So, we should remember and consider that
the improvement in energy efficient lighting will also be helpful for the progress in developing
countries. Every change in technologies, in customers’ consumption behaviour, even in lifestyle, has
influences on global energy consumption and indirectly, on environment. Therefore, energy saving
in lighting, and the methods of achieving this goal should be considered at different levels (state,
region, town, enterprise) and by supranational organizations, too.

People stay in indoor environment for most of the day. Characteristics of light in indoor
environment are much different than that of natural outdoor environment. On the other hand people
do not stop activities after sunset. The artificial lighting has therefore impact on their well-being.
The needed artificial light has to be provided in energy efficient and environmentally conscious
way. It is important to search for the technological solutions which meet human needs with the
lowest impact on the environment during operation, when most of the impacts take place. The
environmental impacts also include production and disposal of lamps, and related materials.
To summarize, energy savings / efficiency and economics are dependent on:

Improvement of lighting technologies:

 making better use of available cost-effective and energy efficient lighting
technologies

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 Lighting design (identify needs; avoid misuses, proper interaction of technologies,

automatic controls, daylight integration)
 Building design (daylight integration and architecture)
 Knowledge dissemination to final users
 Knowledge dissemination to operators (designers, sellers, decision makers)
 Its reduction of resources uses by recycling and proper disposal size reduction, using
less aluminium, mercury, etc.
 Life cycle Cost Assessment LCCA

Types of lamp
A) Incandescent lamp
In incandescent lamp, which is also called General Lighting Service Lamp (GLS), light is produced
by leading current through a tungsten wire. The working temperature of tungsten filaments in
incandescent lamps is about 2700 K. Therefore the main emission occurs in the infrared region. The
typical luminous efficacy of different types of incandescent lamps is in the range between 5up to15
lm/W.
Advantages of incandescent lamps:

 Inexpensive
 Easy to use, small and does not need auxiliary equipment
 Easy to dim by changing the voltage
 Excellent colour rendering properties
 directly work at power supplies with fixed voltage
 Free of toxic components
 Instant switching

Disadvantages of incandescent lamps

 Short lamp life (1000 h)
 Low luminous efficacy
 Heat generation is high
 Lamp life and other characteristics are strongly
 Dependent on the supply voltage
 The total costs are high due to high operation costs.

B) Tungsten halogen lamp

Tungsten halogen lamps are derived from incandescent lamps. Inside the bulb, halogen gas limits
the evaporation of the filament, and re-deposit’s the evaporated tungsten back to the filament
through the so called halogen cycle. Compared to incandescent lamp the operating temperature is
higher, and consequently the colour temperature is also higher, which means that the light is whiter.

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Colour rendering index is close to 100 as with incandescent lamps. Their lifetime spans from 2000
to 4000 hours, and luminous efficacy is 12-35 lm/W.

Advantages of tungsten halogen lamps

 Small size
 Directional light with some models (narrow beams)
 low-voltage alternatives
 Easy to dim
 Excellent colour rendering properties

Disadvantages of tungsten halogen lamps

 Low luminous efficacy
 Surface temperature is high
 Lamp life and other characteristics are strongly dependent on the supply voltage

C) Fluorescent lamps
A fluorescent lamp is a low-pressure gas discharge light source, in which light is produced
predominantly by fluorescent powders activated by ultraviolet radiation generated by discharge in
mercury. The lamp, usually in the form of a long tubular bulb with an electrode at each end,
contains mercury vapour at low pressure with a small amount of inert gas for starting. The majority
of the emission (95%) takes place in the ultraviolet (UV) region and the wavelengths of the main
emission peaks are 254 nm and 185 nm. Hence, the UV radiation is converted into light by a
phosphor layer on the inside of the tube.

Advantages of fluorescent lamps

 Inexpensive
 Good luminous efficacy
 Long lamp life, 10 000 – 16 000 h
 Large variety of CCT and CRI

Disadvantages of fluorescent lamps

 Ambient temperature affects the switch-on and light output
 Light output depreciates with age
 contain mercury
 Short burning cycles shorten lamp life

D) Compact fluorescent lamps (CFL)

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The CFL is a compact variant of the fluorescent lamp. The overall length is shortened and the
tubular discharge tube is often folded into two to six fingers or a spiral. For a direct replacement of
tungsten filament lamps, such compact lamps are equipped with internal ballasts and screw or
bayonet caps. There are also pin base CFLs, which need an external ballast and starter for operation.
The luminous efficacy of CFL is about four times higher than that of incandescent lamps. Therefore,
it is possible to save energy and costs in lighting by replacing incandescent lamps with CFLs.

Today, CFLs are available with: - different shapes, with bare tubes or with an external envelope
(look alike for incandescent lamp)

Advantages of compact fluorescent lamps

 Good luminous efficacy
 Long lamp life (6000-12 000 h)
 The reduced cooling loads when replacing incandescent lamps

Disadvantages of compact fluorescent lamps

 Expensive
 E-27 based are not dimmable (apart from special models)
 Light output depreciates with age
 Short burning cycles shorten lamp life
 the current waveform of CFLs with internal electronic ballast is distorted

E) Light-emitting diodes (LEDs)

Solid-state lighting (SSL) is commonly referring to lighting with light-emitting diodes (LED),
organic light-emitting diodes (OLED) and light-emitting polymers (LEP). At the moment there is
still no official definition for solid-state lighting, the expression ―solid-state‖ refers to the
semiconductor crystal where charge carriers (electrons and holes) are flowing and originate photons
(i.e., light) after radioactive recombination.

Operation principle and light generation

An LED is a p-n junction semiconductor which emits light spontaneously directly from an external
electric field (electroluminescence effect). LEDs work similarly to a semiconductor diode, allowing
current flow in one direction only. The diode structure is formed by bringing p- and n-type
semiconductor materials together in order to form a p-n junction. P-type material is obtained by
doping an intrinsic semiconductor material with acceptor impurities resulting in an excess of
positive charges (holes). To produce an N-type semiconductor, donor impurities are used to create
an excess of negative charges (electrons). The p and n materials will naturally form a depletion
region at the junction, which is composed of ionized acceptors in the p-side and ionized donors in
the n-side forming a potential barrier at the junction. The applied external electric field across the
junction will allow electrons in the conduction band, which are more mobile carriers than holes, to
gain enough energy to cross the gap and recombine with holes on the other side of the junction

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emitting a photon as a result of the decrease in energy from the conduction to the valence band
(radioactive recombination). All information’s about lumps from [12].

Advantages of LEDs:
 Mall size (heat sink can be large)
 Physically robust
 Long lifetime expectancy (with proper thermal management)
 Switching has no effect on life, very short rise time
 contains no mercury
 Excellent low ambient temperature operation
 High luminous efficacy (LEDs are developing fast and their range of luminous efficacies is
wide)
 New luminaries design possibilities
 Possibility to change colours
 No optical heat on radiation

Disadvantages of LEDs:
 High price
 Low luminous flux / package
 Risk of glare due to high output with small lamp size
 Need for thermal management
 Lack of standardization

Fig (2b): Picture of LED

2.1.2Weight
The weight or mass which is suspended by the Chain is the initial source of energy (fuel) of our
device. We can use any material to be suspended, like compacted metal, rock, concrete, sand …etc.
comparing by compactness, availability and cost we chose concrete material to be suspended.

2.1.3 Dc Generator
Dc machines (motor/generator) are characterized by their versatility. By means of various
combinations of shunt, series and separately exited field windings they can be designed to display a
wide variety of volt-ampere or speed- torque characteristics for both dynamic and steady state

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operation. The essential features of a Dc machines (motor/generator) are shown schematically in

Fig. bellow. The stator has salient poles and is excited by one or more field coils. [9]

Fig (2b1). Dc machine

Model of electric power generation using gravity: gravity power generation mechanism utilizes a
gravity energy conversion unit to convert the gravity potential energy into the kinetic energy. The
gravity energy conversion unit produces positive torques by adopting outward-spreading single
directional swing arms and reduces the negative torques by cooperating with the folding action of
the single directional swing arms, so as to perform a long-time, effective and continuous energy
conversion of converting gravity potential energy into the kinetic energy. Next, the kinetic energy
will be transmitted to a power generating unit to perform another energy conversion of converting
the kinetic energy into the electric energy. And finally, a power supply system is used to transmit
the electric energy out.

2.1.4 Flywheel mechanism

A flywheel is a rotating disk that stores energy as kinetic energy. The faster the flywheel spins the
more kinetic energy it stores. The flywheel rotates with a connecting rod, known as the shaft. The
shaft is where the energy moves in and out of the flywheel.

Energy: When more kinetic energy can be stored in a flywheel, the less energy needs to come from
the main power source. This increases the efficiency of the mechanism’s energy output. Because a
flywheel can be used in such a variety of mechanisms, the amount of energy stored in the flywheel
varies. There are two factors that control the amount of energy the flywheel stores: the moment of
inertia and the rotational speed of the flywheel.

Moment of Inertia: Newton’s Second Law of Motion states that force is equivalent to the mass of
the object multiplied by its acceleration. However, this equation is different for an object that
rotates. In rotation, force is replaced with torque; acceleration is replaced with rotational
acceleration, and mass is replaced with the moment of inertia. Newton’s Second Law of Rotation
states that torque is equivalent to the moment of inertia multiplied by rotational acceleration. The
object’s mass, radius, and inertia constant determine the moment of inertia.
The mass and radius of a flywheel can easily be determined by weighing and measuring.

However, the inertia constant of a flywheel is dependent on the shape. Flywheels are usually one of
two shapes: a ring with spokes or a solid disk. A ring with spokes most clearly resembles a wheel,
while a solid disk looks like a CD without a hole in the middle. Since flywheels usually only come
in these two shapes we will only be concerned with two values of inertia constant. The inertia
constant for a ring is 1.0 and the inertia constant for a disk is 0.5. The difference in the inertia

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constants is due to the fact that all of the mass in a ring is concentrated at its circumference, while
the mass of a disk is evenly distributed from the centre to the outside.

A Force is any influence that causes an object to undergo a certain change either concerning its
moment, direction or geometrical construction.

Torque or moment of force is the tendency of a force to rotate an object about an axis, fulcrum or
pivot.

Moment of inertia is a property of rotating bodies that defines its resistance to a change in angular
velocity about an axis of rotation. It is how; rotation of body is affected by Newton’s law of inertia.
F = ma
Where, F is force
M is mass
a is acceleration
T=Iα
Where, T is torque
I is moment of inertia

Is rotational acceleration

I = km Where, I is moment of inertia

K is the inertia constant

M is mass
R is radius
k = ½for disk

Rotational Speed: The second factor determining the energy a flywheel stores is the rotational
speed. The energy a flywheel stores is proportional to the square of the rotational speed. Therefore,
if a flywheel’s speed doubles, the amount of energy it stores will quadruple. Rotational speed is a
factor that must be measured using a tachometer. [11]

2.2 Founding and developing

The idea GoGo campaign of gravity light was ended on January 15, 2013 with 355590 founded by
6215 founders. Gravity light was called one of the 25 best inventions of the year 2013 by time
magazine. The gravity light foundation is a charity with a mission to:
Relative poverty caused by lack of access to electricity and reliance on kerosene for light.

