A PROJECT REPORT Submitted by in partial fulfillment of the award of the degree of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING FABRICATION OF SELF LUBRICATION SYSTEM FOR COMPLICATED MACHINES J. GAUTHAM KUMAR K. KARTHIK RAJ M. KARTHIK Karthik
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Fabrication of Self Lubrication System for Complicated Machines
FABRICATION OF SELF LUBRICATION SYSTEM FOR COMPLICATED MACHINES
ABSTRACT This system for precisely controlling lubricant supply to one or more rotating mechanical gear parts in machines. The pump draws lubricant form a lubricant source and supplies it to a rotating machine. This system is automated by means of a timer device. The sequential time is controlled by using micro controller, which is fed by a programming language. The time interval can be varied by a controller. Self lubricating system is used to reduce the noise produced inside the machine and to achieve the efficient work.
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Transcript
A PROJECT REPORT
Submitted by
in partial fulfillment of the award of the degree
of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
FABRICATION OF SELF LUBRICATION SYSTEM FOR COMPLICATED MACHINES
J. GAUTHAM KUMAR
K. KARTHIK RAJ
M. KARTHIK
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ABSTRACT
This system reduces manual errors and prevent from major accidents while
lubricating on the complicated machines. It typically delivers a controlled amount
of lubricant (oil) to multiple, specific locations on a machine while the machine is operating,
at specific times from a central location. Self lubrication systems offer superior features than
manual lubrication. The benefits of self lubrication include less downtime due to bearing
failure, reduced man-hours required for the lubrication task, and increased worker safety, as
well as reduced lubricant and cleanup costs.
This system or method for precisely controlling lubricant supply to one or more
rotating mechanical gear parts in machines. The pump draws lubricant form a lubricant
source and supplies it to a rotating machine. This system is automated by means of a timer
device. The sequential time is controlled by using microcontroller, which is fed by a
programming language. The time interval can be varied by a controller. Self lubricating
system is used to reduce the noise produced inside the machine and to achieve the efficient
work.
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TABLE OF CONTENTS
CHAPTER
NO.
TITLE PAGE
NO.
1 INTRODUCTION 1
2 LITERATURE REVIEW 2
3 PROBLEM DESCRIPTION 6
4 FABRICATION OF EXPERIMENTAL SETUP 7
4.1 LAYOUT DESCRIPTION 8
4.2 AC MOTOR 9
4.2.1 AC Motor’s Principle and Working 9
4.2.2 AC Motor Feedback 9
4.2.3 Basic Types of an AC Motor 10
4.2.3.1 Induction AC Motor 10
4.2.3.2 Synchronous AC Motor 10
4.2.3.3 Industrial AC Motor 11
4.2.4 Applications 11
4.2.5 Advantages of an AC Motor 11
4.2.6 Disadvantages of an AC Motor 11
4.2.7 Grinder Motor 12
4.3 DYNAMO 13
4.3.1 Working 13
4.3.2 Armatures 15
4.3.3 Bicycle Dynamo Specification 15
4.4 12V DC PUMP 16
4.4.1 Features 18
4.4.2 Applications 18
4.4.3 Limitations 18
4.5 RECHARGABLE BATTERY 19
4.5.1 Specification 19
4.5.2 Applications 19
iii
ABSTRACT iiLIST OF FIGURES vLIST OF TABLES viLIST OF ABBREVIATIONS vii
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4.6 SUMP 20
4.7 LUBRICATING OIL 20
4.7.1 Motor Oil 20
4.7.2 Uses 21
4.7.3 Non-Vehicle Motor Oils 23
4.7.3 Properties 23
4.7.4 Grades 24
4.8 TIMER CIRCUIT 25
4.8.1 Microcontroller 264.8.1.1 Applications 26
4.8.2 Capacitor 27
4.8.2.1 Working Principle of Capacitor 27
4.8.2.2 Applications 27
4.8.3 Resistor 28
4.8.3.1 Working of Resistor 28
4.8.3.2 Applications 28
4.8.4 Diode 29
4.8.4.1 Working of Diode 29
4.8.4.2 Applications 29
4.8.5 Relay 30
5 ROLE OF MICROCONTROLLER IN TIMER CIRCUIT 315.1 MICROCONTROLLER 31
5.2 8051 ARCHITECTURE 32
5.3 PROGRAM FED IN MICROCONTROLLER 33
6 DISCUSSION 38
7 CONCLUSION 39
8 REFERENCE 40
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LIST OF FIGURES
FIGURE No. TITLE PAGE No.
