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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
48

Fabrication of Self Lubrication System for Complicated Machines

Oct 30, 2014

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Karthik Mayandy

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.

WATCH WORKING VIDEO OF SYSTEM
YOUTUBE LINKS
http://www.youtube.com/watch?v=TLBIh9-gpkY&feature=youtu.be

or

http://www.youtu.be/TLBIh9-gpkY


By
Karthik(cartickm)
Karthik Raj
Gautham Kumar

MECHANICAL ENGINEERS
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Transcript
Page 1: Fabrication of Self Lubrication System for Complicated Machines

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

Karth

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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.

ii

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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

iv

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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

v

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LIST OF TABLES

TABLE No. TITLE PAGE No.

4.1 12V DC Pump specification 17

vi

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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

vii

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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

from sump to supply on gear parts which needs to be lubricate.Karth

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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

bearing), continues work, low noise, stable performance.

Figure 4.6 12V DC Pump

Pump chamber and the motor is absolutely isolated, magnetic drive technology

can be guaranteed no leak forever, completely avoid the presence of traditional

DC motor pumps' liquid leakage. If the mining epoxy resin package, you can

completely and totally waterproof diving use.

Brushless motor circuit design optimization using a large movement of low-

temperature, stable performance, long life. Closed impeller simple structure, with

less water loss, pump output high efficiency, can effectively enhance higher water

head.

Impeller/rotor shaft with ceramic materials, enhance the wear resistance, high

accuracy, precision with resistance to shock, to extend the life of the pump.

Bearing sleeve with graphite self-lubricating properties, reduce noise at work.

Low noise down to 35dB, smaller consumption pump even down to 30 decibels,

almost silent operation.

Pump chamber seal can withstand 5 bar pressure without leakage. Each pump in

the production line has to go through stress tests, which can effectively prevent

the leakage of product defects.

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Pump uses high-strength engineering plastics, PPS PPE, PA66, etc., can be used

for hot water circulation, strong endurable capacity, resistance to weak acid

corrosion. Can be recycled with a small impurity of the liquid; do not plug the

pump chamber.

For our project, we have used 12V DC pump and specification below:

Table 4.1 12V DC Pumps Specification

No. Items Specifications

1 Sizes and weight 83x63x48; 250g

2 Dimension of inlet 5mm

3 Dimension of outlet 6mm

4 Driving method Brushless, Magnetic , 2 phase or 3 phase

5 Pump material PA66+GF30% (optional)

6 Condition of use Continuously

7 Fluids Water, oil, gasoline, acid and alkali solution etc

8 Max working temp 60 degree (2 phase)or 100 degree (3 phase)

9 Power consumption 2.5W~26.4W

10 Rated voltage 12Vdc

11 Voltage used 5Vdc ~ 12Vdc

12 Max rated current 1.2A

13 Power supply Solar panel; DC electric source; battery

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4.4.1 Features

1. Durable magnetic rotor and ceramic /stainless steel shaft

2. Long life brushless pump, ideal life for 30000 hours

3. Low noise: ≤ 42dB far from 1m distance

4. Low or no maintenance

5. Low power consumption

4.4.2 Applications

1. Circulation system

2. Solar energy panel

3. Aquarium

4. Cooling system

5. Water heater and so on

4.4.3 Limitations

1. Power to DC Power Supply, reverse polarity is strictly prohibited, generally red

positive power supply, black to negative.

2. Pumps in addition to immersible work can be identified, the rest cannot be immersed

in water, or they will cause a short circuit burned.

3. Pumps is prohibited by the strong shock, fall from a height on the ground and other

external damage.

4. Pumps cannot take strong acid and other corrosive liquids and granular solids with a

tiny hard.

5. Pumps were not long-time stall, causing the motor burned.

6. Pumps cannot withstand high voltage shock.

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4.5 RECHARGEBLE BATTERY

The rechargeable batteries are lead-lead dioxide systems. The dilute sulfuric acid

electrolyte is absorbed by separators and plates and thus immobilized. Should the battery be

accidentally overcharged producing hydrogen and oxygen, special one-way valves allow the

gases to escape thus avoiding excessive pressure build-up. Otherwise, the battery is

completely sealed and is, therefore, maintenance-free, leak proof and usable in any position.