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Protect the environment through clean, affordable off grid products, the first of which is gravity
light.
The gravity light foundation tackles poverty and protects the environment through its innovative.
Where the design and model of gravity light service being used?

Gravity light has three distinct markets, spanning the globe. The first off-grid and under electrified
households relying on kerosene for light across sub-Saharan Africa and across many Asian
countries used the gravity light servicing.

The second relief operations worldwide providing shelter and services to those displaced by natural
disaster and conflict due to this it uses gravity light servicing.

The third on outdoors market of people wanting to light their log cabins to garden gazebos with a
clean, sustainable solution. [7]

2.2.1 Design approach

Doing more with fewer characteristics the design mind set behind gravity light. Starting from the
users’ perspective co-inventors Martin and Jim took a different approach bench marking the amount
of power and light needed asking is it better than a kerosene lamp? This led them to explore what
much lower sustainable, safe and healthy.

2.2.2 Technology used

Design and model electric power generation using gravity used in the trial) involved lifting up a bag
filled with up to 20 kg of rocks, sand or similar. The force of gravity causes the weight to descend
and that kinetic energy is converted via a series of small gears and generator in to electrical energy
that powers the light.

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CHAPTER THREE: RESULT AND DISCUSSION

3.1General Considerations in Machine Design

Following are the general considerations in designing a machine component.

1. Type of load and stresses caused by the load .The load, on a machine component, may act in
several ways due to which the internal stresses are set up.

2. Motion of the parts or kinematics of the machine. The successful operation of any machine
depends largely upon the simplest arrangement of the parts which will give the motion required.
The motion of the parts may be:
• (a) rectilinear motion which includes unidirectional and reciprocating motions
• (b) Curvilinear motion which includes rotary, oscillatory and simple harmonic
• (c) Constant velocity
• (d) Constant or variable acceleration

3. Selection of materials. It is essential that a designer should have a thorough knowledge of the
properties of the materials and their behaviour under working conditions.

• Some of the important characteristics of materials are: strength, durability, flexibility, weight,
resistance to heat and corrosion, ability to cast, welded or hardened, mach inability, electrical
conductivity, etc.

4. Form and size of the parts. The form and size are based on judgement. The smallest practicable
cross‐section may be used, but it may be checked that the stresses induced in the designed
cross‐section are reasonably safe. In order to design any machine part for form and size, it is
necessary to know the forces which the part must sustain. It is also important to anticipate any
suddenly applied or impact load which may cause failure.

5. Frictional resistance and lubrication. There is always a loss of power due to frictional
resistance and it should be noted that the friction of starting is higher than that of running friction.
It is, therefore, essential that a careful attention must be given to the matter of lubrication of all
surfaces which move in contact with others, whether in rotating, sliding, or rolling bearings.

6. Convenient and economical features. In designing, the operating features of the machine
should be carefully studied. The starting, controlling and stopping levers should be located on the
basis of convenient handling. If parts are to be changed for different products or replaced on
account of wear or breakage, easy access should be provided and the necessity of removing other
parts to accomplish this should be avoided if possible.

7. Use of standard parts. The use of standard parts is closely related to cost, because the cost of
standard or stock parts is only a fraction of the cost of similar parts made to order. The standard
or stock parts should be used whenever possible; parts for which patterns are already in existence

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such as gears, pulleys and bearings and parts which may be selected from regular shop stock such
as screws, nuts and pins.

8. Safety of operation. Some machines are dangerous to operate, especially those which are
speeded up to insure production at a maximum rate. Therefore, any moving part of a machine
which is within the zone of a worker is considered an accident hazard and may be the cause of an
injury

9. Workshop facilities. A design engineer should be familiar with the limitations of his
employer’s workshop, in order to avoid the necessity of having work done in some other
workshop. It is sometimes necessary to plan and supervise the workshop operations and to draft
methods for casting, handling and machining special parts.

10. Number of machine to be manufactured. The number of articles or machines to be

manufactured affects the design in a number of ways. The engineering and shop costs which are
called fixed charges or overhead expenses are distributed over the number of articles to be
manufactured. If only a few articles are to be made, extra expenses are not justified unless the
machine is large or of some special design.

11. Cost of construction. The cost of construction of an article is the most important
consideration involved in design. In some cases, it is quite possible that the high cost of an article
may immediately block it from further considerations. If an article has been invented and tests of
handmade samples have shown that it has commercial value, it is then possible to justify the
expenditure of a considerable sum of money in the design and development of automatic
machines to produce the article, especially if it can be sold in large numbers.

12. Assembling. Every machine or structure must be assembled as a unit before it can function.
Large units must often be assembled in the shop, tested and then taken to be transported to their
place of service. The final location of any machine is important and the design engineer must
anticipate the exact location and the local facilities for construction. [1]

3.2 General Procedure in Machine Design

In designing a machine component, there is no rigid rule. The problem may be attempted in
several ways. However, the general procedure to solve a design problem is as follows:

1. Recognition of need. First of all, make a complete statement of the problem, indicating the
need, aim or purpose for which the machine is to be designed.

2. Synthesis (Mechanisms).Select the possible mechanism or group of mechanisms which will

give the desired motion.

3. Analysis of forces. Find the forces acting on each member of the machine and the energy
transmitted by each member.
4. Material selection. Select the material best suited for each member of the machine.

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5. Design of elements (Size and Stresses). Find the size of each member of the machine by
considering the force acting on the member and the permissible stresses for the material used. It
should be kept in mind that each member should not deflect or deform than the

6. Modification. Modify the size of the member to agree with the past experience and judgment
to facilitate manufacture. The modification may also be necessary by consideration of
manufacturing to reduce overall cost.

7. Detailed drawing. Draw the detailed drawing of each component and the assembly of the
machine with complete specification for the manufacturing processes suggested.
8. Production. The component, as per the drawing, is manufactured in the workshop

Note: When there are number of components in the market having the same qualities of
efficiency, durability and cost, then the customer will naturally attract towards the most
appealing product. The aesthetic and ergonomics are very important features which give grace
and lustre to product and dominates the market. [2]

3.3Conceptual frame work and analysis

The reason behind generating power by using gravity is that it is available all over the earth.
Comparing to the other sources like chemical, thermal and other sources gravity is weak, is
scalable. This weakness is due to uniformity, or steady state of our interactions with gravity.

As gravity is weak as compared to the other sources, it cannot be efficiently converted into
electrical energy or in the other form. The concept of gravity power generation is simple. The
basic concept of gravity power generation mechanism is, when a body moves down from higher
altitude to lower one its potential energy is converted into kinetic energy. This motion is
converted into circular motion and that circular motion is converted into electricity by using a
Mini DC generator.
Energy demand is increasing day by day with rapid growth in industrialization as well as
modernization. But the energy resources are gradually decreasing at high extent. Within a few
years the energy resources will be finished and hence there will be lack of fuel (coal, wood,
water, etc.) for power generation. The other renewable sources such as solar, wind, biomass etc is
available only for a particular duration of time during the day and night. Therefore the gravity
power generation is one of the methods to generate power which fulfil energy demands and
requirements of present time.

It is possible to deflect gravitational action away from an object so that the object is partially
deviated. That effect makes it possible to extract energy from the gravitational field, which
makes the generation of gravitational electric power technologically feasible. Such plants would
be near about similar to hydro-electric plants. Gravitational electric power plant has advantages
over the hydro-electric plant, such as not needing of fuel and not polluting the environment.
However, the gravitational electric plant would be much smaller than hydro-electric plants.

There are many ways to convert gravitational energy into electrical energy. Gravity lamp is one
of the mechanisms.
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Figure (3a): Procedure for Power generation

When a body is at certain height from the ground, it possesses potential energy. Due to
gravitational pull the body falls down. In this process, potential energy is converted to kinetic
energy in the form of torque. And this converted into electrical energy using generator. The
electrical energy is supplied to the LEDs, where electrical energy is converted into light energy.
Gravity lamp and Gravity Generator follows the same mechanism. [11]

3.4 Material selection

Selection of materials and the processes used in fabrication are integral parts of the design of a
machine component. But some designer designs machine components in improper methods. This
Problem in material selection for machine design usually involve the selection of a material for a
new or redesigned component, and although the goals generally involve performance, reliability,
and cost, the selection process usually involves making a decision with insufficient or inaccurate
property data subject multiple constraints, sometimes competing, and usually without clear-cut
(known) objectives. The knowledge of materials and their properties is of great significance for a

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design engineer. The machine elements should be made of such a material which has properties
suitable for the conditions of operation. In addition to this, a design engineer must be familiar
with the effects which the manufacturing processes and heat treatment have on the properties of
the materials. In this chapter, we shall discuss the commonly used engineering materials and their
properties in Machine Design.

A methodology of materials selection is based on:

1. Engineering performance considerations for a given application,
2. The relative importance of the required material properties, and
3. The availability and final cost.

The goal is to select an appropriate material to best meet the demands of the design requirement.
For a given application, the approach is to identify the connection between the functional
requirements and the material requirements and thus reduce the number of candidate materials
from which to select. Material selection involves iterative decision making, when we have a
description or definition of the part or component, we recognize that the steps in selecting a
material for a component follows a typical path:

(a) Determine the “purpose” of the component. Establish the service performance requirements
for the part. The service performance or operational conditions for the component need to be well
understood as these conditions influence the material selection.

(b) Select a material that appears suitable for the “purpose.”This second step may initially
involve screening and ranking candidate materials before a candidate material is selected.

(c) Make a final evaluation of the candidate materials including manufacturing processes and
finishing methods if necessary and make a final recommendation.

(d)Test, test, test. Once a material candidate has met the material properties, availability, and cost
criteria, it is recommended that the candidate selected be tested. The test(s) should simulate the
product operating conditions. [4]
The mechanical properties of the metals are those which are associated with the ability of the
material to resist mechanical forces and load. These mechanical properties of the metal include
strength, stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience,
used for this machine should have the following properties:

The material used for this machine should have the following properties: It should have high
wear resistant properties

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Types of cast iron:

Gray cast iron: it contains carbon in form of iron carbide. It is suited to the parts subjected to
abrasion. It is cheap and common material for casting. It is strong in compression but relatively
weak in tension. It is good in wear resistance.

