IRJET- Automated Machine Design through Software Controller Support

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 02 | Feb 2020 www.irjet.net p-ISSN: 2395-0072
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2493
Automated machine design through software controller support
Vaheedbasha Shaik1
1Senior Oracle Database Administrator, IT Department, CenturyLink Technologies Pvt. Ltd.
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Abstract - The idea behind this paper is that can we create a
continuous cyclic mechanism in Machines with the help of
software! The Engine Core Components are designedtoutilize
the energy which is released by Electricity or Combustion or
Steam. Here, we are using mechanical power to generate
electricity and from Electric motor to Mechanical power
again. This cyclic motion will be controlled by Controller with
help of software and Predefined constant values.
the same process will be repeated to get into the Cyclic
Mechanism. The Software main intention is to Control the
Engine revolution and theConsumptionoftheReleasedPower.
The left-out Energy from the Machine is the Output from the
Machine.
Key Words: Crank, Shaft, Jack, House Jack, Torque, Power,4
stoke, Revolutions, Rotations, KW, W, and Arduino.
1. INTRODUCTION
The Sun is the best and the cleanest source of natural energy
available to us. The best part about the solar energy is that it
is present in abundance and will not disappear in the years
to come. However, the availability of sun with beneficial
state is up to 7 to 9 hours per day and Cost is one of the main
factors for the disappointment.To overcome these
undeniable obstacles, I am looking for the possible options
which can help us to produce more reliable and continuous
energy generation ways. One of them was creating self-
sustained machines. The Advantages would be,
 We can replace the Volatile Oil utilization by this
Process.
 Echo Friendly.
 Pollution Free.
 Low Maintenance.
Here, Most of the Work is related to Machine (90%).
However, we need software (10%) to control the Released
Energy which is the key component in the Project. The
Software would provide the monitoring and Power
adjustment capabilities.
2. EXISTING SYSTEM
As of Today, Some Technologies are available to run Engines
as Echo friendly. But those are not completely successful.
Their disposal is very much hazardous to Nature. For
example, Some Automobile companies have developed
mechanical technology to run the vehicles with Lithium
Batteries and they will get recharged again with Electricity.
Some Companies have developed Hybrid Technology as the
vehicle get recharged on running. However, both
technologies are failed to create Cyclic motion energy in the
vehicle.
3. PROPOSED SYSTEM
A jack is a mechanical liftingdevice usedtoapplygreatforces
or lift heavy loads. A mechanical jack employs a screw
thread forlifting heavy equipment. A house jack,alsocalleda
screw jack, is a mechanical device primarily used to lift
buildings from their foundations for repairs or relocation.
These types of jacks are used to lift very great weights. To
make it lift the 100Kg Weight only I have to spend only 1/40
power using this Jack that means 2.5Kg of weight pressure is
required to lift 100Kg weight by the jack.
If we use the electric machine to lift same weight, we need
nearly 1kw electric power to lift 100kg at the rate of 1meter
per second.
Let's do a quick calculation here:
power = work/time
work = force x distance
So, power = force x distance/time or equivalently,
power = force x speed of lifting (rate)
Force needed to hold 100 kg against gravity = 100*9.8,
rounding it up to 1000N.
Let's say the machine lifts it up at a rate of 1 meter per
second.
So power needed would be 1000 x 1 = 1kW.
But this is the power needed without frictionalandother
losses. Fairly if assembly is 80% efficient, actual power
the motor pumps in from the source would be
1000/0.8 = 1.25kW.
This verifies the afore mentionedfactthathighertherate
with which the weight needs to be lifted, more would be
the wattage rating.
With the same Calculations, If I wanted to lift 2.5Kg of weight
with 1-meter lift per second.
Power=2.5*9.8*1
=24.5W