Figure 4.7 Rechargeable Battery

4.5.1 Specification

Voltage: 6V

Capacity: 4ah

Dimensions (mm): 70(L)*45(W)*99(H)*104(TH)

Approx Weight (Kgs): 0.7

4.5.2 Application

Power: Electric tools, toys, portable suction fans, Robots, electric bicycle

Speakers: Insert earphones, cassette decks, portable CD players

Video: Cameras, portable TV sets, lap-tops

Correspondence: Car telephone, mobile system, portable radio transmitter

Survey: Measuring instruments

Medical treatment: Blood-pressure meters, electric wheelchairs

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4.6 SUMP

The oil is used to lubricate the machine's moving parts and it pools in a reservoir,

known as a sump. Use of a sump requires the engine to be mounted slightly higher to make

space for it. Often though, oil in the sump can surge during hard cornering starving the oil

pump.

4.7 LUBRICATING OIL

4.7.1 Motor Oil

Motor oil or engine oil is an oil used for lubrication of various internal combustion

engines. The main function is to lubricate moving parts; it also cleans, inhibits corrosion,

improves sealing, and cools the engine by carrying heat away from moving parts. Motor oils

are derived from petroleum-based and non-petroleum-synthesized chemical compounds.

Figure 4.8 Motor Oil

Motor oils today are mainly blended by using base oils composed of hydrocarbons,

polyalphaolefins (PAO), and polyinternal olefins (PIO), thus organic compounds consisting

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entirely of carbon and hydrogen. The base oils of some high-performance motor oils however

contain up to 20% by weight of esters.

4.7.2 Uses

Motor oil is a lubricant used in internal combustion engines. These include motor or

road vehicles such as cars and motorcycles, heavier vehicles such as buses and commercial

vehicles, non-road vehicles such as go-karts, snowmobiles, boats (fixed engine installations

and outboards), lawn mowers, large agricultural and construction equipment, locomotives

and aircraft and static engines such as electrical generators. In engines, there are parts which

move against each other causing friction which wastes otherwise useful power by converting

the energy to heat. Contact between moving surfaces also wears away those parts, which

could lead to lower efficiency and degradation of the engine. This increases fuel

consumption, decreases power output and can lead to engine failure.

Lubricating oil creates a separating film between surfaces of adjacent moving parts to

minimize direct contact between them, decreasing heat caused by friction and reducing wear,

thus protecting the engine. In use, motor oil transfers heat through convection as it flows

through the engine by means of air flow over the surface of the oil pan, oil cooler and

through the buildup of oil gases evacuated by the Positive Crankcase Ventilation (PCV)

system. In petrol (gasoline) engines, the top piston ring can expose the motor oil to

temperatures of 160 °C (320 °F). In diesel engines the top ring can expose the oil to

temperatures over 315 °C (600 °F). Motor oils with higher viscosity indices thin less at these

higher temperatures.

Coating metal parts with oil also keeps them from being exposed to oxygen,

inhibiting oxidation at elevated operating temperatures preventing rust or corrosion.

Corrosion inhibitors may also be added to the motor oil. Many motor oils also have

detergents and dispersants added to help keep the engine clean and minimize oil sludge

build-up. The oil is able to trap soot from combustion in itself, rather than leaving it

deposited on the internal surfaces. It is a combination of this, and some singeing that turns

used oil black after some running.

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Rubbing of metal engine parts inevitably produces some microscopic metallic

particles from the wearing of the surfaces. Such particles could circulate in the oil and grind

against moving parts, causing wear. Because particles accumulate in the oil, it is typically

circulated through an oil filter to remove harmful particles. An oil pump, a vane or gear

pump powered by the engine, pumps the oil throughout the engine, including the oil filter.

Oil filters can be a full flow or bypass type.