White cast iron: when cast iron with low silicon content is cooled rapidly, all the carbon remains
in the combined form and white cast iron is formed. It is hard brittle but difficult in machining
also it may be used for bearings of disc harrow gangs or wheel bearings for implements. It may
be used for mouldboards also.

Malleable cast iron: is obtained when white cast iron is properly annealed by heating to a
temperature for several days and then cooling slowly. It is tough easily machined and much
stronger than gray cast iron.

Ductile cast iron: is formed when magnesium and ferrosilicon are added to the molten cast iron.
It has high ductility and can take up greater impact resistance than gray cast iron. It may be used
for gears, sprockets, and plough shares.
Steel: is malleable alloy of iron and carbon or iron, carbon and some other elements. If the
alloying material is only carbon it is known as carbon steel otherwise alloy steel. Low carbon
steel, medium carbon steel, high carbon steel types of steel.

Low carbon steel: contains less than 0.25 percent carbon. It is also called mild steel (ms) it is
used for nuts, bolts, and other simple components of agricultural implements.

Medium carbon steel: it contains 0.25 percent to 0.6 percent carbon. It is used for shafts, gears,
axles.

High carbon steel: it contains 0.6 to 1.5 percent carbon. It is used for plough shares, blades,
shovels, disc, coulters and cutting tools.

Several components used in farm equipments are made of steel having different carbon contents.
The following table gives the different applications of steel in different grades. Material selection
of each component has explained in each component design.

Table (3a): different steel grades

Percentage of carbon Applications
0.05 to 0.30 Sheets, wires, stampings, carriage bolts,
screws, nuts and bolts.
0.3 to 0.6 Gears, axles, cutter bar, shafts, and forging
tools.
0.6 to 0.8 Plough beam, tool bar, springs, hammers,
wrench and set screws.
0.8 to 1.0 Plough shares, mould board, sweep shoves,
punches and springs.
1.0 to 1.5 Drills, taps, milling cutters, metal cutting

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3.5 Geometric analysis

The geometric analysis of gravity light is depending on the average height of the house at
anywhere. Then the average height of the house is 3000 mm from observed houses and that is the
model of gravity light machine has install 2000 mm above the ground with 1000 mm
underground in order to safety and use of adding working height. The height of underground is
assumed to increase the time to fail 20 kg of weight. Since the weight fails down total height is
3000 mm. Then the lighting time is increased. The frame of return mechanism installs 600mm
distance horizontally far apart for poles.

Figure (3b): geometric analysis

tan

The contact between chain and sprocket

The length of chain pulley up to sprocket is

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L=

Length of chain for connection of sprocket and chain circumference is calculated as:

D= Where; p = 8 pitch value from table

Z=21 number of teeth

D= pitch circle diameter of sprocket

D= = 53.6mm

Contact circumference length 169 , r is 26.8mm

Lc =2.95
The other part of chain length is sprocket up to the underground tip length is 3000mm.
The total length of chain = 3900+79+3000 =6979mm
The length of chain is approximately 7m long.

3.6 Force analysis

Energy is the conserved property of a physical system, which can be calculated from its state. It
has many forms such as kinetic energy, potential energy, electrical energy, heat energy etc. One
form of energy can be converted into other forms by changing the state of the physical system.
This property of can be used to convert potential energy of a system into electrical energy.
If a mass is hanging at balance at a height, the force of gravity acts upon it downwards. A
potential energy is stored in this mass until it is allowed to fall freely. In case of free fall, the
potential energy converts into kinetic energy and finally this mass acquires a new state upon
impact, losing all the kinetic energy.

To obtain the electricity from the potential energy of the hanging mass, we need to reduce the
kinetic energy losses. These losses can be reduced by regulating the downward motion of the
mass by speed control methods. If we attach a dynamo with the given physical system, it will
generate the electricity as the mass is going down. The longer it takes to reach to the ground, the
more will be electricity production.

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Figure(3c):gravity light mechanism

In gears, power is transmitted by means of a force exerted by a tooth of the diving gear on the
meshing tooth of the driven gear. The tooth of the driving small gear exerted force P N 0n the
tooth of driven gear. According to the fundamental law of gearing, this resultant force P N always
acts along the pressure line. The resultant force can PN can be resolved in to two components
tangential component PT and radial component PR at the pitch point. The tangential component Pt
is a useful load because load because it determines the magnitude of the torque and consequent
the power, which is transmitted. The radial component PR is a separating force that is always
directed towards the centre of the gear. The torque transmitted by gear is given by

Mt = where Mt = torque transmitted by gears

Kw = power transmitted by gears (kW)

N = speed of gyration (rpm)

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In gear tooth force it is always required to find out the management and direction of two
components. The magnitude is determined by using the following equations.

Mt =

Pt = where, suffix P is used for the pinion

Pt = pt tan

The tangential component Pt acts at the pitch circle radius there for,

Pt (d/2) = Mt or Pt =

Pr = Pt tan

The resultant force Pt is given by

PN =

The above analysis gear tooth force is based on the following assumptions;

I) as the point of contact moves, the magnitude of resultant force PN changes. This effect is
neglected in the above analysis.

II) It is assume that only that only one pairs of teeth takes the entire load. At times the there are
two pairs, that are two pairs that are simultaneously in contact and share the load this aspect is
neglected in the analysis.

III) The analysis is valid under static conditions, (i.e. when the gear is running at very low
velocities).

In practice there are dynamic forces in addition to force due to power transmitted. The effect of
the dynamic forces is neglected in the analysis. Given by;

Pt = PN cos

Pr = PN sin

Pr = Pt tan

Where, = pressure angle = 20

Pt = PN cos

PN = = there for 208.8 N

Pr = PN sin = 208.8 N sin 20 there for

Pr = 71.4 N

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3.7Part design

3.7.1Chain drive
Belt and rope drives that slipping may occur. In order to avoid slipping, steel chains are used.
The chains are made up of number of rigid links which are hinged together by pin joints in order
to provide the necessary flexibility for wrapping round the driving and driven wheels. These
wheels have projecting teeth of special profile and fit into the corresponding recesses in the links
of the chain. The toothed wheels are known as sprocket wheels or simply sprockets. The
sprockets and the chain are thus constrained to move together without slipping and ensures
perfect velocity ratio.
The chains are mostly used to transmit motion and power from one shaft to another, when the
centre distance between their shafts is short such as in bicycles, motor cycles, agricultural
machinery, conveyors, rolling mills, road rollers etc. The chains may also be used for long centre
distance of up to 8 meters. The chains are used for velocities up to 25 m / s and for power up to
110 kW. In some cases, higher power transmission is also possible.
Advantages and Disadvantages of Chain Drive over Belt or Rope Drive
Following are the advantages and disadvantages of chain drive over belt or rope drive:

Advantages
1. As no slip takes place during chain drive, hence perfect velocity ratio is obtained.

2. Since the chains are made of metal, therefore they occupy less space in width than a belt or
rope drive.
3. It may be used for both long as well as short distances.
4. It gives high transmission efficiency (up to 98 percent).
5. It gives fewer loads on the shafts.
6. It has the ability to transmit motion to several shafts by one chain only.
7. It transmits more power than belts.
8. It permits high speed ratio of 8 to 10 in one step.
9. It can be operated under adverse temperature and atmospheric conditions.

Disadvantages
The production cost of chains is relatively high.

The chain drive needs accurate mounting and careful maintenance, particularly lubrication and
slack adjustment.
The chain drive has velocity fluctuations especially when unduly stretched.

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.
Figure(3d): simple roller chain

3.7.1.1 Design of chain Drive

There are two important rules in design of chain drive. They are as follows:
The number of pitches or links o the chain should be always “even”
The number of teeth on the driving sprocket should be always “odd” such as 17, 19, or 21 etc
The odd number of teeth of the sprocket, in combination off even number of chain length
facilitates uniform wear, in this combination, every time anew link comes in contact with
particular tooth on the sprocket and the wear is distributed.
We can calculate the pitch (p) value of chain

P ( )2/3 _ _ _ _ _ _ _ _ _ _ _ _ equation (1)

Due to this equation (1) substitute the values of variable we get P

Table (3b): dimensions and breaking loads of roller chains

Iso chain Pitch (p) Roller Width(b) Transverse
number In-mm diameter(d) In- pitch (pt) Simple duplex Triplex
In-mm(max) mm(min)
05B 8.00 5.00 3.00 5.64 4,400 7,800 11150
06B 9.525 6.35 5.72 10.24 8,900 16,900 24,900
08A 12.7 7.95 7.85 14.38 13,800 27,600 41,400
(ANSI- 12.7 8.51 7.75 13.92 17800 31100 44,500
40)
08B
10A 15.875 10.16 9.4 18.11 2,800 43,600 65,400

According to the value of pitch we select is chain number 05B.

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Table (3c): service factor (ks)

Type of driven load type of input power
Hydraulic drive electric motor Mechanical drive
Smooth 1.0 1.0 1.2
Moderate shock 1.2 1.3 1.4
Heavy shock 1.4 1.4 1.7

Table (3d): tooth coercion factor (K2)

Number of teeth on K2
the driving
sprocket
15 0.85
16 0.92
17 1.00
18 1.02
19 1.11
20 1.18
21 1.26
22 1.29

Terms Used in Chain Drive:

The following terms are frequently used in chain drive.

Pitch of chain. It is the distance between the hinge centre of a link and the corresponding hinge
centre of the adjacent link, as shown in Fig. It is usually denoted by p.

Pitch circle diameter of chain sprocket. It is the diameter of the circle on which the hinge canters
of the chain lie, when the chain is wrapped round a sprocket as shown in Fig. The points A, B, C,
and Dare the hinge centres of the chain and the circle drawn through these centres is called pitch
circle and its diameter (D) is known as pitch circle diameter. [1]

Fig (3e): terms used in chain drive

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Assume number of strand is single strand then the strand factor (k1) =1.0. Using the above table
and assumptions we can design chain.

Calculation of number of links, the length of chain is always expressed in terms of the number of
links or

L=Ln _ _ _ _ _ _ _ _ _ _ _ _ _ equation (1)

Where, L = length of chain (mm)

L n = number of links in the chain
P = pitch of chain

L n = , from the geometric analysis length of chain (L)

Ln=

Calculation of pitch angle:

_ _ _ _ _ _ _ _ _ _ _ _ equation (2)

Where, pitch angle

Z = number of teeth on the sprocket

The average velocity of the chain is equal to the linear velocity of sprocket

V=W

Next calculate the power rating of the chain in watt

Power rating of chain = _ _ _ _ _ _ _ _ equation (3)

Where, Ks = service factor

K1 = strand factor
K2 = correction factor
The driving power of the chain is down ward in the form of potential energy with specific time
((i.e. 20 min).

Driving power = =

The value of variable comes from tables

Power setting of chain =

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Power transmitted by the chain on the basis of breaking load is given by:

P= (in watt) _ _ _ _ _ _ _ _ equation (4)

Where, WB = breaking load = 4400N from above table

V = the velocity of chain
n = factor of safety for chain take (10-15)
KS = service factor taken from table.

