[2010] 1
Oct 23, 2014
[2010][2010]
CERTIFICATECERTIFICATE 1
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
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
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
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
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
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
7
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
8
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
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
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
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.
12
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
13
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
14
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.
15
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.
16
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.
17
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
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
19
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.
20
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
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.
22
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.
23
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.
24
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
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
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.
27
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
29
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 .
30
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
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
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
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
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
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
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
37
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
38
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
Splayed
Cutter
Dismiss
Multi meter
Continue meter
Series taste lamp
Varian
Load panel
Taster
De-soldering
40
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
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
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
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
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