4.1 Layout 8
4.2 Rotor Magnets interaction with Stator 9
4.3 AC Motor 12
4.4 Armature 14
4.5 Dynamo 15
4.6 12V DC Pump 16
4.7 Rechargeable battery 19
4.8 Motor oil 20
4.9 Timer Circuit 25
4.10 8051 Microcontroller 26
4.11 Relay 30
5.1 8051 Microcontroller Architecture 32
6.1 Comparison between Manual vs Automated Lubrication 38
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LIST OF TABLES
TABLE No. TITLE PAGE No.
4.1 12V DC Pump specification 17
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LIST OF ABBREVIATIONS
AC Alternating Current
DC Direct Current
HP Horse Power
RPM Revolutions Per Minute
ISO International Standards Organization
SAE Society of Automotive Engineers
LCD Liquid Crystal Display
I/O Input and Output
RAM Random Access Memory
ROM Read Only Memory
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CHAPTER 1
INTRODUCTION
Machines produce more heat and noise due to the motion of rotating and
reciprocating parts. Lubrication will minimize the noise produced by the machine
components. Lubrication systems and equipment are essential components of manufacturing
and industrial machinery and technology. To ensure reliable and efficient operation of such
equipment, these moving parts often need a constant supply of lubricating fluids, and the
lubrication system is able to provide this at the proper temperature, viscosity, flow rate and
pressure. Lubrication allows smooth continuous operation of equipment, with only mild
wear, and without excessive stresses or seizures at bearings. When lubrication breaks down,
metal or other components can rub destructively over each other, causing destructive
damage, heat, and failure. The most important components of a lubricating system are the
reservoir, pump and filter. The reservoir is the area in which the lubricant is stored after
coming back from the area it lubricates. The pump is used to move the lubricant through the
system and into areas that need to be lubricated.
OBJECTIVES
To fabricate the self lubricating setup with timer circuit
To lubricate the complicated machine components
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CHAPTER 2
LITERATURE REVIEW
Nathan E. McIntire and Zelma M. Porter proposed on automatic lubrication system.
An automatic lubrication system for conveyors and the like, said system comprising means
for initiating a lubrication cycle whereby a lubricant agitator and pump are sequentially
actuated to deliver lubricant to a dispensing passageway, a timer and relay arrangement
effective to open a lubrication solenoid valve to permit a quantity of lubricant to flow into the
dispensing passageway and subsequently open a gas solenoid valve to blow gas through the
passageway and expel substantially all of the lubricant there from onto the member being
lubricated, in such a manner that dripping of the excess lubricant or clogging of the
passageway is eliminated.
Richard W.dochterman and Fort Wayne were invented the lubrication system for
electric machine. A lubrication system which serves both to lubricate bearings and to occlude
the primary airflow path through a machine. The system includes a capillary seal (spaced
apart plates with or without wick material there between) serving both as a capillary air seal
and as portion of lubricant transfer path. This system is especially effective to support a
pressure differential across an electric motor. This invention relates generally to lubrication
systems for bearing supported shaft members , and more particularly to improved air sealing
lubrication systems for supplying lubricant to the bearing journaling surfaces in electric
machines while also preventing air flow there –through .
In current refrigeration systems having at least one refrigerated compartment and a
compartment open to the ambient area and housing such systems components as a condenser
and compressor, a motor driven fan is usually mounted in each compartment for purposes of
circulating air. In such systems, it has been the practice to mount a separate motor and fan
within each compartment.
In order to reduce cost and yet retain the air circulation benefits, it is quit desirable to use
only one motor to drive a number of fans since this obviously will cost less than a separate
motor for each fan. It is also desirable in order to accomplish this end that this one motor be
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mounted exteriorly of the refrigerated compartment so that motor heat will not be introduced
in to the refrigerated compartment during operation of the motor.