P=

Factor of safety for chains

Factor of safety for chain driver is defined as the ratio of the breaking strength (WB) of the chain
to the total load on the driving side of the chain (W) mathematically.

Factor of safety = _ _ _ _ _ _ _ _ _ _ _ Equation (5)

W=m
WB = 4400N from table

Factor of safety = = 22.426

Since the factor of safety of this chain from table is 7 and the calculation 22.426 is safe.
The chain has made up of plain carbon steel grade 10C4, and its properties are;
Easily hardened by heat treatment
It is stronger and tougher
It is easily welded
It is higher wear resistance

3.7.2 Design of sprocket

Sprocket: there are different constrictions for sprocket wheels; small sprockets up to 100mm in
diameter are usually made of a disk or a solid disk with a hub on one side. They are machined
from low carbon steel bars. Larger sprockets with more than 100mm diameter are either welded
to steel hub or bolted to cast iron hub in general; sprockets are made of low carbon or medium
carbon steel. In certain applications, stain less is used for sprockets.

When the chain velocity is less than 180m/min, the teeth of sprocket wheel are heat treated to
obtain hardness. The teeth are hardened either by car bursting in case of low carbon steel or by
quenching and tempering in case of high carbon steel.
A difference between the gear and sprocket as follows:

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A gear meshes with another gear a sprocket meshes with an intermediate link, namely chain,
which intern meshes with another sprocket.

The face width of gear is usually more with respect to its diameter. The sprockets are
comparatively thin so as to fit between inner link plates of chain.

The teeth of gears have involutes profile, which circular areas are used for the profile of sprocket
teeth.

Note: the number of teeth on the smaller sprocket plays an important role in deciding the
performance of chain drive. Small number of teeth tends to make the drive noisy. A large number
of teeth make chain pitch smaller which is favourable for keeping the drive silent and reducing
shock, centrifugal force and friction force.
The sprocket wheel there are standard profiles or the teeth of sprocket wheel, as illustrated in fig

Figure (3f): tooth profile of sprocket

Table (3e): the Properties sprocket wheel

No Dimension Notation Equation
1 Chain pitch P From table 14.1
2 Pitch circle D
diameter D=

3 Roller diameter d1 From table 14.1

The main values of sprocket are calculated as follows:

From durability and noise considerations, the minimum number of teeth should be 21. (I.e. T=21)
according to geometric analysis the contact between chain and sprocket is at 169°, this is
meshing contact angle. The meshing circumference of sprocket is:

But first we calculate the value of radius.

Pd = _ _ _ _ _ _equation (1)

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Where, P = is pitch it is 800mm from chain design.

Z = number of teeth
Pd = is pitch circle diameter of sprocket

Pd =

R=

Sprocket meshing with chain circumference is

Cs = 79.05mm

Using the value of circumference to finish the working length of chain is revolution (i.e. the
working length of chain is 3000mm)

Revolution it is approximately 38 revolutions this revolution speed duration

is 20 min, then the speed is

Angular velocity of sprocket is calculated as:

Ws = _ _ _ _ _ _ _ _ equation (2)

Where, Ws = angular velocity of sprocket

D = pitch diameter of sprocket
N = Number of revolution

Where,

Torque: it is the multiplication of its radius and load to drive the sprocket

T = F r _ _ _ _ _ _ equation (3)

T = 196.2 N
The power of sprocket is:

P=T _ _ _ _ _ _ _ _ equation (4)

We are calculated the value of torque and angular velocity from equation (2) & (3)

P = 5.26 N.m 5.613 rad/sec = 29.52 watt,

Because, T = 5.26N.m from equation (3)
Ws = 5.613 rad/sec from equation (2)
Linear velocity of sprocket is angular velocity time’s radius

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V = Ws _ _ _ _ _ _ _ _ _ equation (5)

Where, V = linear velocity

Ws = angular velocity of sprocket
Ds = pitch diameter of sprocket

V = 5.613

Due to the value of pitch of chain we can select iso chain number 05b in properties o the sprocket
table taken as:
Roll diameter (d1) = 5mm
With between inner plates (b1) =3mm
Transverse pitch (pt) = 5.64mm
Top diameter (Da) max = D+1.25p-d1 = 53.6+1.25(8)-5 = 58.6 mm

(Da) min = D+ p (1- ( )

Root diameter (Df) = D –

= 53.6

Roller seating radius ( √ ) = 2.643 mm

Tooth flank radius ( (z2 +180) = 24.84 mm

Roller seating angle (

( ) = 135.7°

Tooth height above the pitch polygon (

= 2.8 mm

Tooth side radius (

Tooth width (bf1) = 0.93b, if

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= 0.95b, if , due to this p= 8.00mm

So we can calculated by bf1 =0.93

Tooth side relief (ba) = 0.19 to 0.15 p

= 0.8 up to 1.2

3.7.3 Design of gear train

The slipping of a belt or rope is a common phenomenon, in the transmission of motion or power
between two shafts. The effect of slipping is to reduce the velocity ratio of the system. In
precision machines, in which a definite velocity ratio is of importance (as in watch mechanism),
the only positive drive is by gears or toothed wheels. A gear drive is also provided, when the
distance between the driver and the follower is very small. [2]

Gear Materials
The material used for the manufacture of gears depends upon the strength and service conditions
like wear, noise etc. The gears may be manufactured from metallic or non-metallic materials. The
metallic gears with cut teeth are commercially obtainable in cast iron, steel and bronze. The non-
metallic materials like wood, rawhide, compressed paper and synthetic resins like nylon are used
for gears, especially for reducing noise.

The cast iron is widely used for the manufacture of gears due to its good wearing properties,
excellent mach inability and ease of producing complicated shapes by casting method. The cast
iron gears with cut teeth may be employed, where smooth action is not important.

The steel is used for high strength gears and steel may be plain carbon steel or alloy steel. The
steel gears are usually heat treated in order to combine properly the toughness and tooth
hardness.

Material selection of gear

The speed reduction or velocity ratio for a single pair of spur or helical gears is normally taken as

6:1 on rare occasions, this can be raised to 10:1, when velocity ratio increases, the size o gear
wheel increases, also increase material cost.
The desirable properties of a gear material are as follows:
The load carrying capacity of a gear tooth depends up on the ultimate tensile strength or

Yield strength of the material. When the gear tooth is subjected to fluctuating forces the
endurance strength o the tooth is the deciding factor. The gear material should have sufficient
strength to resist failure due to breakage of the tooth.

In many cases, it is wear rating rather than strength rating which decides the dimension of the
gear tooth. The resistance to wear depends up on alloying elements, grain size, and percentage o
carbon surface hardness. The gear material should have sufficient surface endurance strength to
avoid failure due to instructive pitting.
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For high speed power sliding velocities are very high and the material should have a low
coefficient of friction to avoid failure due to scoring.

The amount off thermal distortion or wiping during the heat treatment process is major problem
in gear application.

Larger size gears are made of gray cast iron of grades FG200, FG 260 or FG350. They are cheap
and generals less noise compared with steel gears and also they have a good resistance. [1]

Gray cast iron has been the following properties.

 Good wear resistance

 Rigidity
 Easily manufactured
 Good bending strength
 Cheap and abundantly available

Gray cast iron

Ultimate tensile strength 100-400 Mpa
Ultimate compressive strength 3 to 4 times ultimate tensile strength
Modulus of elasticity 75 to 150 GPA
75000 Mpa = 75 GPA = 75000N/mm2

Terms used in Gears

The following terms, which will be mostly used in this chapter, should be clearly understood at
this stage.
1. Pitch circle. It is an imaginary circle which by pure rolling action, would give the same motion
as the actual gear.

2. Pitch circle diameter. It is the diameter of the pitch circle. The size of the gear is usually
specified by the pitch circle diameter. It is also called as pitch diameter.
3. Pitch point. It is a common point of contact between two pitch circles.

4. Pitch surface. It is the surface of the rolling discs which the meshing gears have replaced at the
pitch circle.

5. Pressure angle or angle of obliquity. It is the angle between the common normal to two gear
teeth at the point of contact and the common tangent at the pitch point. It is usually denoted by .
1
The standard pressure angles are 14 /2° and 20°.
6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of the tooth.
7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom of the tooth.

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8. Addendum circle. It is the circle drawn through the top of the teeth and is concentric with the
pitch circle.

9. Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also called root
circle.

Note: Root circle diameter = Pitch circle diameter × cos , where is the pressure angle.

10. Circular pitch. It is the distance measured on the circumference of the pitch circle from a
point of one tooth to the corresponding point on the next tooth. It is usually denoted by pc.
Mathematically,
Circular pitch, pc= D/T
Where, pc=diameter of pitch circle, and
T= number of teeth on wheel

A little consideration will show that the two gears will mesh together correctly, if the two wheels
have the same circular pitch.

Note: If D1 and D2 are the diameters of the two meshing gears having the teeth T1 and T2
respectively; then for them to mesh correctly,
11. Diametrial pitch. It is the ratio of number of teeth to the pitch circle diameter in millimetre.

12. Module. It is the ratio of the pitch circle diameter in millimetres to the number of teeth. It is
usually denoted by m. mathematically,
Module, m = D / T

Note : The recommended series of modules in Indian Standard are 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6,
8, 10, 12, 16,20, 25, 32, 40 and 50.The modules 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5,5.5, 7, 9,
11, 14, 18, 22, 28, 36 and 45 are of second choice.

13. Clearance. It is the radial distance from the top of the tooth to the bottom of the tooth, in a
meshing gear. A circle passing through the top of the meshing gear is known as clearance circle.
14. Total depth. It is the radial distance between the addendum and the dedendum circle of a
gear. It is equal to the sum of the addendum and dedendum.

15. Working depth. It is radial distance from the addendum circle to the clearance circle. It is
equal to the sum of the addendum of the two meshing gears.
16. Tooth thickness. It is the width of the tooth measured along the pitch circle.

17. Tooth space. It is the width of space between the two adjacent teeth measured along the pitch
circle.

18. Backlash. It is the difference between the tooth space and the tooth thickness, as measured on
the pitch circle.

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19. Face of the tooth. It is surface of the tooth above the pitch surface.
20. Top land. It is the surface of the top of the tooth.
21. Flank of the tooth. It is the surface of the tooth below the pitch surface.
22. Face width. It is the width of the gear tooth measured parallel to its axis.
23. Profile. It is the curve formed by the face and flank of the tooth.24. Fillet radius. It is the
radius that connects the root circle to the profile of the tooth.

25. Path of contact. It is the path traced by the point of contact of two teeth from the beginning to
the end of engagement.

