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Page 1: Magnetic Crane

[2010][2010]

CERTIFICATECERTIFICATE 1

Page 2: Magnetic Crane

This is to certify that

1. SHAH VAIBHAV. 2. DHIRAJ GOHIL.

3. AMIT PATEL 4.KRUNAL PANDYA

5. UJVAL DHARVAPARMAR 6. MANHAR NAKUM

7. ANAND PANCHAL

Students of Mechanical Engineering Have

satisfactorily partially completed and presented Their

Project on

Magnetic Crane

Within four walls of the institute For the D.M.E.

Semester8th. For the term ending APRIL, 2010.

Guide Teacher: Head of

department:

MR. Sunil Sonigra

2

ACKNOWLEDGEMENTACKNOWLEDGEMENT

Page 3: Magnetic Crane

We would like to express a gratitude to

everyone who gave us the every possible guidance and

help to learn more about Magnetic Crane Which

imparted more knowledge about the topic.

In the first instance we would like to thanks

mechanical department of our Institute for giving us

permission to commence this project.

1. SHAH VAIBHAV. (S923005008)

2. DHIRAJ GOHIL.(S923005009)

3. AMIT PATEL (S923005009)

4. KRUNAL PANDYA (S923005012)

5. UJVAL DHARVAPARMAR (S92305025)

6. MANHAR NAKUM (S923005040)

7. ANAND PANCHAL (S923005204)

3

ABSTRACTABSTRACT

Page 4: Magnetic Crane

In manufacturing industry and nuclear industry,

a large fraction of the work is repetitive and judicious

application of automation will most certainly result in

optimum utilization of machine and manpower. 

A `Magnetic Crane' has been developed to

achieve automation in applications where great

sophistication is not needed and simple tasks like

picking up of small parts at one location and placing

them at another location can be done with great

ease.

4

Table Of ContentsTable Of Contents

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5

SR. NO. NAME

1. ACKNOWLEDGMENT

2. ABSTRACT

3. INDEX

4. LIST OF MATERIAL

5. COST OF MATERIAL

6. FLOW CHART

7. INTRODUCTION & HISTRY OF

CRANES

8. INTRODUCTION TO ELECTROMAGNET

9. WORKING & SPEED CALCULATION

10 FABRICATION STEP

11. APPLICATION

12. ADVANTAGES

13. GLOSSARY

14. INSTRUMENTS USE

15 REFREANCES

LIST OF MATERIALLIST OF MATERIAL

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We started our project for we survey some

types of using under materials for our project. Before we

make project collect air required listing as u material.

6

No Particular Qty.

1 DC Gear Motor 3

2 Electromagnet 1

3 Wheel 4

4 Wooden Body 1

5 Battery 1

6 Bearingl 1

7 Electrical remote 1

8. Fabrication

9 Switches 2

10 Switch Board 1

11 Nut Bolt 10

12 Wire etc. ….

BILL OF MATERIALBILL OF MATERIAL

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Costing

All manufacturing companies

sell their products to make profit.

The profit on each product sold can

be defined as the difference

between the selling price of the

product and the total cost of making

the product. Cost therefore plays a

very important role in the product design process. To

be successful, a product must not only satisfy a set

of functions defined in the product design

specification, but it must also be possible to build the

product within the cost criteria set out at the start of

the project. Before the development of any product

begins, it is essential to perform some form of

economic analysis on the product to determine if it is

worth making. This may involve some form of market

analysis to determine what the customer is willing to

pay for a product.

The costs involved in any product can be spilt

into development costs and the product cost.

Interestingly, some companies do not actually

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Page 8: Magnetic Crane

know what their costs are which leaves them open to

the possibility that their actual costs may be more

than the selling price of their product! An example of

this was the Mini when it was first produced in the

early 60’s. Market research suggested that the car

should be sold for less than £500 so the company

priced the car at £499. Later when they analyzed the

cost of producing the car they found that the car cost

around £530 to build, resulting in large losses for the

manufacturer.