However, this approach introduces certain difficulties since there is a pressure
differential between the interior of a refrigerated compartment and the ambient area about the
compartment. Thus, when a refrigerated compartment is cooled, the pressure and the
temperature in the compartment are lowered, and a pressure differential is created between
the compartment and the surrounding area such an s the room or the condenser compartment.
It is well known that in commercial refrigerator units for example, pressure differentials
ranging between three and six inches of water occur during at least the first portion of the
each cooling cycle. Normal leakage through the door seal, electrical conduit openings etc,
equalizes the pressure within and without the refrigerated compartment after some period of
time.
It would be desirable to place externally mounted fan motor in sealed engagement
within an opening in the wall of a refrigerated compartment with the motor shaft extending
through the opening into the compartment for mounting the fan with the shaft also being
accessible in order to drive a second fan in another compartment. However, if there is an air
flow path through the motor, relatively warm, moist ambient air will be drawn through the
motor into the refrigerated compartment due to the initial pressure differential across the
motor. this air flowing through the motor into the compartment deposits it’s moisture on to
the first cold object it conducts, which is the motor shaft, fan blades, fan enclosure is will
results in ice forming on the shaft and blades and the motor may then over load and
eventually burn out, damage to the motors used in this application is especially undesirable
as this motors are normally mounted in relatively inaccessible locations and thus are difficult
to repair and replace.
I have found that the usual fan motor is unacceptable for the discussed application as
it will not support a pressure differential without at least some air leakage. The primary path
of air flowing through the usual totally enclosed fan motor when it is mounted across a
pressure differential occurs in the bearing lubrication system.
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Accordingly it would be highly desirable to provide a fan motor which may be
mounted externally of a refrigerated compartment in communication both with the interior of
the compartment and with the surrounding locations such as the room in which the
refrigeration apparatus is present or the compressor compartment. In this regard, it would be
advantageous to provide an inexpensive fan motor having a highly dependable air sealing
lubrication system which prevents air flow through the motor and especially through the
primary air flow path of the motor.
It is therefore, a general object of this invention to provide an electric machine having
a lubrication system which alleviates the problems and incorporates the desired result
mentioned above. It is a more specific object of the present invention to provide an improved
lubrication system for an electric machine having a bearing supported rotatable shaft which
incorporates an air flow sealing arrangement for occluding the primary air flow path through
the machine.
A further object of the present invention is the provision of a capillary sealed
lubrication arrangement for an electric machine which is inexpensive to produce and highly
dependable in operation, and which nonetheless provides adequately controlled lubricant
feed to the motor bearing shaft area.
Hermann Werner, Erich Lessol and Burkard Mueller were invented the bicycle
dynamo having a rotary-current generator. Bicycle dynamo having a rotary-current generator
having stator and a rotator which can be rotated relative to the stator. The stator or the rotor
has radially extending pole fingers which are wound individually with one surrounding
magnetic coil winding respectively. The ratio of the number of poles of the rotor to the
number of poles of the stator is a non-integer value, this permits the implementation of a
bicycle dynamo of a high efficiency event at a relatively low riding speed, which may be
used, for an example, to power bicycle lighting systems.
Cheng-Hsien Wu and Yu-Tai Kung proposed journal of a parametric study on oil/air
lubrication of a high-speed spindle. The ball-bearing is widely used on many high-speed
spindles due to its low starting friction and high load capacity. However, heat generation and
dynamic loading caused by high-speed rotation have been obstacles for increasing the speed
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limit in many high-speed ball-bearing applications. Applying an appropriate lubrication and
preload cannot be overemphasized. Recently, oil/air lubrication has been used on high-speed
spindles because of its accuracy in oil quantity control and high cooling efficiency. However,
an oil/air supply with inadequate parameters is undesirable. In this study, the performance of
a high-speed spindle under different lubrication parameters and preloads was investigated.