26. Length of the path of contact. It is the length of the common normal cut-off by the addendum
circles of the wheel and pinion.

27. Arc of contact. It is the path traced by a point on the pitch circle from the beginning to the
end of engagement of a given pair of teeth. The arc of contact consists of two parts, i.e.
(a) Arc of approach. It is the portion of the path of contact from the beginning of the engagement
to the pitch point.

(b) Arc of recess. It is the portion of the path of contact from the pitch point to the end of the
engagement of a pair of teeth. Note: The ratio of the length of arc of contact to the circular pitch
is known as contact ratio (i.e. the ratio of Number of pairs of teeth in contact of spur gear.)[1]

This a cylindrical shaped spur gear in which the tooth are parallel to the axis. It is the most
common used gear with a wide range of applications and is the easiest to manufacture. The
calculation for spur gear is also simple and they are used as the basis for the calculations for other
types of gears. The meshing of standard gears means the reference circle of two gears contact and
roll with each other. (I.e. Meshing gears are like pinion and gear).Assumptions:
Number of teeth on larger gear NT1=72
Gear ratio of largest gear over small gear NG12=4
Module M=3mm

Reference pressure angle

Number of teeth for smaller gear,

Using speed ratio NG12=

NG12= =

4= ⇒ T2=72

NT2=18

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Number of teeth of smaller gear is 18, and larger gear is 72.

Centre distance (a) ( ) ( ) =150mm

Where z=number of teeth

Pitch circle diameter or reference diameter (d) = Z

Smaller gear (d2) = 18 mm

Larger gear (d1) = 72

Base diameter (db) = d

Where,
db1=202.97mm

db2=50.74mmaddendum (ha) = 1.00

ha1=ha2=3mm

Addendum (hd) = 1.25

hd1=hd2=3.75mm

Tooth depth (h) =2.25

h1=h2=6.75mm

Tip diameter (da) = d +2

da1 = 222mm, da2 = 60mm
Root diameter (df) = d-2.5m
df1 = 208.5mm, df2 = 46.5mm
Speed of gear two is using speed ratio (NG12) = (NG2/NG1)

⇒ 4 = (NG2/2 rpm)
NG2 = 8 rpm
Note: the subscripts 1 & 2 denoted as smaller gear and larger gear respectively.

N.B: the velocity v of any point on the circle must be the same for all the gears other ways they
would be sleeping.

Angular velocity of meshing spur gears are (W) =

For larger gear, W1= = 22.62 mm/sec

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For smaller gear, W2= = 22.62 mm/sec

Circular pitch (pc) = = 9.42 mm

Diameteral pitch (pd) = = = = 0.33 mm

Face width (b) may be taken as 3 pc to 4 pc or (9.5m to 12.5m) for cut tooth and 2 pc to 3 pc or
(6.5 m to 9.5 m) fore cast teeth. We can take average of cut tooth variation (i.e. 11mm).
Face width, (b) = 11m=33mm

Design Considerations for a Gear Drive

In the design of a gear drive, the following data is usually given:
1. The power to be transmitted.
2. The speed of the driving gear,
3. The speed of the driven gear or the velocity ratio, and
4. The centre distance
The following requirements must be met in the design of a gear drive:

(a) The gear teeth should have sufficient strength so that they will not fail under static loading or
dynamic loading during normal running conditions.

(b) The gear teeth should have wear characteristics so that their life is satisfactory. (c) The use of
space and material should be economical.

(d) The alignment of the gears and deflections of the shafts must be considered because they
effect on the performance of the gears.
(e) The lubrication of the gears must be satisfactory.

Dynamic Tooth Load

In the previous article, the velocity factor was used to make approximate allowance for the Effect
of dynamic loading. The dynamic loads are due to the following reasons:
1. Inaccuracies of tooth spacing,
2. Irregularities in tooth profiles, and
3. Deflection of teeth under load

A closer approximation to the actual conditions may be made by the use of equations based on
extensive series of tests, as follows:

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Table (3f): the value of endurance limit ( es)

WD= WT + W Where, WD= Total dynamic load,

WI= Increment load due to dynamic action.

But, C =

Where, C= value of deformation factor for cast iron 20° full depth in volute system
K = load stress factor

WT = in calculating dynamic load (WD) the value of tangential tooth load may be calculated by
neglecting the service factor (CS)

WI = WT +
√

WT = p/v = 0.448watt/0.0213m/sec =21.03N

Table (3g): value of deformation factor

Material Value of deformation factor in N/mm2
In volute Tooth error
Pinion Gear 0.01 0.02 0.04 0.06 0.08
Cast iron Cast iron 20° 57 114 128 342 456
Steel Steel 114 228 456 684 912

The load stress factor depends on the maximum fatigue limit of compressive stress, the pressure
angle and the modulus of elasticity of the material of the gears. According to bulking ham, the
load stress factory is given by the following relations.

K=

Where, N/mm2

EP=young’s modules for mate55rial of the pinion in N/mm2

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EG=young’s modulus for materials of the gear in N/mm2

K=0.111 for 20°full depth in volute system

In calculating the dynamic load (WD), the value of tangential load (WT) may be calculated by
neglecting the service factor (CS).
From the values of deformation factor table we take e=0.01mm, c=57N/mm

WI = W T +
√

= 21.03 +
√

= 21.03N +

= 1.869N+21.03N
= 22.9N

WD=WT+WI=21.03N+22.9N=43.93N

Static Tooth Load

The static tooth load (also called beam strength or endurance strength of the tooth) is obtained by
Lewis formula by substituting flexural endurance limit or elastic limit stress (

e) In place of permissible working stress ( w)

Static tooth load or beam strength of the tooth (ws)

WS= e b pc y = e b m y

The following table shows the values of flexural endurance limit ( e) for different materials.

Table (3h): Values of flexural endurance limit.

Material of pinion & gear Berinell hardness Flexural endurance
number ( BHN) limit
( ) in Mpa
Gray cast iron 160 84
Semi-steel 200 126
Phosphor bronze 100 168
Steel 150 252

Ws =

= 84N/mm
= 3691.53N

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Buckingham suggests the following relationship between WS & WD.

3691.53N N

For safety, tooth breakage, the static tooth load (WS) should be greater than the dynamic load
(WD).
Finally find wear tooth load by using the relation

WW = DP

The wear load (WW) should not less than the dynamic load (WD)
Where, Q = ratio factor

Q= for external gear

We use Q = because Of our design is the external gear.

Q=

K = load stress factor also known as material combination factor in N/mm2 (i.e. k = 0.111)

WW = 216

WW = 1139N .

Causes of Gear Tooth Failure

The different modes of failure of gear teeth and their possible remedies to avoid the failure are as
follows:

1. Bending failure. Every gear tooth acts as a cantilever. If the total repetitive dynamic load
acting on the gear tooth is greater than the beam strength of the gear tooth, then the gear tooth
will fail in bending, i.e. the gear tooth will break.

In order to avoid such failure, the module and face width of the gear is adjusted so that the beam
strength is greater than the dynamic load.

2. Pitting. It is the surface fatigue failure which occurs due to much repetition of Hertz contact
stresses. The failure occurs when the surface contact stresses are higher than the endurance limit
of the material. The failure starts with the formation of pits which continue to grow resulting in
the rupture of the tooth surface.

In order to avoid the pitting, the dynamic load between the gear teeth should be less than the
wear strength of the gear tooth.

3. Scoring. The excessive heat is generated when there is an excessive surface pressure, high
speed or supply of lubricant fails. It is a stick-slip phenomenon in which alternate shearing and
welding takes place rapidly at high spots. This type of failure can be avoided by properly

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designing the parameters such as speed, pressure and proper flow of the lubricant, so that the
temperature at the rubbing faces is within the permissible limits.

4. Abrasive wear. The foreign particles in the lubricants such as dirt, dust or burr enter between
the teeth and damage the form of tooth. This type of failure can be avoided by providing filters
for the lubricating oil or by using high viscosity lubricant oil which enables the formation of
thicker oil film and hence permits easy passage of such particles without damaging the gear
surface.

5. Corrosive wear. The corrosion of the tooth surfaces is mainly cause’s type of wear; proper
anti-corrosive additives should be used.

3.7.4 Design of shaft

Shaft; is a rotating machine element which is used to transmit d due to the presence of corrosive
elements such as additives present in the lubricating oils. In order to avoid this power from one
place to another, The power is delivered to the shaft by some tangential force and resultant torque
(twisting moment) set up within the shaft permits the power to be transmitted to various
machines linked up to the shaft. In order to transfer the power from one shaft to another the
various member such as pulleys, gears etc. are mounted on it. These members along with the
force exerted up on the causes the shaft to bending. In other words shaft is used for transmission
of torque and bending moment.

Materials used for shaft

The material used for shafts should have the following properties;
– It should have high strength
– It should have good mach inability
– It should have low notch sensitivity factor
– It should have good heat treatment properties
– It should have high wear resistance
The material for ordinary shaft is carbon steel grades 40c8, 45c8, 50c8 and 50c12.
Carbon steel is selected for shaft material which has 290 N/mm2 yield shear stress grade
50c12.this carbon steel has satisfy the above properties.

Manufacturing of Shafts
Shafts are generally manufactured by hot rolling and finished to size by cold drawing or turning
and grinding. The cold rolled shafts are stronger than hot rolled shafts but with higher residual
stresses. The residual stresses may cause distortion of the shaft when it is machined, especially
when slots or keyways are cut. Shafts of larger diameter are usually forged and turned to size in a
lathe.

Types of Shafts
The following two types of shafts are important from the subject point of view:

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1. Transmission shafts. These shafts transmit power between the source and the machines
absorbing power. The counter shafts, line shafts, over head shafts and all factory shafts are
transmission shafts. Since these shafts carry machine parts such as pulleys, gears etc., therefore
they are subjected to bending in addition to twisting. [4]
2. Machine shafts. These shafts form an integral part of the machine itself. The crank shaft is an
example of machine shaft.
Standard Sizes of Transmission Shafts (b) Shafts subjected to bending moment only,
(c) Shafts subjected to combined twisting and bending moments, and
(d) Shafts subjected to axial loads in addition to combined tensional and bending loads.

⁄ ………………………………...................................................................... (1)

Where; WN normal tooth load and

WT tangential tooth load

Pressure angle for full depth in volute system

A trust parallel equal to WN will act at the gear centre as shown in the figure below.