Development Costs

Product Costs

Deign Costs

Material Costs

Manufacturing Costs

Storage Costs

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Our Project Construction for rewarded material as

cost above local market Fabrication and job work charge

extra.

No. Particular Cost

1 DC Gear Motor 900

2 Electromagnet 250

3 Wheel 40

4 Wooden Body 70

5 Battery 600

6 Bearing 130

7 Electrical Remote 150

8 Fabrication 150

9 Switches 50

10 Switch Board 50

11 Nut Bolt 70

12 Wire etc. 50

9

FLOW CHARTFLOW CHART

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10

START

Installed Proper Place

Arm Leval

Create Magnet & lift arm

HOW TO SELECT THE PROJECT

HOW TO SELECT THE PROJECT

Traveling Crane

Stop

Put Load

Page 11: Magnetic Crane

Magnetic Crane system project for our academic

year 2009 the project is part of our syllabus related

work, we through we done something different project in

our academic final year. We survey different type of

project like.

Are all project for we survey up listing subject

related, web site books and group discussion after we

decide up listing all project very higher coasting and raw

material is also not easily available in local market and

too much time consumption job because we avoid upper

listing projects. And we decide Chain Cooling System

Using Magnetic Crane system project.

Magnetic Crane system is an affordable coasting

project it project for not required heavy engineering

workshop. Raw material is easily available in local

market. It projects for more information also available in

website and books so this project for we discuss with our

group, friend circle, and our professors and after all

conveyance regards this project and after granted this

project to our collage. We got permission for this project

after we started construction and assembly of this

project

11

INTRODUCTION INTRODUCTION

Page 12: Magnetic Crane

Cranes with electromagnetic lift are also known as electromagnetic cranes. Such cranes are used widely in lifting and moving scrap metals. Even in a production line of many products, electromagnetic lifts are used to lift and move metal objects.

Electromagnets have special simplicity and many advantages to other lifting tools. They are faster and easier to work with.

History

The idea of robotics began as far back as the eighth

century, in the Iliad. Hephaestus, the Greek god of fire, was

said to have handmaidens mechanically active and made

from gold. However, the first true account of robotics comes

from the golden tree of Baghdad. Kept in a palace during the

ninth and tenth centuries, it featured birds singing on

branches while they flapped their wings. Early water clocks

were also examples of early robotics. They were often fitted

with astrological signs, giving a dual purpose to the

inventions. During the twelfth century, a royal inventor

named Al-Jazari created the first automatons.

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Page 13: Magnetic Crane

His hand washing basins had servant figures that would

fill a water basing and offer soap and towels. He also created

a robotic band, which would float on a lake and perform

different rhythms depending on the programming of a series

of pegs. Most of his inventions used water to initiate the

actions, but he also employed crankshafts and escapement

wheel mechanisms to make his devices operate at a fixed

speed

Structure

The structure of a robot is usually mostly mechanical

and can be called a kinematic chain (its functionality being

similar to the skeleton of the human body). The chain is

formed of links (its bones), actuators (its muscles), and joints

which can allow one or more degrees of freedom. Most

contemporary robots use open serial chains in which each

link connects the one before to the one after it. These robots

are called serial robots and often resemble the human arm.

Some robots, such as the Stewart platform, use a closed

parallel kinematical chain. Other structures, such as those

that mimic the mechanical structure of humans, various

animals, and insects, are comparatively rare.

However, the development and use of such structures

in CRANE is an active area of research (e.g. biomechanics).

Robots used as manipulators have an end effector mounted

on the last link. These end effectors can be anything from a

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welding device to a mechanical hand used to manipulate the

environment.

Electric motors:

The vast majority of robots use electric motors, often

brushed and brushless DC motors in portable robots or AC

motors in industrial robots and CNC machines.

STRUCTURE OF ELECTRO MEGNET

Electromagnetic is use in different industries like medical

use, appliances and good manufacturing, heavy engineering

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and crane industries electromagnet is a operate on electrical

supply AC or DC.

PRINCIPLE OF ELECTROMAGNET

First electromagnet has discovered since 1800 Centre

old doctor J.J. Thomson from America he decide electrons

atom road in same path up MS material will convert magnet.