The Taguchi method was applied to study the effects of design parameters on the lubrication
efficiency. This method can also be used to obtain the optimum lubrication conditions. The
optimum operating conditions that create the smallest temperature increase were established.
The effects of preload on the temperature increase, the thermal deformation and the static
stiffness of an oil/air lubricated spindle were studied. The results provide a useful tool in
designing a high-speed spindle with a small increase in temperature and sufficient static
stiffness.
James C. Gwynn proposed paper on programmable electronic timer circuit. A
programmable timer circuit includes a counter that contains a plurality of sequentially
arranged counter stages. A toggle logic gate is disposed between each sequential pair of
counter stage to accept the output signal from the preceding stage and to the input signal
from the preceding stage and to issue an input signal to the succeeding counter stage. The
logic state of the input signal is determined by the logic state of the program signal is
determined by the state of a fuse associated with the program stage. The logic state of the
program signal is determined by the state of a fuse associated with the program stage.
Selected fuses can be blown by a programming routine to adjust the time delay between the
initiation signal and issuance of the output signal. This sets the counter stages at power-up to
a predetermined logic state in which the output signal will be produced with a predetermined
time delay when the initiation signal is applied to the integrated circuit. The program routine
includes activating the counter stages that will be active at the desired count and issuing a
programming signal to burn the fuse associated with the active counter stage.
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CHAPTER 3
PROBLEM DESCRIPTION
In some major industries, machine runs continuously for their production. Due to
continuously running process of machines leads to more tear and wear. For this problem,
some industries employed labours to lubricate the machine. Manual lubrication typically
produces inconsistent lubrication. The uneven lubrication cycle leads to wasted lubricant and
allows contaminants to enter the bearing – producing premature wear. Even though labours
are equipped with safety features, during manual lubrication many accidents are happened in
industries. Many machines are dangerous to lubricate while running. Under lubrication will
cause bearing damage and premature failure.
This project describes a fabrication of self lubrication system which automated by timer
that works by dynamo. Dynamo gets power by rotational motional for ac motor which is
coupled with belt.
Benefits of an Automatic Lubrication System
All critical components are lubricated, regardless of location or ease of access
Lubrication occurs while the machinery is in operation causing the lubricant to be
equally distributed within the bearing and increasing the machine’s availability
Less wear on the components means extended component life, fewer breakdowns,
reduced downtime, reduced replacement costs and reduced maintenance costs
Safety - no climbing around machinery or inaccessible areas
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CHAPTER 4
FABRICATION OF EXPERIMENTAL SETUP
The experimental apparatus of our project consists of major parts like ac motor,
dynamo, pump, sump, timer circuit and rechargeable battery. First of all the materials were
brought to fabricate the ac motor and dynamo, and then the major parts of the system that is
pump, timer circuit and rechargeable battery. The whole experimental setup made into
rectangular steel frame with supported bars.
AC motor is mounted on the steel frame and in other end dynamo is mounted. The
top surface of the steel frame is covered by sheet metal where other components like timer
circuit and pump are placed on it. Sump contains lubricating oil, which placed in bottom of
steel frame.
For our convenience, we have used AC motor of 1440 rpm converted to dynamo by
means of belt. Dynamo produces 5V ac voltage which is used for timer circuit. With
programmed microcontroller, which performs further operations based upon the preset value.
Thus relay gets activated by the signal instructed from the timer. Based the relay function,
pump gets power supply from rechargeable battery. Whereas pump draws lubricating oil
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4.1 LAYOUT DESCRIPTION
Dynamo produces electric energy by rotation motion of AC motor. Power produced
by dynamo used to run the timer circuit. Relay switch is activated by timer circuit which
incorporates microcontroller. Relay switch is placed between the rechargeable battery and
pump. Lubricating oil can be pumped from sump and distributed to varies complicated
components of machines.