Figure (3g): load acting on gears

The weight of the gear is given by;

WG ………….............................................................................. (2)

Where; WG number of teeth on the larger gear

b face width in mm

m module in mm

3. Now the resultant load acting on the gear can be evaluated as

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WR = √ ……………………................... (3)

4. If the gear is over hung on the shaft then bending moment on the shaft due to the resultant
load,

M WR X……………………………………………………………….................... (4)

Where; M bending moment, X over hung ie the distance between the centre of gear and the
centre of bearing

5. Since the shaft is under the combined effect torsion and bending, therefore we shall determine
the equivalent torque. We now that the equivalent torque;

Te √ …………………………………………………………....................... (5)

Where; T twisting moment WG ⁄

DG diameter of larger gear

Now the diameter of the shaft (d) is determined by using the following relation. i.e

Te ⁄ ……………………………………………………………….... (6)

Where; the yield shear stress for the gear shaft material

To calculate the diameter of the shaft we should calculate the gear weight, normal tooth
load, and the resultant gear load. And also there is additional suspended weight of 20 kg of sand
with 1 kg of sprocket on the shaft.
We can calculate Gear weight:

(WG) ........................................................................ from equation (2)

25.23 N

Weight of sprocket 1kg 9.81 ⁄ 9.81N

The suspended weight on the chain side 20kg 9.81 ⁄ 196.2 N

The total load on the shaft is the sum of all the above 231.24 N.
Then calculate the normal tooth load (WN)

WN = 196.2N/COS 20

= 208.79N by using equation (1) formula

WT = 196.2N from gear design
The resultant load acting on the gear is by using equation (3)

WR =√

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= 472.35N

The gears are over hung on the shaft the shaft the bending moment on the shaft due to the
resultant load can be calculated as follow:

M = WR Where; x is the distance from gear center to the bearing centre assume 220mm.

M = 472.35

=103918.15N-mm

Since the shaft is under the combined effect of torsion and bending, therefore we should
determine the equivalent torque (Te)

Where,

Yield shear stress for steel (Sy) = 290N/mm2

SSy= = 290/2 = 145 N/mm2

Shear stress ( ) = , assume factor of safety is 3

D =√
=27.24mm, say 30mm

The standard diameter of shaft is 30mm.

Then we need to check the selected material strength by calculating shear stress of our shaft
design (material).

= should less than 29N/mm2

Then 0.277N/mm2 is less than 29N/mm2, since our material has enough strength.

Calculation of shaft two diameters:

Assuming that the torque at b and c is the same (i.e. 283.9N/mm), and also tangential force on the
gear c, acting down ward.

Ftc =

And tangential force on the larger pulley d, acting horizontally,

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Ftd =

The vertical and horizontal load diagram is c and d respectively. Now let us find the maximum
bending movement for vertical and horizontal loading. First of all, considering the vertical load at
c let RAV and RBV be the reactions at the bearings A and B respectively. We know that

RAV RBV = 262.9N

Taking moments about A we get; RBV

RBV = 262.9 and RAV = 262.9-96.4 = 166.5N

We know that bending movement at A and B

MAV = MBV = 0

Bending movement (BM) at C, MCV = RAV

BM at D, MDV = RBV

See the bending moment diagram for vertical loading, now considering horizontal loading at D,
let RAH and RBH Be the reactions at the bearings A and B Respectively, we know that
RAH + RBH = 1059.3N
Taking moments about A, we get

RBH
RBH = 1011.7N
RAH = 4718.7N-1011.7N = 3707N
We know that B.M at A and B
MAH = MBH = 0

Bending moment at c; MCH = RAH

Bending moment at D; MDH = RBH

Look at the bending movement diagram for horizontal loading at f we know that resultant
bending moment diagram at c:

MC =√ √

=408181N-mm
And also bending moment at point D;

MD =√ √

=105955.6N-mm

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The resultant bending moment diagram shows that the bending movement is maximum at d
(larger pulley). Maximum bending movement M=MC = 408118N-mm.

Power is supply to the shaft (p) =

Where;
T= F

⇒
A steel solid shaft transmitting approximately 0.5947 watt at 8rpm is supported on two bearings
600mm apart and has one gear and one larger pulley hub keyed to it.
We can see bending moment diagram of shaft two is:

Figure (3h): bending moment diagram

Since the second shaft under the combined effect of torsion and bearing, therefore we should able
to determine the equivalent torque.

Te=√ Where T= twisting moment

Te =√

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= 402955.9N-mm

T = WT = 2189.6N-mm

Now the diameter of shaft (2) is determined by using the following relations.

Te= -----------------------------------------------------equation

Where, =Shear stress from the selected material i.e carbon steel

Yield shear stress for steel is SY = 290N/mm2

2
SSY

Shear stress ( ) = , Assume factor of safety FS=3

Using the above equation Te=

402955.9 =

D2 =√
D2=29.06mm, we can say 30mm.it is also standard diameter of shaft

3.7.5 Design of v- belt with pulley

V-belt is mostly used in factories and workshops where a great amount of power is to be
transmitted from one pulley to another when the two pulleys are very near to each other. The V-
belts are made of fabric and cords moulded in rubber and covered with fabric and rubber.

Figure (3i): pulleys with v belt

In our design the transmitted power the belt velocity ratio:

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Length of the belt that passes over the driver in one minute =

Length of the belt that passes over the follower in one minute =

Then, _ _ _ _ _ _ _equation (1)

Velocity ratio of the belt

The peripheral velocity of the belt on the driving pulley

V1 =

V2 = m/sec for driven pulley _ _ _ _ _ _ equation (2)

If V1 = V2 there is no slip.
Density of belt material in the following table

Table (3i): density of belt material

Material Mass density in kg/m3
Leather 1000
Convulse 1220
Rubber 1140
Balata 1110

Coefficient of friction between belt and pulley depends up on the following factors.
The material of belt
The material of pulley
The slip of belt
The speed o belt

For leather belt cast iron pulley.

V = speed of the belt in meters per minute

Length of pulley in terms of diameter off pulley can be expressed as:

L= _ _ _ _ _ _ _ equation (3)

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Figure (3j): basic belt drive geometry

Where, radial of larger and smaller pulley in (N)

C= distance between the centre of two pulleys

L = Total length of the belt.
T1& T2 = tensile in the tight side & slack side of the belt in (N)
V = Velocity of a belt in m/sec
P = (T1 – T2) V = Watt _ _ _ _ _ _ _ equation (4)
Maximum tension in the belt

A little consideration will show that the maximum tension in the belt (T) is equal to the total
tension in the tight side of the belt (Tt1)

T= _ _ _ _ _ _ equation (5)

Where, maximum safe stress

b = width of the belt
t = thickness of the belt
To design the belt there are some assumptions:

Assume: the diameter of the larger pulley should be less than the centre to centre distance
between larger and smaller gear which is 150mm from gear design since we can assign the radius
of larger pulley less 150mm which will be 125mm radius = 250mm diameter and the smaller
pulley diameter is less to get high speed ratio which will be 40mm.

From this we can determine the velocity ratio by inserting the diameter of larger and smaller
pulley in equation (1)

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Speed ratio = = 6.25

Where, d1= diameter of longer pulley

d2= diameter of smaller pulley

Then from the poor design the longer gear has a speed of 8rpm which used as in put for larger
pulley then we can determine the speed of smaller pulley in rpm.

N1 = N2 (6.25) = 8RPM (6.25) = 50RPM for smaller pulley

After determine the speed of each pulley calculate the linear velocity of each pulley also as
follows.

V1 = where, N1 = 8rpm, d1 = 250 mm

= 0.1047 m/sec

V2 = where, d2 = 40 mm, N2 = 50rpm

= 0.1047 m/sec
Since the linear velocity of each pulley equal there is no slip in the belt drive.

To calculate the length of belt first determines the centre distance between from one pulley to the
next pulley(x).

C- Can be determine based on the amount of speed ratio. Since the velocity ratio less than 3 X
will be:

C = d1+ 1.5 d2 and for velocity ratio more than 3X will be equal to the diameter of larger pulley
hence, X1 = d1 = 250 mm
Then we can determine the length of the belt by using equation (3).

L=

= 1039.6 mm = 1040 mm
Since 1040 mm length belt is needed.
Power from belt drive can be calculated by using equation (4)

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= 0.26

sin = where, r1 = 125mm, r2 =20mm, x = 250mm

sin

α sin = 24.8

= 2.2747 rad
T1 = 1.8T2 _ _ _ _ _ _ _ _ _ _ _ equation (6)
From gear design the smaller gear transmit the power to the larger pulley is 118.9 watts.
Then determine the tension in the tight side of the belt.

118.9 = (T1 T2) V

(T1 T2) = _ _ _ _ _ _ _ _ _ _ _ _ equation (7)

= 1135.6 N
From equation (6) determined the tension in the slack side of the belt (T2)
T1 = 1.8 T2

T2 = _ _ _ _ _ _ _ _ _ _ _ equation (8)

Then the tension of the belt can be determined by using equation (6) & (7)

(T1 T2) = 1135.6N, but T1 =1.8T2

(1.8T2 T2) = 1135.6N

0.8T2 = 1135.6N
T2 =1418.75N

T1 = 1418.75

Power transmitted by the belt can be determined by the following equation in both larger and
smaller pulley.
P1 = T1 (V) = 26.737 Watts
P2 = T2 (V) = 62.4 Watts
Where, P = power transmitted from larger pulley to the smaller pulley.

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P2 = Power transmitted to the fly wheel or to the next machine part.

To calculate the width & thickness of belt & pulley first of all take the following stresses may be
taken for design purpose.

Shaft key:
Tension & compression ( ) = 80 mpa = 80 N/mm2

Shear ( s= k) = 50 Mpa = 50 N/mm2

Belt tension ( b) = 15 Mpa.

We know that the centrifugal stress ( t) of the material

0.5 106 = 7200 V2

V = 25 m/sec

The cross section area of the belt = b t = b 10mm, where t = 10 mm

= 10b mm2 = m2

Mass of the belt per meter = area length density. Where, Density of cast iron is 1000 kg/m3

M=

= 0.0104b kg/m
Next calculate the centrifugal tension of the belt.
We know that centrifugal tension (TC) = MV2 _ _ _ _ _ _ _ _ equation (8)

TC = 0.0104b sec

= 1.14b N _ _ _ _ _ _ _ _ _ equation (9)

The maximum tension in the belt will be finding as the following relation from equation (5)

T = 2.5 N/mm2 _ _ _ _ _ _ _ _ _ _ equation (10)

We know that the relation of tension in the tight side of the belt (T1)

T1 = T –TC _ _ _ _ _ _ _ _ _ _ _ equation (11)

T1 = 25b 1.14b N

2553.75N = 25b 1.14b N)

= N

b=

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Width of the belt in standard 100mm

So we can calculate the width of pulley .by using the relation of pulley and belt standard
dimensions;
WP=1.25WB
Where WP=Width of pulley
WB=Width of belt
WP=1.25(100) mm

WP=125mm

Calculation for Diameter of shaft three

Let TC1andTC2are tensions in the tight side and slack side of the belt for pulley D, We know that
torque transmitted by the pulley D is;
T= (TD1-TD2) RD where, RD is radius of pulley D=125mm
TD1=2553.75N
TD2=1418.75N
T= (2553.75N-1418.75N) (0.125mm)
T=141.95N-m
For solid shaft, we know that we can calculate the diameter of shaft.