In the crankcase of a vehicle engine, motor oil lubricates rotating or sliding surfaces

between the crankshaft journal bearings (main bearings and big-end bearings), and rods

connecting the pistons to the crankshaft. The oil collects in an oil pan, or sump, at the bottom

of the crankcase. In some small engines such as lawn mower engines, dippers on the bottoms

of connecting rods dip into the oil at the bottom and splash it around the crankcase as needed

to lubricate parts inside. In modern vehicle engines, the oil pump takes oil from the oil pan

and sends it through the oil filter into oil galleries, from which the oil lubricates the main

bearings holding the crankshaft up at the main journals and camshaft bearings operating the

valves. In typical modern vehicles, oil pressure-fed from the oil galleries to the main bearings

enters holes in the main journals of the crankshaft. From these holes in the main journals, the

oil moves through passageways inside the crankshaft to exit holes in the rod journals to

lubricate the rod bearings and connecting rods. Some simpler designs relied on these rapidly

moving parts to splash and lubricate the contacting surfaces between the piston rings and

interior surfaces of the cylinders. However, in modern designs, there are also passageways

through the rods which carry oil from the rod bearings to the rod-piston connections and

lubricate the contacting surfaces between the piston rings and interior surfaces of the

cylinders. This oil film also serves as a seal between the piston rings and cylinder walls to

separate the combustion chamber in the cylinder head from the crankcase. The oil then drips

back down into the oil pan. Motor oil may also serve as a cooling agent. In some

constructions oil is sprayed through a nozzle inside the crankcase on the piston to provide

cooling of specific parts that underly high temperature strain. On the other hand the thermal

capacity of the oil pool has to be filled up, i.e. the oil has to reach its designed temperature

range until it can protect the engine under high load. This typically takes longer than heating

the main cooling agent - water or mixtures thereof - up to its operating temperature.

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4.7.3 Non-Vehicle Motor Oils

An example is lubricating oil for four-stroke or four-cycle internal combustion

engines such as those used in portable electricity generators and "walk behind" lawn mowers.

Another example is two-stroke oil for lubrication of two-stroke or two-cycle internal

combustion engines found in snow blowers, chain saws, model airplanes, gasoline powered

gardening equipment like hedge trimmers, leaf blowers and soil cultivators. Often, these

motors are not exposed to as wide service temperature ranges as in vehicles, so these oils

may be single viscosity oils.

In small two-stroke engines, the oil may be pre-mixed with the gasoline or fuel, often

in a rich gasoline: oil ratio of 25:1, 40:1 or 50:1, and burned in use along with the gasoline.

Larger two-stroke engines used in boats and motorcycles will have a more economical oil

injection system rather than oil pre-mixed into the gasoline. The oil injection system is not

used on small engines used in applications like snowblowers and trolling motors as the oil

injection system is too expensive for small engines and would take up too much room on the

equipment. The oil properties will vary according to the individual needs of these devices.

Non-smoking two-stroke oils are composed of esters or polyglycols. Environmental

legislation for leisure marine applications, especially in Europe, encouraged the use of ester-

based two cycle oil.

4.7.4 Properties

Most motor oils are made from a heavier, thicker petroleum hydrocarbon base stock

derived from crude oil, with additives to improve certain properties. The bulk of typical

motor oil consists of hydrocarbons with between 18 and 34 carbon atoms per molecule.[6]

One of the most important properties of motor oil in maintaining a lubricating film between

moving parts is its viscosity. The viscosity of a liquid can be thought of as its "thickness" or a

measure of its resistance to flow. The viscosity must be high enough to maintain a lubricating

film, but low enough that the oil can flow around the engine parts under all conditions. The

viscosity index is a measure of how much the oil's viscosity changes as temperature changes.

A higher viscosity index indicates the viscosity changes less with temperature than a lower

viscosity index.

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Oil is largely composed of hydrocarbons which can burn if ignited. Still another

important property of motor oil is its flash point, the lowest temperature at which the oil

gives off vapors which can ignite. It is dangerous for the oil in a motor to ignite and burn, so

a high flash point is desirable. At a petroleum refinery, fractional distillation separates a

motor oil fraction from other crude oil fractions, removing the more volatile components, and

therefore increasing the oil's flash point (reducing its tendency to burn).

Another manipulated property of motor oil is its Total Base Number (TBN), which is

a measurement of the reserve alkalinity of an oil, meaning its ability to neutralize acids. The

resulting quantity is determined as mg KOH/ (gram of lubricant). Analogously, Total Acid

Number (TAN) is the measure of a lubricant's acidity. Other tests include zinc, phosphorus,

or sulfur content, and testing for excessive foaming.

The NOACK volatility (ASTM D-5800) Test determines the physical evaporation

loss of lubricants in high temperature service. A maximum of 15% evaporation loss is

allowable to meet API SL and ILSAC GF-3 specifications. Some automotive OEM oil

specifications require lower than 10%.