Figure 4.1 Layout
MAINMOTOR
DYNAMO
RECHARGABLEBATTERY
TIMER
CIRCUIT
RELAY PUMP
SUMP
(Lubricating Oil)
To lubricatingparts
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4.2 AC MOTOR
4.2.1 AC Motor’s Principle and Working
The standard definition for an AC Motor is an electric motor that is driven by
alternating current. The AC Motor is used in the conversion of electrical energy into
mechanical energy. This mechanical energy is made from utilizing the force that is exerted
by the rotating magnetic fields produced by the alternating current that flows through its
coils. The AC Motor is made up of two major components: the stationary stator that is on the
outside and has coils supplied with AC current, and the inside rotor that is attached to the
output shaft.
The fundamental operation of an AC Motor relies on the principles of magnetism.
The simple AC Motor contains a coil of wire and two fixed magnets surrounding a shaft.
When an electric (AC) charge is applied to the coil of wire, it becomes an electromagnet,
generating a magnetic field. Simply described, when the magnets interact, the shaft and the
coil of wires begin to rotate, operating the motor.
Figure 4.2 Rotor Magnets interaction with Stator
4.2.2 AC Motor Feedback
AC Motor products have two options for feedback controls. These options are either
an AC Motor resolver or an AC Motor encoder. Both the AC Motor resolver and the AC
Motor encoder can sense direction, speed, and the position of the output shaft. While both the
AC Motor resolver and AC Motor encoder offer the same solution in multiple applications,
they are greatly different.
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AC Motor resolvers use a second set of stator coils called the transformer to provoke
rotor voltages across an air gap. Since the resolver lacks electronic components, it is very
rugged and operates over a large temperature range. The AC Motor resolver is also naturally
shock resistant, due to how it is designed. The resolver is often used in harsh environments.
The type of application will establish whether a resolver or an encoder is desired. AC
Motor encoders are easier to implement and more precise, so they should be the primary
preference for any application. A resolver should only be chosen if the environment in which
it will be used requires it.
4.2.3 Basic types of an AC Motor
The AC Motor comes in three different types known as Induction, Synchronous, and
Industrial. These AC Motor types are determined by the rotor design used in the construction.
Anaheim Automation carries all three types in its product line.
4.2.3.1 Induction AC Motor
Induction AC Motor is referred to as asynchronous motors or rotating transformers.
This type of AC Motor uses electromagnetic induction to power the rotating device which is
usually the shaft. The rotor in Induction AC Motor products typically turns slower than the
frequency that is supplied to it. Induced current is what causes the magnetic field that
envelops the rotor of these motors. This Induction AC Motor is designed in one or three
phases.
4.2.3.2 Synchronous AC Motor
The Synchronous Motor is typically an AC Motor that has its rotor spinning at the
same rate as the alternating current that is being supplied to it. The rotor can also turn at a sub
multiple of the current it is supplied. Slip rings or a permanent magnet supplied with current
is what generates the magnetic field around the rotor.
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4.2.3.3 Industrial AC Motor
Industrial AC Motors are designed for applications requiring a three-phase, high-
power induction motor. The power ratings of an industrial motor exceed those of a standard
single-phase AC induction motor. Anaheim Automation offers Industrial AC Motors from
220W to 2200W, in 3-Phase operation at 220VAC or 380VAC.
4.2.4 Applications
AC Motors are primarily used in domestic applications due to their relatively low
manufacturing costs, and durability, but are also widely used in industrial applications.
They can also be found in industrial applications:
Pumps
Blowers
Conveyors
Compressors
4.2.5 Advantages of an AC Motor
Low Cost
Long Lifespan
High-Efficiency and Reliability
Simple Construction
High Starting Torque (Induction)
No Slip (Synchronous)
4.2.6 Disadvantages of an AC Motor
Frequency Causes Rotation Slips (Induction)
Starting Switch Needed (Induction)
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4.2.7 Grinder Motor
Figure 4.3 AC Motor
Capacity: 0.5 HP
Speed: 1440 RPM
Phase: Single Phase
Features
Stampings: Stator consists of thin lamination of high quality low core loss silicon
steel
Copper Wire: Super enamel insulated high conductivity copper wire of an ISO
9002 company
Rotor: Dynamically balanced pressure die cast rotor for complete vibration free
operation
Shaft: High graded mild steel machined and centrelex grinding to close tolerance.
Insulation: Class B insulation specially treated to withstand a maximum
temperature of 120°C.