So according to J.J.Tomson electric atom rotated MS material

than electrical atom rotated to magnetic energy.

So electro magnetic principle is a electrical energy is a

covert to magnetic energy is a electro magnet.

CONSTRUCTION OF ELECTROMAGNET

Electromagnet construction for required MS (Metal of Still)

rods or plates. Still rod on winding electrical copper wire

different-different gravity for winding will change of type.

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An electromagnet is a type of magnet in which the magnetic

field is produced by the flow of an electric current. The

magnetic field disappears when the current ceases. British

electrician William Sturgeon invented the electromagnet in

1825. The first electromagnet was a horseshoe-shaped piece

of iron that was wrapped with a loosely wound coil of several

turns. When a current was passed through the coil; the

electromagnet became magnetized and when the current

was stopped the coil was de-magnetized. Sturgeon displayed

its power by lifting nine pounds with a seven-ounce piece of

iron wrapped with wires through which the current of a

single cell battery was sent.

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Sturgeon could regulate his electromagnet; this was the

beginning of using electrical energy for making useful and

controllable machines and laid the foundations for large-

scale electronic communications.

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The simplest type of electromagnet is a coiled piece of wire.

A coil forming the shape of a straight tube (similar to a

corkscrew) is called a solenoid; a solenoid that is bent so

that the ends meet is a torpid. Much stronger magnetic fields

can be produced if a "core" of paramagnetic or

ferromagnetic material (commonly soft iron) is placed inside

the coil. The core concentrates the magnetic field that can

then be much stronger than that of the coil itself.

`

Current (I) flowing through a wire produces a magnetic field

(B) around the wire. The field is oriented according to the

left-hand rule.

Magnetic fields caused by coils of wire follow a form of the

left-hand rule. If the fingers of the left hand are curled in the

direction of current flow through the coil, the thumb points in

the direction of the field inside the coil. The side of the

magnet that the field lines emerge from is defined to be the

North Pole.18

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Electromagnets and permanent magnets

The main advantage of an electromagnet over a permanent

magnet is that the magnetic field can be rapidly manipulated

over a wide range by controlling the amount of electric

current. However, a continuous supply of electrical energy is

required to maintain the field.

As a current is passed through the coil, small magnetic

regions within the material, called magnetic domains, align

with the applied field, causing the magnetic field strength to

increase. As the current is increased, all of the domains

eventually become aligned, a condition called saturation.

Once the core becomes saturated, a further increase in

current will only cause a relatively minor increase in the

magnetic field. In some materials, some of the domains may

realign themselves. In this case, part of the original magnetic

field will persist even after power is removed, causing the

core to behave as a permanent magnet.

This phenomenon, called remnant magnetism, is due to

the hysteresis of the material. Applying a decreasing AC

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Page 20: Magnetic Crane

current to the coil, removing the core and hitting it, or

heating it above its Curie point will reorient the domains,

causing the residual field to weaken or disappear.

In applications where a variable magnetic field is not

required, permanent magnets are generally superior.

Additionally, permanent magnets can be manufactured to

produce stronger fields than electromagnets of similar size.

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GRAVITY RATIO

No

.

Current Gravit

y

Wire

gage

Tones Shaft

dai

meter

Suppl

y

1 0.2 Amp 29 189 50 4 mm 6V

2 0.4 Amp 49 189 100 4 mm 6V

3 0.7 Amp 109 209 100 6 mm 9V

4 0.7 Amp 149 209 100 6 mm 12V

5 1 Amp 209 209 1200 9 mm 12V

6 1.2 Amp 229 219 1200 9 mm 16V

It ratio through we observe requirement gravitational force

input supply, current and wire tones

21

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STEPS OF FABRICATION

First measure the diameter of the motor shaft.

Then measure the internal diameter of the axis the

wheel.

If both match then you can fix it directly.

Otherwise choose a rod that is at least 4 mm greater in

diameter than the motor shaft.(so that you can use a

minimum size of 2mm screw to secure it)

Step turn one side of the rod slightly larger than the

internal diameter of the axis of wheel to give a tight fit.