4.7.5 Grades

The Society of Automotive Engineers (SAE) has established a numerical code

system for grading motor oils according to their viscosity characteristics. SAE viscosity

grading includes the following, from low to high viscosity: 0, 5, 10, 15, 20, 25, 30, 40, 50 or

60. The numbers 0, 5, 10, 15 and 25 are suffixed with the letter W, designating their “winter”

(not "weight") or cold-start viscosity, at lower temperature. The number 20 comes with or

without a W, depending on whether it is being used to denote a cold or hot viscosity grade.

The document SAE J300 defines the viscometrics related to these grades.

Kinematic viscosity is graded by measuring the time it takes for a standard amount of

oil to flow through a standard orifice, at standard temperatures. The longer it takes, the higher

the viscosity and thus higher SAE code. The SAE has a separate viscosity rating system for

gear, axle, and manual transmission oils, SAE J306, which should not be confused with

engine oil viscosity. The higher numbers of a gear oil (e.g., 75W-140) do not mean that it has

higher viscosity than an engine oil.

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4.8 TIMER CIRCUIT

Timer circuit will create and maintain the on and off time delay to do the specific job

or task. The sequential time is controlled by using microcontroller, which is fed by a

programming language. The time interval can be varied by push type switches in circuit.

Timer circuit consists of general circuit elements like capacitors, diode, resistor, voltage

regulator, LCD display, microcontroller and relay.

Figure 4.9 Timer Circuit

Initially the power produced from dynamo is rectified using a rectifier and output

supplied to microcontroller. Microcontroller is then control the signal to actuate the pump

using relay switch. LCD displays OFF and ON time, and changes can be performed by push

type switches. LCD displayed by additional power. By setting the value, OFF TIME tends to

work the pump and ON TIME tends to delay interval for further operations. While off timing

condition, power supplies from rechargeable battery to pump by means of relay circuit.

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4.8.1 Microcontroller

A micro controller is an integrated circuit or a chip with a processor and other support

devices like program memory, data memory, I/O ports, serial communication interface etc

integrated together. Unlike a microprocessor (ex: Intel 8085), a microcontroller does not

require any external interfacing of support devices. Microcontrollers are usually dedicated

devices embedded within an application. Since microcontrollers are powerful digital

processors, the degree of control and programmability they provide significantly enhances

the effectiveness of the application. The 8051 is the first microcontroller of the MCS-51

family introduced by Intel Corporation at the end of the 1970s. The timer function is one of

the basic features of a microcontroller. Although some compilers provide simple macros that

implement delay routines, in order to determine time elapsed and to maximize use of the

timer, understanding the timer functionality is necessary.

Figure 4.10 8051 Microcontroller

4.8.1.1 Applications

Microcontrollers are used in products that are controlled automatically. The various

products that make use of microcontrollers in our everyday life are given below:

Home: Television, DVD player, Telephone, Fax machine, Cellular phones, Security

systems, Camera, Sewing machine, Musical Instrument, Exercising machine, Video

games, Computer, Microwave oven.

Office: Computers, Printers, Telephones, Fax machine, Security systems.

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4.8.2 Capacitors

The capability of a capacitor to store electricity is known as capacitance of that

capacitor. It is denoted by C. The measuring unit of capacitance is Farad, but Farad is very

large unit. Its smaller units are Kilo Micro Farad (KMFD), Micro Farad (MFD), Kilo Pico

Farad (KPF) or Nano Farad (NF) and Pico Farad (PF).

4.8.2.1 Working Principle of Capacitor

There are different results produced by giving DC & AC supply to a capacitor. The

working of a capacitor in both the conditions is as follows: When any capacitor is connected

between an AC supply sources, one plate is at a negative potential and the other plate is at a

positive potential (due to the voltage source). Hence opposite charges develop on the both the

plates. The time when the plates of capacitor are charging there is flow of current from the

supply source into the capacitor, and when the value of voltage across the two plates of the

capacitor becomes equal to maximum input voltage to the capacitor, this flow of current

stops. In this way, we can say that at the time of charging of capacitor the flow of current

stores charges in the both of the plates. It is known as charging state of capacitor.