Where, shear stress from the selected material i.e. carbon steel
Yield shear stress for steel is SY = 290N-mm2
2
SSY

Shear stress ( ) = , Assume factor of safety FS=3

Using the above equation T= we can get diameter formula

D=√

D= √ =24.56mm

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The shaft diameter standard value is to be say D=25mm.

3.7.6 Return mechanism

While the suspended weight slides 3000mm height slowly, the sprocket rotates clockwise
direction. During this time, the time taken to reach from high level to the ground is the lighting
time. Since after the weight hit the ground, never return upward direction without any source of
power.
So to return up ward direction the return mechanism is needed. This return mechanism is
operated by one person by using handle to turn 3000mm long chain anti clockwise direction as
much as possible rapidly.

The return mechanism contains two plates with roller casing. The plates are put at both ends of
roller case. One end of the chain connected to the roller casing hardly. Roller casing is set a
rectangular steel bar made by welding frame as length of 600mm long.
Calculation of return mechanism:
Assumptions:
The time taken for one revolution is 4 second
Diameters of roller casing shaft = 130mm

Human effort estimated from (193-210) N by helping freely rotating roller. It is safe for to lift the
weight.

Length of roller casing is depend up on width of chain (w = 5mm with clearance) it is gap of
plates.

Circumference of roller (CR) = 2

=2 = 40mm
Then calculate the required return revolution to turn 3000mmchain length is given as;

Revolution = = =7.353revolutions

The chain mounted on roller is fluently arranged and this revolution decrease that becomes 7
revolution.

Circumference of plate (Cp) = CR c where, CR is circumference of roller 408mm

Tc is thickness of chain

(Cp) = 408

From our assumption one revolution is equal to four seconds. Then for 7.35 revolutions will be
stay in 29 second duration of return turning. This is known as return set up duration time.

Time checking

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The average velocity of chain is given by;

Vav = Where, from geometric analysis the chain contact with sprocket

d= pitch diameter of sprocket

N= speed in rpm

Vav=

= 9.2936
To find the time duration for the mass to move from the height of three meter is:

Distance = velocity

Time =

T=

Therefore the lighting duration will be 3228 second or 53.8 minutes.

We are assigning to assumption for the light duration will be firstly 20minutes, but our design
will becomes for 53.8 minutes. So our design will be satisfy the light duration consideration.

3.7.7 Roller ball bearing

In rolling contact bearings, the contact between the bearing surfaces is rolling instead of sliding
as in sliding contact bearings. The ordinary sliding bearing starts from rest with practically metal-
to-metal contact and has a high coefficient of friction. It is an outstanding advantage of a rolling
contact bearing over a sliding bearing that it has a low starting friction. Due to this low friction

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offered by rolling contact bearings, these are called antifriction bearings. [1]

Figure (3k): roller ball bearing

Advantages and Disadvantages of Rolling Contact Bearings over Sliding Contact Bearings:
The following are some advantages and disadvantages of rolling contact bearings over sliding
contact bearings.

Advantage
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.

Disadvantages
1. More noisy at very high speeds.

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2. Low resistance to shock loading.

3. More initial cost.
4. Design of bearing housing complicated.

Types of Rolling Contact Bearings

Following are the two types of rolling contact bearings:
1. Ball bearings; and
2. Roller bearings.

The ball and roller bearings consist of an inner race which is mounted on the shaft or journal and
an outer race which is carried by the housing or casing. In between the inner and outer race, there
are balls or rollers. A number of balls or rollers are used and these are held at proper distances by
retainers so that they do not touch each other. The retainers are thin strips and are usually in two
parts which are assembled after the balls have been properly spaced. The ball bearings are used
for light loads and the roller bearings are used for heavier loads.
The rolling contact bearings, depending upon the load to be carried, are classified as:
(a) Radial bearings, and (b) Thrust bearings.

Bearing supports only a radial load (WR), the plane of rotation of the ball is normal to the centre
line of the bearing, the action of thrust load (WA) is to shift the plane of rotation of the balls. The
radial and thrust loads both may be carried simultaneously.

Standard Dimensions and Designations of Ball Bearings

The dimensions that have been standardized on an international basis, these dimensions are a
function of the bearing bore and the series of bearing. The standard dimensions are given in
millimetres. There is no standard for the size and number of steel balls. The bearings are
designated by a number. In general, the number consists of at least three digits. Additional digits
or letters are used to indicate special features e.g. deep groove, filling notch etc. The last three
digits give the series and the bore of the bearing. The last two digits from 04 onwards, when
multiplied by 5, give the bore diameter in millimetres. The third from the last digit designates the
series of the bearing. The most common ball bearings are available in four series as follows. The
following table shows the principal dimensions for radial ball bearings.

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Table (3j): the principle dimensions for radial ball bearing

According to the shaft and rpm and the above characteristics we are selected from the principal
dimensions for radial ball bearing as for the first and second shaft bearing number 206 are
selected.
Bore diameter (mm) = 30mm
Outside diameter = 62mm
Width (mm) = 16mm

For the last shaft ( = 25mm) we are selected bearing number 205

Bore diameter (mm) = 25m

Outside diameter = 52mm
Width of bearing = 15mm

Bearing is a mechanical element that permit relative motion between parts such as shaft and
housing with minimum friction phosphors bronze (sut=190N/mm2) is select material for bearing
because;

 Soft and high wear resistance

 It has low coefficient of friction, excellent conformability & machinability with low cost.

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Servicing and Maintenance

Maintenance is derived from the word maintain which means to repair the machine or any other
device in order to increase the service life of these machines or devices. The performance of the
machine to be maintained is called maintainability of the machine. Maintain ace is used to
minimize the cost of buying new machines when the previous machine is old. When we have
designed this project, we have considered the maintainability of this machine. In order to be
suitable for maintenance, the bar is locked by bolt with some distance gap. The bar has high
contact with shafts that is2000mm distance from the ground to the first shaft. The distance from
the first shaft to the second shaft is 150 mm and also the distance from second to third shaft is
250 mm. according to the working area the bar is partitioned by a length of (1500,2050,2270)mm
respectively. The roller bearing is maintained by lubrication using lubricants. Lubrication is the
process of lubricating the machines by using lubricants. The fluid oil that is used to lubricate is
called lubricants. Grease is one type of lubricant used for roller ball bearing to move constant
motion and increase service life under its condition.

3.7.8 Key
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key. [10]

There are two basic functions of the key. They are so follows:
1). the primary function of the key is to transmit the torque from the shaft to the gear of mating
elements and vice versa.

2). the second function of the key is to prevent rotational motion between the shaft and joined
machine element like gear or pulley. Arecas or slot machined either on the shaft or in the hub to
accommodate the key is called key way. Keyway is usually by vertical or horizontal milling
cutter.

Types of Keys
The following types of keys are important from the subject point of view:

 Sunk keys and Saddle keys

 Square key and flat key
 Taper key and parallel key with and without gibe head
The selection of types of keys for a given application depends up on the following;

 Power to be transmitted
 Tightness of fit
 Stability of connection
 Cost

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According to the above character select a sunk key, but saddle key is a key that fits in the key
way of the hub only. In this case there is no key way on the shaft. The other one type is sunk key,
this is a key in which half of the thinness of the key fits in to the key way on the shaft and the
remaining half in the key way on the gear there for key ways are required both on the shaft as
wells the hub or gear of the mating element. The standard form of key and may be ether
rectangular or square cross section are give in table.

In sunk key power is transmitted due to shear resistance of the key. The relative motion between
the shear and the hub of gear also prevented by shear resistance of key. Sunk key is suitable for
heavy duty application. Since there is no possibility of the key to slip around the shaft it is the
positive drive this is the main advantage of the sunken key over the saddle key.

Table (3k): dimensions of square and rectangular sunk key

Shaft diameter Key size Key way
Above up to & including b h Depth
6 8 2 3 1.2
8 10 3 3 1.8
10 12 4 4 2.5
12 17 5 5 3.0
17 22 6 6 3.5
22 30 8 7 4.0
30 38 10 8 5.0
38 44 12 8 5.0
44 50 14 9 5.5
50 58 16 10 6.0
58 65 18 11 7.0

Material selection of the key:

The keys are made of plain carbon steels like 45c8 or 50c8 in order to withstand shears and
compressive stresses resulting from transmission of torque according to Indian standards, steel of
tensile strength not less than 600N/mm shall be used as the material for the key.

According to the diameter of shaft (d= 30mm) we are select the dimension of sun key, width of
key (b) = 10mm, height or thickness of key (h) =8mm, and key way depth 5.0mm.

Sunk keys with square or rectangular cross section are wily used in practice. Sunk keys with
rectangular cross section is called flat key. The flat key has more stability as compared to square
key more suitable it is more suitable for machine tool applications, where additional stability of
the connection is desirable. While selecting the square key without stress analysis, following
rules of thumb may be used. The industrial practice is to use a square key with side equal to one
quarter of the shaft diameter and length at least at least 1.5 times the shaft diameter.

b=h=

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L = 1.5 d
Where, b = width of key (mm)
h = height or thickness of key (mm)
L = length of key (mm)
d = diameter of shaft (mm)
For flat key, the thumb-rule dimensions are as follows

b= = = 7.5 mm

h= = = = 5mm

L =1.5d = 45mm

The key is standard key for 30mm diameter shaft, but for 25mm diameter shaft the standard
dimension of the key is:
Width of key (b) = 6mm
Thickness of key (h) = 5mm

Length of key (L) = = 40mm.

3.7.9 Steel Poles

All steel poles will have a metal plate affixed to each pole section which will include the mass
measurement for that section. The most critical pole marker will appear at a height between 0.8m
and 2m above ground level, which should indicate other separable sections as well as details of
its own section. Because the ground level can vary from pole to pole, Austria will nominate a
distance from the pole tip for the nameplate to be installed. The required information to be
provided on the plate will include, name of the manufacturer, year of manufacture, length
(m)/mass (kg) of pole, load capacity (kN), impact classification and identification reference
number. All nameplates should remain visible and legible for the intended life of the pole and
should have reasonable resistance to vandalism and removal. Poles to be direct buried are to be
provided with a depth indication mark welded into the pole which also indicates the orientation
the pole is to be installed.

Poles are made up of steel and it has a solid rectangular shape and with dimension width is
considered as the outside diameter of bearing, that is 80mm and its thickness is considered as the
width of bearing, which is 20mm thick. Generally pole dimension is b is equal to 40 .

3.7.10 Flywheel design

There are two factors that control the amount of energy the flywheel stores: the moment of inertia
and the rotational speed of the flywheel, those are discussed in to literature review for the
previous.