Then on the other side drill a hole with a drill bit that is

little larger than diameter of the motor shaft in the rod

along its axis .This side is given a loose fit since motor

can be reused .(Note this is a drill to insert the motor)

Drill until a depth that is little shorter than the height of

the motor shaft.

Then grind the motor shaft with grinding machine to

make a flat surface along the axis if your motors shaft

is cylindrical. Some motors shaft will be like half

cylindrical .This step is not needed if the motor is of this

type.

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Page 23: Magnetic Crane

Then drill a hole perpendicular to the axis of the

coupling shaft matching the place where you ground

the motors shaft, then tap the hole to form thread and

use a bolt to tightly secure the coupling shaft with

motor.

Before doing the above step don’t forget to fix the

wheel.

Wheels fitted to the motors with the coupler.

COUPLING MOTORS AND WHEELS

When you have motors and wheels the question arises

how I couples them. As far as I've experienced they never fit

together .So you have to make a coupler to couple both so

that it can be removed and used later in any other robot and

for easy dismantling.

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I've written the steps for fabricating it elaborately .You

can use either ms (Mild steel) or Brass for fabricating it. Then

build your chassis .And decide the steering mechanism that

you are going to use. Always go for differential steering than

Ackerman steering mechanism. Differential steering provides

more maneuverability and easy control which is crucial.

Incase you don’t know what differential steering mechanism

is I will explain you with the following diagram.

I'll explain you the steering mechanism

both motors forward boot moves forward. If left motor is

switched off or reversed boot and right motor is forwarded

turns towards left.and the other way for the right turns. This

is very basic and most people know it.

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Comparison…

Electromagnetic Crane Mechanical Crane

1) Electromagnetic is main

part for lifting.

2) Pollution free system.

3) Noiseless operation.

4) Use for ship breaking

yard.

5) Easily maintenance.

6) Not required any fuel.

7) Single operator required.

8) Compaq machine.

9) Not required lubrication.

10) Easily transportation.

1) S.S. hook is a main part of

lifting.

2) Polluted system

3) Maximum noise

4) Not use in ship yard

5) Regularly required

maintenance.

6) Required liquid fuel.

7) Minimum two operators

required.

8) Heavy machine

9) Much required

10) Difficult transportation

25

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ASSEMBLY

ASSEMBLY

Electromagnetic Crane as a machine of risky metal

scraps dumping on truck and best handling machine.

Electromagnetic crane through work totally safe against

human accident and next main advantage sound and

smoke less pollution free work.

This machine most use ship breaking yard steel scrap

merchant and metal industries.

26ASSEMBLYASSEMBLY

Important DefinitionImportant Definition

Page 27: Magnetic Crane

WORKING

Here is the picture of the pick and place mechanism that I

came up with. The working is pretty straight forward. It has a

moving and a fixed arm.

I use the nut bolt arrangement to close and open the

arm. And it has a center spring which provides the force to

automatically open the arm. And I used a motor fixed with a

pipe in the shaft to rotate the nut. Hers the diagram of it.

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MOTORS AND SPEED CALCULATION

When you start designing wheeled crane start

from the motors. Decide the type of motor you are

going to use. According to gear arrangement DC

motors can be broadly classified into

1. Motors with Internal gear's

2. Motors with External gear's

For beginners I would recommend using motors

with internal gear box motor ,since they are easy

to use(they eliminate the whole process of

designing and fabricating the gear box ) .Internal

gear box are available from a range of anywhere

between 5 to 5000 RPM .And their speed can be

varied either by

1. Varying the supply voltage

After you choose the motor you can calculate the

speed of the robot to get a rough idea about how

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fast your robot will go. (Never forget to do this

while designing a robot, otherwise you will end

with a robot that is either too slow or too fast) .

The speed calculation doesn't involve big

mathematical formulas.

Measure the diameter of the wheel (in meters) that

you are going to use .Then multiply it with PI(pi =

3.14159265) .This gives you the circumference of

the wheel .So you get a rough idea about how far

the robot moves on one rotation of the wheel .