4.8.2.2 Applications

Its function is to store the electrical energy and give this energy again to the circuit

when necessary. In other words, it charges and discharges the electric charge stored in it.

Besides this, the functions of a capacitor are as follows:

It blocks the flow of DC and permits the flow of AC.

It is used for coupling of the two sections.

It bypasses (grounds) the unwanted frequencies.

It feeds the desired signal to any section.

It is used for phase shifting.

It is also used for creating a delay in time.

It is used as motor starter.

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4.8.3 Resistor

A resistor is a two-terminal electrical or electronic component that resists the flow

of current, producing a voltage drop between its terminals in accordance with Ohm's law.

The electrical resistance is equal to the voltage drop across the resistor divided by the current

that is flowing through the resistor.

4.8.3.1 Working of Resistor

The working of a resistor can be explained with the similarity of water flowing

through a pipe. Consider a pipe through which water is allowed to flow. If the diameter of the

pipe is reduced, the water flow will be reduced. If the force of the water is increased by

increasing the pressure, then the energy will be dissipated as heat. There will also be an

enormous difference in pressure in the head and tail ends of the pipe. In this example, the

force applied to the water is similar to the current flowing through the resistance. The

pressure applied can be resembled to the voltage.

4.8.3.2 Applications

Resistors are used as part of electrical networks and electronic circuits.

All resistors dissipate heat. This is the principle behind electric heaters.

In general, a resistor is used to create a known voltage-to-current ratio in an electric

circuit. If the current in a circuit is known, then a resistor can be used to create a

known potential difference proportional to that current. Conversely, if the potential

difference between two points in a circuit is known, a resistor can be used to create a

known current proportional to that difference.

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4.8.4 Diode

A diode is the simplest two-terminal unilateral semiconductor device. It allows

current to flow only in one direction and blocks the current that flows in the opposite

direction. The two terminals of the diode are called as anode and cathode.

4.8.4.1 Working of Diode

The diode operates when a voltage signal is applied across its terminals. The

application of a DC voltage to make the diode operate in a circuit is called as ‘Biasing’. As

already mentioned above the diode resembles to that of a one way switch so it can either be

in a state of conduction or in a state of non conduction. The ‘ON’ state of a diode is achieved

by ‘Forward biasing’ which means that positive or higher potential is applied to the anode

and negative or lower potential is applied at the cathode of the diode. In other words, the

‘ON’ state of diode has the applied current in the same direction of the arrow head. The

‘OFF’ state of a diode is achieved by ‘Reverse biasing’ which means that positive or higher

potential is applied to the cathode and negative or lower potential is applied at the anode of

the diode. In other words, the ‘OFF’ state of diode has the applied current in the opposite

direction of the arrow head. During ‘ON’ state, the practical diode offers a resistance called

as the ‘Forward resistance’. The diode requires a forward bias voltage to switch to the ‘ON’

condition which is called Cut-in-voltage. The diode starts conducting in reverse biased mode

when the reverse bias voltage exceeds its limit which is called as the Breakdown voltage. The

diode remains in ‘OFF’ state when no voltage is applied across it.

4. 8.4.2 Applications

Rectification – The rectification means converting AC voltage into DC voltage.

Clipper- Diode can be used to clip off some portion of pulse without distorting the

remaining part of the waveform.

Clamper – A clamping circuit restricts the voltage levels to exceed a limit by shifting

the DC level. The peak to peak is not affected by clamping. Diodes with resistors and

capacitors are used to make clamping circuits. Sometimes independent DC sources

can be used to provide additional shift.

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4.8.5 Relay

Relay is an electromagnetic device which is used to isolate two circuits electrically

and connect them magnetically. They are very useful devices and allow one circuit to switch

another one while they are completely separate. They are often used to interface an electronic

circuit (working at a low voltage) to an electrical circuit which works at very high voltage.

For example, a relay can make a 5V DC battery circuit to switch a 230V AC mains circuit.

Thus a small sensor circuit can drive, say, a fan or an electric bulb. A relay switch can be

divided into two parts: input and output. The input section has a coil which generates

magnetic field when a small voltage from an electronic circuit is applied to it.