Bearings: Sealed ball bearings are used at both ends to ensure smooth running.
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4.3 DYNAMO
A dynamo is an electrical generator that produces direct current with use of
commutator. It converts mechanical power to electrical power. It converts the mechanical
motion of the driven wheel into electrical energy, with the aid of a magnet. A dynamo is an
electrical generator that produces direct current with the use of a commutator. Dynamos were
the first electrical generators capable of delivering power for industry, and the foundation
upon which many other later electric-power conversion devices were based, including the
electric motor, the alternating-current alternator, and the rotary converter. Today, the simpler
alternator dominates large scale power generation, for efficiency, reliability and cost reasons.
A dynamo has the disadvantages of a mechanical commutator. Also, converting alternating to
direct current using power rectification devices (vacuum tube or more recently solid state) is
effective and usually economic.
In electricity generation, an electric generator is a device that converts mechanical
energy to electrical energy. A generator forces electric charge (usually carried by electrons)
to flow through an external electrical circuit. The source of mechanical energy may be a
reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an
internal combustion engine, a wind turbine, a hand crank, compressed air, or any other source
of mechanical energy.
The reverse conversion of electrical energy into mechanical energy is done by an
electric motor, and motors and generators have many similarities. Many motors can be
mechanically driven to generate electricity and frequently make acceptable generators.
4.3.1 Working
It converts the mechanical motion of the driven wheel into electrical motion, with the
aid of a magnet. Many scientists say that the full circle of energy that keeps the world
spinning, grows crops, and paints the sky with the Aurora Borealis, begins and ends with
magnetism that the sun’s rays are magnetic rays. Magnetism is the force that keeps the
compass needle pointing north and south. Take a steel rod and hold it along the north and
south line, slightly inclined towards the earth, and strike it a sharp blow with a hammer, and
it becomes a magnet feeble, it is true, but still a magnet.
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4.3.2 Armatures
This experiment gives the theory of the dynamo. Instead of passing only one wire
through the field of force of a magnet, we have hundreds bound lengthwise on a revolving
drum called an armature. Instead of one magnetic pole in a dynamo we have two, or four, or
twenty according to the work the machine is designed for always in pairs, a North pole next
to a South pole, so that the lines of force may flow out of one and into another, instead of
escaping in the surrounding air.
Figure 4.4 Armature winding in Dynamo
If we could see these lines of force, they would appear in countless numbers issuing
from each pole face of the field magnets, pressing against the revolving drum like hair brush
bristles trying to hold it back. This drum, in practice, is built up of discs of annealed steel,
and the wires extending lengthwise on its face are held in place by slots to prevent them from
flying off when the drum is whirled at high speed. The drum does not touch the face of the
magnets, but revolves in an air space.
If we give the electric impulses generated in these wires a chance to flow in a circuit
flow out of one end of the wires, and in at the other, the drum will require more and more
power to turn it, in proportion to the amount of electricity we permit to flow. Thus, if one
electric light is turned on, the drum will press back with certain strength on the water wheel;
if one hundred lights are turned on it will press back one hundred times as much. Providing
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there is enough power in the water wheel to continue turning the drum at its predetermined
speed, the dynamo will keep on giving more and more electricity if asked to, until it finally
destroys itself by fire.
We cannot take more power, in terms of electricity, out of a dynamo that we put into
it, in terms of mechanical motion. In fact, to insure flexibility and constant speed at all loads,
it is customary to provide twice as much water wheel, or engine, power as the electrical
rating of the dynamo.
4.3.3 Bicycle Dynamo Specification
The max diameter of the dynamo body is: 40.5mm, the longest length of the main
body is: 94.5mm. Maximum Output: 12V
Figure 4.5 Dynamo
Components of Dynamo
1. Friction roller 6. Coil
2. The dynamo body 7. Wrench
3. Magnetic steel 8. Lug plate
4. Winding support 9. Rear Cover
5. Spring housing
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4.4 12V DC PUMP
This is a brushless DC motor-driven centrifugal pumps, use special design closed
impeller. Main features: High water head, moderate flow rate, long life (use fine ceramic