Circumference = Diameter X PI

Most cheap motors available never work to the

specifics .The best way to find the RPM is trial and

error .Apply the required voltage (remember to

connect the wheel before applying the voltage)

and start a stop watch for (say) 10 seconds and

see how many time it rotates and then multiply it

with 6 .This gives u the approx speed of your

motor in RPM .And also mark a position on the

wheel to make it easier to track it visually .

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After getting the RPM of your motor multiply it with

the circumference of your wheel .This gives u the

approx speed of your robot in meters per minute.

Speed of your robot = RPM of motor x

Circumference of your wheel (meters/min)

1. Chassis 14”x18” x 10mm thick.

2. Wheel Brackets M.S. material

20mm x 5mm Flat

3. Gear Pole: 1.5” x 10” x 8 mm Round

pole.

4. Bearing Housing : outer Diameter :

26mm

5. Bearing Shaft : 10 mm outer

diameter

6. boom platform : 7” x 3.25” x 3mm

thick.

7. boom support flat : 20mm x 5mm x

4.5” length 31

Manufacturing PartsManufacturing Parts

Page 32: Magnetic Crane

8. motor base : 2”x 2” x 10mm thick.

9. boom : 25mm x 25 mm x 30”

length square pipe

10. Gear Motor base : 20mm x 5mm x 3

“ length flat.

1. Motors: 30 R.P.M. – 3 Nos.

60 R.P.M. – 1 Nos.

2 Bearing: Outer Diameter 26

Inner Diameter 10

3. Wheels

4. Toggle Switches

5. Push button switches

6. PVC Box for Remote

7. 3/8 “Nut-Bolt.

32

Purchase PartsPurchase Parts

Page 33: Magnetic Crane

8. 1/4“Nut-Bolt

9. Battery 12V D.C.

10. Wooden Sheet

11. Metal Rod

12 Electro Magnets

Sr

.

No

.

Activity

Detail

Name

Of

Memb

er

Approx.

Time

Require

d

Hours.

Remark

s

1. Project

Survey

1 week

2. Project

decide

2 Days

3. Material

survey

10 Days

33

WORK DISTRIBUTION CHART

WORK DISTRIBUTION CHART

Page 34: Magnetic Crane

4. Cost

survey

5 Days

5. Compan

y Visit

7 Days

6. Machini

ng

2 Days

7. Welding 1 Day

8. Assembl

y

3 Days

9. Testing 2 Days

Easy operated

No pollution of the media

Maintenance free

Easy designing

Smooth operation

With very much exception the crane use in any

installation.

34

AdvantagesAdvantages

Page 35: Magnetic Crane

Specific applications are:

The machine will be of great use to

perform repetitive tasks of picking and

placing of small parts (up to 500 gems) in

an industrial production line.

Its use can be extended and exploited by

few modifications to do difficult and

hazardous tasks for nuclear applications.

35

APPLICATIONAPPLICATION

Page 36: Magnetic Crane

As a basic tool for automation.

It can be used to do small assembly work

effectively due to its great added

accuracy for placement of parts.

36

Scheme & futureScheme & future

Page 37: Magnetic Crane

TOPIO, a crane developed by TOSY that

can play ping-pong. Further information:

Open-source robotics and Evolutionary

robotics

Much of the research in robotics focuses

not on specific industrial tasks, but on

investigations into new types of robots,

alternative ways to think about or design

robots, and new ways to manufacture them

but other investigations, such as MIT's cyber

flora project, are almost wholly academic.

A first particular new innovation in crane

design is the open sourcing of crane-projects.

To describe the level of advancement of a

robot, the term "Generation Robots" can be

used. This term is coined by Professor Hans

Morava, Principal Research Scientist at the

Carnegie Mellon University Robotics Institute

in describing the near future evolution of

crane technology. First generation robots,

Morava predicted in 1997, should have an

intellectual capacity comparable to perhaps a

lizard and should become available by 2010.