This voltage is called the operating voltage. Commonly used relays are available in

different configuration of operating voltages like 6V, 9V, 12V, 24V etc. The output section

consists of contactors which connect or disconnect mechanically. In a basic relay there are

three contactors: normally open (NO), normally closed (NC) and common (COM). At no

input state, the COM is connected to NC. When the operating voltage is applied the relay coil

gets energized and the COM changes contact to NO. Different relay configurations are

available like SPST, SPDT, DPDT etc, which have different number of changeover contacts.

By using proper combination of contactors, the electrical circuit can be switched on and off.

Figure 4.11 Relay

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CHAPTER 5

ROLE OF MIRCOCONTROLLER IN TIMER CIRCUIT

5.1 MICROCONTROLLER

Microcontrollers are usually dedicated devices embedded within an application. For

example, microcontrollers are used as engine controllers in automobiles and as exposure and

focus controllers in cameras. In order to serve these applications, they have a high

concentration of on-chip facilities such as serial ports, parallel input/output ports, timers,

counters, interrupt control, analog-to-digital converters, random access memory, read only

memory, etc. The I/O, memory, and on-chip peripherals of a microcontroller are selected

depending on the specifics of the target application. Since microcontrollers are powerful

digital processors, the degree of control and programmability they provide significantly

enhances the effectiveness of the application.

The microcontroller incorporates all the features that are found in microprocessor. The

microcontroller has built in ROM, RAM, Input Output ports, Serial Port, timers, interrupts

and clock circuit. A microcontroller is an entire computer manufactured on a single chip.

Microcontrollers are usually dedicated devices embedded within an application. For example,

microcontrollers are used as engine controllers in automobiles and as exposure and focus

controllers in cameras. In order to serve these applications, they have a high concentration of

on-chip facilities such as serial ports, parallel input output ports, timers, counters, interrupt

control, analog-to-digital converters, random access memory, read only memory, etc. The

I/O, memory, and on-chip peripherals of a microcontroller are selected depending on the

specifics of the target application.

The 8051 family with its many enhanced members enjoys the largest market share,

estimated to be about 40%, among the various microcontroller architectures. The

microcontroller has on chip peripheral devices. In this unit firstly we differentiate

microcontroller from microprocessor then we will discuss about Hardware details of 8051

and then introduce the Assembly level language in brief.

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Microcontrollers

Microcontroller (MC) may be called computer on chip since it has basic features of

microprocessor with internal ROM, RAM, Parallel and serial ports within single chip.

Or we can say microprocessor with memory and ports is called as microcontroller.

This is widely used in washing machines, vcd player, microwave oven, and robotics or

in industries.

Microcontroller can be classified on the basis of their bits processed like 8bit MC,

16bit MC.

8 bit microcontroller means it can read, write and process 8 bit data. Ex. 8051

microcontroller. Basically 8 bit specifies the size of data bus. 8 bit microcontroller

means 8 bit data can travel on the data bus or we can read, write process 8 bit data.

5.2 MICROCONTROLLER 8051 ARCHITECTURE

It is 8-bit microcontroller, means MC 8051 can Read, Write and Process 8 bit data.

This is mostly used microcontroller in the robotics, home appliances like mp3 player,

washing machines, electronic iron and industries.

Figure 5.1 8051 Architecture

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5.3 PROGRAM FED IN MICROCONTROLLER

This coding fetched into microprocessor to perform delay timing operation

CODING:

// Lcd module connections

sbit LCD_RS at P2_0_bit;

sbit LCD_EN at P2_1_bit;

sbit LCD_D4 at P2_2_bit;

sbit LCD_D5 at P2_3_bit;

sbit LCD_D6 at P2_4_bit;

sbit LCD_D7 at P2_5_bit;

sbit led at P3_0_bit;

sbit alt at P1_0_bit;

sbit inc at P1_1_bit;

sbit dec at P1_2_bit;

sbit set at P1_3_bit;

sbit inp at P1_4_bit;

void Vdelay_ms(unsigned time_in_ms);

long int on=1000,off=1000,j,k;

unsigned int a,d,c;

void main()

{

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P1=0XFF;

P3=0;

Lcd_Init(); // Initialize Lcd

Lcd_Cmd(_LCD_CLEAR); // Clear display

Lcd_Cmd(_LCD_CURSOR_OFF); // Cursor off

Lcd_out(1,1," ON TIME:000");