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The mass moment of inertia of the rim is considered and the mass moment of inertia of the
flywheel is in the rim and a small portion is in the hub and arms. Also the hub and arms are
nearer to the axis of rotation, therefore the moment of inertia of the hub and arms is very small.

The density of cast iron may be taken as 7260 kg / m3 and fore cast steel; it may take as 7800 kg
/ m3.
The mass of the flywheel rim is given by

m = Volume × Density = 2 R×A×

Table (3L): permissible value for coefficient of fluctuation of speed (cs)

The permissible values for coefficient of speed (cs) from the above table we can select class of
service flywheel that is gear wheel transmission coefficient of fluctuation of speed (cs) .the
coefficient of fluctuation speed is a limited factor in the design of flywheel. [1] The reciprocal of
coefficient of fluctuation of speed is known as coefficient of steadiness and it is denoted by m,
From table the value of cs=0.02

m=

Dimension of fly wheel

Let D =diameter of fly wheel in meter=124 mm, t =24mm and k =62mm
We now that peripheral velocity of the flywheel

V= = 324.63 ⁄ Where N =50 rpm

A fly wheel absorbs energy its speed increases and when it gives up energy its speed decreases.
Let thickness of rim (tr) =24mm and
Width of rim (br) =2Tr

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Then the cross sectional area of fly wheel rim is width*thickness

But width (br) = 2t

Area of flywheel rim (Ar) = 2

= 1.152

Calculation of moment of inertia for flywheel

I = m k² = 0.0175 kg-m²
Where; m=mass of the fly wheel in kg
K= Radius of gyration of the flywheel in meters
I=moment of inertial for the flywheel about the axis of rotation in kg-m²

E= I = m k² (in N-m)

But = =5.23 ⁄

Since radius of gyration k = 62 mm

Then by substitute the value of the above we get
E =23.65 kg-m²
We know that mass of fly wheel by using the relation,

= 4.5 kg.

Where, density of fly wheel material (cast steel=7800 ⁄ ³)

The mass of the flywheel rim may also be obtained by using the following relation.

Since the rim contributes 92 of the flywheel effect. Therefore by using

I rim = 0.92 I flywheel

We also calculate hoop stress ( ) =

= 7800 (324.63)2

= 822MPa
Fly wheel and pinion gear dimensions:

The flywheel diameter is assuming 80 mm with its gear module 2.5mm. In order to assumption
we can get number of teeth on transmission gear type flywheel that is;

Pd = where, NT = is number of teeth

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m= is module

NT = = 32

The pinion gear pitch diameter (Pd) is can be calculated as assume number of teeth is 16, and also
it has equal module because of meshing of tooth characters. Then it gives as;

Pd= (2.5 ) = 40mm

The relationship between teeth ratio and speed ratio we can get the pinion gear speed (
). (NP = 100 rpm)

The diameter of pinion gear and small pulley is the same then it should be use the same shaft
diameter and material. The fly wheel is horizontally set apart from pulley is 320mm of a shaft
from right or 280mm from left the length of shaft that connects generator and pinion gear
basically 280mm length.

Generally transmission gear type fly wheel has 32 number of teeth with in mesh of a pinion
gear has 16 number of teeth. Due to this meshing the speed of pinion gear (100rpm) and the input
shaft of generator speed is the same and known. According to rated speed we can select type
model.

3.8 DC Generator
Although a far greater percentage of the electrical machines in service are A.C. machines, the
D.C. machines are of considerable industrial importance. The principal advantage of the D.C.
machine, particularly the D.C. motor, is that it provides a fine control of speed. Such an
advantage is not claimed by any A.C. motor. However, D.C. generators are not as common as
they used to be, because direct current, when required, is mainly obtained from an A.C. supply
by the use of rectifiers. Nevertheless, an understanding of D.C. generator is important because it
represents a logical introduction to the behaviour of D.C. motors. Indeed many D.C. motors in
industry actually operate as D.C. generators for a brief period. In this chapter, we shall deal with
various aspects of D.C. generators.[9]

Generator Principle
An electric generator is a machine that converts mechanical energy into electrical energy. An
electric generator is based on the principle that whenever flux is cut by a conductor, an emf is
induced which will cause a current to flow if the conductor circuit is closed. The direction of
induced emf (and hence current) is given by Fleming’s right hand rule. Therefore, the essential
components of a generator are:
(a) a magnetic field
(b) Conductor or a group of conductors
(c) Motion of conductor w.r.t. magnetic field.

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DC Generator: The direct current (DC) generator is only used for special application or local
power generation. The limited of implementation is weaken on commutation required to rectify
the internal generated AC voltage to DC voltage; thereby the operating characteristics of DC
generators are still importance, because most concept can be applied to all others electrical
machine. We can classify the generator machine into two parts.
1. The stationary part generally called “stator”.
2. The rotating part usually called “rotor” or the armature referred to a DC machine.

Generator selection
Selecting the right generator for the job doesn’t take rocket science, but it does take planning. We
must determine that the amount and type of power required and where and for how long that
power is needed in order to pick the right size generator for the job. Three factors play a part in
sizing a generator for the job: type of load, total watts to be connected and power of the generator
on the above selected by type of generator, gear reduction ratio.

Generator power
Once you determine the wattage, you can choose your generator. The basic guide to follow is if
the generator has enough power to start the load, its surge rating, it will have enough power to
continually run it. Considering the above factors we have searched different Dc generator
catalogues from the internet. [13]

Table (3m): Dc generator model type

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Model DG 22 S (1/62)
Rated speed (N) =100 rpm
Rated torque (Tr) = 78.5Nm
Rated voltage (v) = 24v
Rated current (I) =230 A
No load speed = 140rpm
No load current =80 mA
Total length = 54.4 mm
We know that from above data we can get rated power output by a relation bellow
Rated power output = rated current X rated voltage
Pr = Ir x Vr

Pr= 2.3 24V

=55.2watt (sufficient to light a fluorescence lamp)

There are two types of power we know that the mechanical power (pa) = T = 57.5 watt it
occurs the input shaft of generator by 100rpm. The other power is output power of by generator
say electrical power. According to this power we can calculate efficiency of Dc generator.

3.9 Lamp selection

There are different types of lamps. Therefore for a specific application we desired, we should be
wise at selecting them. Considering the following characteristics of lamps will help us when
choosing a lamp for an application.
a. Luminous efficacy

 Luminous flux
 Lamp power and ballast losses
b. Lamp life

 Lumen depreciation during burning hours

 Mortality
c. Quality of light

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 Spectrum
 Correlated colour temperature (CCT)
 Colour rendering index (CRI)
d. Effect of ambient circumstances

 Voltage variations
 ambient temperature
 Switching frequency
 Burning position
 Switch-on and restrict time
 Vibration
e. Luminaries

 Lamp size, weight and shape

 Luminance
 Auxiliaries needed (ballast, starter, etc.)
 Total luminous flux
f. Purchase and operation costs

 Lamp price
 Lamp life
 luminous efficacy

The following table compares the main lamp types and gives the first indication of possible
application fields.

Table (3N): lamp types and their typical charcterstics

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Referring each lump’s advantages and disadvantages from section and also considering the above
parameters in the table we have chosen fluorescence for our project.

3.10 Cost analysis

Cost is the most important factor for every part of any business and in engineering applications in
the case of material selection and others. Cost analysis is also called economic evaluation, cost
allocation, efficiency assessment, cost benefit analysis or cost effective analysis.

Table (3p): table of cost analysis

This table contains some parts not include all parts of the machine. The cost which list in the
table is the actual cost of the parts excluding the manufacturing cost. These are the minimum cost
of some parts. The total cost of the project is the summation of the listed part in the table which is
1914 birr. This is the minimum cost as compared to the cost of kerosene or other light sources for
surviving the dark. In addition, this is advantageous economically and provides safety. The
people buy this machine with 1914 birr and use several years rather than buying kerosene weekly

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or monthly to decrease the cost and avoid burning of fire. Based on this cost information we can
conclude that the design project is more preferable than other light sources (i.e. kerosene).

3.11 Assembly drawing

Assembly drawing is consists of all components of the design. The gravity light assembly
drawing with its part is shown as:

Fig (3L): assembly drawing

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CHAPTER FOUR: CONCLUSION AND RECOMMENDATION

4.1 Conclusion
To design this project we have considered some parameters such as; bending moment, torque, power, and duration of
lighting time, the force and geometric analysis assembly drawing of the project. We have also select materials and design
the parts such as key, chain, sprocket, belt, shaft and bar, bearing is not design simply selected, and also we select the DC
generator by number of rotation of shaft of pinion gear or input shaft. This DC generator type gives output of power due
to this power we are also select type of lamp.

This project contains the calculation of bending moment, torque, output power, and duration of the lightening time, force
analysis, geometric analysis, assembly drawing, and the design considerations such as maintainability, cost analysis,
factor of safety, and the determination of part length, diameter, and width.
Design and model electric power generation using gravity produce 55.2watt electrical power from the input power of 57.5
watt. And also this power is produces starting from a minimum of 2 rpm rotational speed developed to maximum (in put
rpm) for DC generator is 100rpm transmitted by pinion gear. DC generator is selected depend on the maximum rotational
speed and torque which produces 2.3A Current with 24volts.

We conclude that this design project is more advantageous and safe for users. As a result, the design and model for
electric power generation using gravity provides safety for them and is used to avoid the burning of fire for rural areas.

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4.2 Recommendation
 We have recommended that the companies to manufacture our design and we have also recommended companies
economically profitable from this lighting service manufactured.
 We have also recommended the future re designers to design this project within a minimum initial cost.
 Finally we recommended there design mechanism would be continuous that means increasing the duration of
lightening time, by increasing the height of the bar and the light would be used for many villages rather than one
house and the starting mechanism should be automatically rather than manual.

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Reference
1. A text Book of Machine Design, fourteenth edition, R.S KHURMI J.K Gupta, 2005

2.McGraw–Hill Company, Mechanical Engineering Design, six edition, Joseph E. shigley& Charles
R.mischke, 2001
3. chun -chao wang, yun-suning wang “gravity power generation mechanism” united states patent number
4. Machine Element in Mechanical Design, fourth edition, Robert L.Mott
5. www.ijirset.com
6. www.indegogo.com
7. http://www.tadx worwik.com
8. Shigley’s, Mechanical Engineering, 8th edition
9. Google search //about selection of generator//

10. Hand book of mechanical design, second edition, Girtin M. MAITRA L V Prasad

11.gokaraju rangasaju institute of engineering and technology, batchupally-hyderabad A.p india ,2013

12.text book of modern building of installation ,fourth edition

13.www.controllis/aliexpress/bth.com

14. Quality Management power point of Wolli University KIOT 2007 Each Department of Mechanical Engineering

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