Because the first generation robot would be

incapable of learning, however, Morava

predicts that the second generation robot

would be an improvement over the first and

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become available by 2020, with intelligence

maybe comparable to that of a mouse. The

third generation robot should have intelligence

comparable to that of a monkey. Though

fourth generation robots, robots with human

intelligence, professor Morava predicts, would

become possible, he does not predict this

happening before around 2040 or 2050.

The second is Evolutionary crane. This is

a methodology that uses evolutionary

computation to help design robots, especially

the body form, or motion and behavior

controllers. In a similar way to natural

evolution, a large population of robots is

allowed to compete in some way, or their

ability to perform a task is measured using a

fitness function. Those that perform worst are

removed from the population, and replaced by

a new set, which have new behaviors based on

those of the winners. Over time the population

improves, and eventually a satisfactory robot

may appear. This happens without any direct

programming of the robots by the researchers.

Researchers use this method both to create

better robots, and to explore the nature of

evolution. Because the process often requires

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many generations of cranes to be simulated,

this technique may be run entirely or mostly in

simulation, then tested on real robots once the

evolved algorithms are good enough.

Currently, there are about 1 million industrial

robots toiling around the world, and Japan is

the top country having high density of utilizing

robots in its manufacturing industry.

39USED OF MACHINE AND TOOLS

Page 40: Magnetic Crane

Splayed

Cutter

Dismiss

Multi meter

Continue meter

Series taste lamp

Varian

Load panel

Taster

De-soldering

40

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A nine-volt battery, sometimes

referred to by its original designation as a

PP3 battery, is shaped as a rounded

rectangular prism and has a nominal output

of nine volts. Its nominal dimensions are

48 mm × 25 mm × 15 mm (ANSI standard

1604A).

Uses

9v batteries are commonly used in

smoke detectors, guitar effect units,

pocket radios, and radio-controlled

vehicle controllers. They are also used

as backup power to keep the time in

digital clocks and alarm clocks.

41

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Connectors

The connector (snap) consists of two

connectors: one smaller circular (male) and

one larger, typically either hexagonal or

octagonal (female). The connectors on the

battery are the same as on the connector

itself -- the smaller one connects to the larger

one and vice versa.

Technical specifications

Inside of a Nine-volt battery, showing

five of six AAAA batteries (6th one not

shown)

The battery has both the positive and

negative terminals on one end. The negative

terminal is fashioned into a snap fitting

which mechanically and electrically connects

to a mating terminal on the power

connector.

42

Page 43: Magnetic Crane

The power connector has a similar snap

fitting on its positive terminal which mates

to the battery. This makes battery

polarization obvious since mechanical

connection is only possible in one

configuration.

The clips on the 9-volt battery can be

used to connect several 9-volt batteries in

series. One problem with this style of

connection is that it is very easy to connect

two batteries together in a short circuit,

which quickly discharges batteries,

generating heat and possibly a fire. While

this is a danger, the same thing can be done

with multiple 9 volt batteries to create

higher voltage (they can snap together). The

wiring usually uses black and red wires, red

for positive, and black for negative.

Inside a PP3 there are ordinarily six

alkaline or carbon-zinc 1.5 volt (nominal) cells

arranged in series. These are either AAAA

cells, or special flat, rectangular cells. The

exact size of the constituent cells varies from

brand to brand -- some brands are slightly

longer than others -- as does the manner in

which they are joined together. Some brands 43

Page 44: Magnetic Crane

use soldered tabs on the battery, others press

foil strips against the ends of the cells.

Very cheap versions may contain only

five 1.5 volt cells. Rechargeable NiCad and

nigh batteries have various numbers of 1.2

volt cells. Lithium versions use three 3.2 V

cells - there is a rechargeable lithium

polymer version. There is also a Hybrid Nigh

version that has a very low discharge rate

(85% of capacity after 1 year of storage). .

44

Literature survey Literature survey

Page 45: Magnetic Crane

Website

http://wiki.answers.com

http://www.google.co.in/search?

hl=en&q=.*pdf

www.projectmaker.in

http://en.wikipedia.org/wiki/File:TOPIO_3.0.jpg

BOOKS

Prof. Khurmi: Machines and design

45