Lcd_out(2,1," OFF TIME:000");

while(1)

{

while(set==0)

{

led=0;

if(inp==0)

{

if(inc==0)

{

on=on+1000;delay_ms(200);

if(on>99999)

{on=999999;}

}

if(dec==0)

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{

if(on<=1000)

{on=1000;}

else

{on=on-1000;delay_ms(200);}

}

j = on/1000;

a = j/100;

d = j%100;

c = d%10;

d = d/10;

Lcd_Chr(1, 11, a+48);

Lcd_Chr(1, 12, d+48);

Lcd_Chr(1, 13, c+48);

}

///////////////////

if(inp==1)

{

if(inc==0)

{

off=off+1000;delay_ms(200);

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if(off>99999)

{off=999999;}

}

if(dec==0)

{

if(off<=1000)

{off=1000;}

else

{off=off-1000;delay_ms(200);}

}

k = off/1000;

a = k/100;

d = k%100;

c = d%10;

d = d/10;

Lcd_Chr(2, 11, a+48);

Lcd_Chr(2, 12, d+48);

Lcd_Chr(2, 13, c+48);

}

}

//////////////////////////

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while(set==1)

{

Vdelay_ms(on);

led=1;

Vdelay_ms(off);

led=0;

}

}

}

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CHAPTER 6

DISCUSSION

Many machines are dangerous to lubricate while running. So safety is an issue when

lubricating hard-to-reach bearings. Under lubrication will cause bearing damage and

premature failure. Over lubrication can cause product spoilage, bearing seal damage and

cleanup issues. Manual lubrication typically produces inconsistent lubrication. The uneven

lubrication cycle leads to wasted lubricant and allows contaminants to enter the bearing –

producing premature wear.

Figure 6.1 Comparison between Manual vs Automated Lubrication

Advantages of an Automatic Lubrication System

Lubrication occurs while the machinery is in operation causing the lubricant to be

equally distributed within the bearing and increasing the machine’s availability. All critical

components are lubricated, regardless of location or ease of access. Proper lubrication of

critical components ensures safe operation of the machinery. Less wear on the components

means extended component life, fewer breakdowns, reduced downtime, reduced replacement

costs and reduced maintenance costs. There is no climbing around machinery or inaccessible

areas by the use of this system.

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CHAPTER 7

CONCLUSION

This self lubrication systems offer superior features than manual lubrication. This

system eliminates productions loss where as manual lubrication requires machine shut down.

It provides effective and clean lubrication. Self lubrication system will improve safety

features and prevents accidents that occur during manual lubrication. It provides consistent

lubrication that extends bearing life and prevents unplanned downtime. This system can be

used complicated machines in small scale industries.

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CHAPTER 8

REFERENCES

1. C. James Erickson, Charles D. Potts, Byron M. Jones “Electrical and Electronics

Engineering”

2. Muhammad Ali Mazidi, Janice Gillispie Mazidi and Rolin D. McKinlay “The 8051

Microcontroller and Embedded Systems Using Assembly and C” Second

EditionNathan E. McIntire and Zelma M. Porter (1972) “Automatic Lubrication

System”

3. Hermann Werner, Erich Lessol and Burkard Mueller (1996) “Bicycle Dynamo having

a rotary-current generator” – US patent

4. Richard W. Dochterman and Fort Wayne (1967) “Lubrication System for Electric

Machines”

5. Cheng-Hsien Wu, Yu-Tai Kung “A parametric study on oil/air lubrication of a high-

speed spindle” Precision Engineering, Volume 29, Issue 2, April 2005, pp 162-167

6. James C. Gwynn (1995) “Programmable Electronic Timer Circuit” - US patent

7. Willam Bolton “Mechatronics” (2011) Fourth Edition - Microprocessor pp 336-372

8. www.wikipedia.org

9. www.wikitronics.com

10. www.interlubesystem.co.uk

11. www.electronicsforu.com

12. www.engineergarage.com

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PHOTO: FABRICATION SETUP
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WORKING OF SYSTEM - VIDEO LINK YOUTUBE http://youtu.be/TLBIh9-gpkY or http://www.youtube.com/watch?v=TLBIh9-gpkY&feature=youtu.be
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FABRICATION OF SELF LUBRICATION SYSTEM FOR COMPLICATED MACHINES
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