According to this calculation I can lift 100Kg of weight with
24.5W using House Jack.
3. COMPONENTS
In this machine design I am using below components.
 Ball Nut Screw
 Replacing Crank Setup
 Gear shafts
 Coils of wire
 Controller
3.1 Ball Nut Screw
The Friction between threads of House jack is another
challenge. To decrease the friction, I am intended to use Ball
Nut Screw technique since the friction constant co-efficient
is very low as show below table.
If a more accurate calculation of bearing friction taking into
account the effects of speed and lubrication is required for
an application, please contact American’s sales department.
More important to the equipment designer than frictional
force is the amount of frictional torque that must be
overcome. This parameter can easily be calculated using the
formula below:
Where:
P = Equivalent Load on the bearing
μ = Coefficient of friction
dm = Pitch diameter of bearing
The ball screw assembly consists of a screw and a nut, each
with matching helical grooves, and balls which roll between
these grooves providing the only contact between the nut
and the screw. As the screw or nut rotates, the balls are
deflected by the deflector into the ball return system of the
nut and they travel through the return system to the
opposite end of the ball nut in a continuous path. The balls
then exit from the ball return system into the ball screw and
nut thread raceways continuously to recirculate in a closed
circuit.
The ball nut determines the load and life of the ball screw
assembly. The ratio of the number of threads in the ball nut
circuit to the number of threads on the ball screw
determines how much sooner the ball nut will reach fatigue
failure (wear out) than the ball screw will.
(a) The External Ball Return System. In this type of
return system, the ball is returned to the opposite
end of the circuit through a ball return tube which
protrudes above the outside diameter of the ball
nut.
(b) The Internal Ball Return System (There are several
variations of this type of return system) The ball is
returned through or along the nut wall, but below
the outside diameter.
Example (1): Some manufacturers have one revolution
circuits where the balls are forced to climb over the crest of
the thread on the screw by the return system. This is known
as a cross-over deflector type internal return system. In the
cross-over deflector type of ball nuts, the balls make only
one revolution of the shaft and the circuit is closed by a ball
deflector (B) in the nut (C) allowing the ball to cross over
between adjacent grooves at points (A) and (D).

3.2 Replacing Crank Setup
The Crank setup was used convert up and down movement
to rotational motion. This is revolutionary invention in
Mechanical industry. Here, I wanttoreplacethissystemwith
Worm Gear Wheel Technology.
The below mentioned Worm Gear Technology will generate
back and forth movement of threads to Rotational
movement.
3.3 Gear Shafts
The Most modern gearboxes are used to
increase torque while reducing the speed of a prime mover
output shaft (e.g. a motor crankshaft). This means that the
output shaft of a gearbox rotates at a slower rate than the
input shaft, and this reduction in speed produces
a mechanical advantage, increasingtorque.Agearboxcanbe
set up to do the opposite and provide an increase in shaft
speed with a reduction of torque. Some of the simplest
gearboxes merely change the physical rotational direction of
power transmission.
The above Diagram has 2 Gear wheels. The Big one has
nearly double radius means the rotation and revolution of
Small one will be high when we attach both as shown in the
picture.
If I attach another Big wheel as above pic, Then the double
rotation of the small one will be passed on to Big one. That’s
how the Big wheel has double the rotation to double. The
same process repentance the Big wheel might get 4
rotations.
These rotations will be attached to one shaft which is going
to be discuss in the next section.
3.4 Coils of Wire
This Components is the electricity generator for the whole
machine. In traditional powergeneratorstherotational shaft
will be connected to the Coils for the Frequency generation.
This frequency can be converted to output power.
The sample Power generator specifications:
In this existing system we will replace the 4-stroke engine
with the gear shaft for the rotation as medium.

3.5 Controller
When we are running the Machine in Cyclic mode one
Controller is required to handle inputandoutputenergyand
Power Consumption. Since it is difficult with Human touch,
we are proposing a Controller to do this Job.
The Design of the Controller will be made by Arduino Chip
setup and Arduino Programming and Commands will be
used to develop the component.
The Rotational sensor will be worked as we programmed in
the Controller. The below image depicts the actual image of
the Sensor.
 Arduino compatible
 Can rotate 10 full rounds
 Based on multi-turn precision potentiometer
 Operation voltage:3.3V-5.0V
 Weight: 10g
This component will be targeted to shaft of the Power
Generator. As instructed with Arduino programming it will
calculate the current rotational speed of the shaft. These
calculations will be used as stabilized state. If User wants to
produce more power and according to his/her setting the
machine will follow the instructions.
REFERENCES
[1] https://www.jena-
tec.co.uk/downloads/ballscrews/Guide-Book.pdf
[2] https://www.scribd.com/document/408543385/ball-
screw-pdf
[3] Dynamics of Crank-Piston Mechanisms Book by Nodar
Davitashvili and Valeh Bakhshalie
[4] https://docs.rs-
online.com/3961/0900766b815c2376.pdf
[5] Programming Arduino: Getting Started with Sketches
[6] Getting Started with Arduino Book by Massimo Banzi
[7] Arduino Workshop: A Hands-On Introduction with 65
Projects
BIOGRAPHIES
Vaheedbasha Shaik has received
Master of Technology (M.TECH)in
Specialization of Databasesystems
From SRM University and
Currently working asSenior Oracle
Database Administrator for the IT
Department in CenturyLink
Technologies Pvt. Ltd.

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