Module 3

Mechanical Components
 Course Outline
Mechanical Components

Chain Drives
Gears
Bearing
Power Transmission Shafts
Coupling Types
Clutches
Belt Drives
 Course Goals
Upon completion of the course, students should:
1. Understand the role of mechanical
components and electrical drives in complex
mechatronic systems, modules and
subsystems.
2. Understand the flow of energy in the system.
3. Understand troubleshooting, preventive
maintenance and safety issues revolving
around mechanical components and electrical
drives within a mechatronic system.
 Mechanical Actuation Systems

• Mechanical devices are motion converters: they

transform motion from one form into another form. For
example they transform linear motion into rotational
motion.
 Mechanical systems
Devices which can be considered to be motion converters in that
they transform motion from one form to some other required form.
ex: Transform linear motion into rotational motion
and vice versa.

Mechanical elements can include the use of linkages, cams, gears,

rack-and-pinion, chains, belt drives, etc.
ex: rack-and-pinion can be used to convert rotational
motion to linear motion.

Many of the actions which previously were obtained by the use of

mechanism are, however, often nowadays being obtained, as a result
of a mechatronics approach by the use of microprocessor systems.
 Mechanical systems
Mechanisms play an important role in mechatronics systems. For
example, the mechatronics system in use in an automatic camera for
adjusting the aperture for correct exposures involves a mechanism for
adjusting the size of diaphragm.
Other functions:
– Force amplification – given by levers.
– Change of speed – given by gears.
– Transfer of rotation about one axis to rotation about
another – timing belt.
The term kinematics is used for the study of motion without regard to
forces. When we consider just the motions without any consideration
of the forces or energy involved then we are carrying out a kinematic
analysis of the mechanism.
 Mechanical systems
Types of Motion

Translation motion Rotational motion

Movement which can be Rotation which has components

resolved into components along rotating about one or more of
one or more of the 3 axes. the axes.
Freedom and Constraints
An importance aspect in the design of mechanical
elements is the orientation and arrangement of the
elements and parts.
A body that is free in space can move in three,
independent, mutually perpendicular directions and
rotate in three ways about those directions.

The number of degree of freedom is the number of

components of motion that are required in order to
generate the motion.
Freedom and Constraints

Figure (a) shows a joint with just this one translational

degree of freedom.
Figure (b) shows a joint which has one translational
degree of freedom one rotational degree of freedom.
 Kinematic Chains
Each part of a mechanism which has motion relative to some other part is termed
a link.

A rigid body which has two or more points of attachment to other links is termed
nodes.

Each link is capable of moving relative to its neighboring links.

A joint is a connection between the connected links at their nodes and which
allows some motion between the connected links.

Levers, cranks, connecting rods and pistons, sliders, pulleys, belts and shafts are all
examples of links.
Kinematic Chains

(a) with two (b) with three (c) with four

nodes nodes nodes
 Kinematic Chains
A sequence of joints and links is
Fixed
known as kinematic chain. frame
For a kinematic chain to transmit
motion, one link must be fixed.
Slider
Movement of one link will then
produce predictable relative
movements of the others. Connecti
ng rod
It is possible to obtain from one
kinematic chain a number of
different mechanisms by having a
different link as the fixed one.
The design of many mechanisms Crankshaft
are based on two basic forms of
kinematic chains, the four-bar chain The reciprocating motion of a piston is
and the slider-crank chain. transformed into rotational motion of a
crankshaft on bearings mounted in a
fixed frame.
 Kinematic Chains
The Four-bar Chain
Consists of 4 links connected to give 4 joints about
which turning can occur.

Double-lever mechanism
Lever-crank mechanismDouble-crank mechanism
 Kinematic Chains
The Four-bar Chain
Example of a mechanism can be used to advance the
film in a cine camera.
Link 1 rotates, so the end of link 2 lock into a sprocket
of the film, pulls it forward before releasing and
moving up and back to lock into the next sprocket..

Cine film advance mechanism

 Kinematic Chains
The Four-bar Chain
Some linkages may have toggle positions. These are
positions where the linkage will not react to any input
from one of its links.

Figure below illustrates such a toggle, being the

linkage used to control the movement of the tailgate
of a truck so that when link 2 reaches the horizontal
position no further load on link 2 will cause any further
movement.

There is another toggle position for the linkage and

that is when links 3 and 4 are both vertical and the
tailgate is vertical.
The Four-bar Chain
 Kinematic Chains
The Slider-crank Mechanism
Consists of a crank, a connecting rod and a slider.

The position sequence

for the links in a slider-
crank mechanism
Threads
 Cams
Cam is a body which rotates or oscillates and in doing so imparts a
reciprocating motion to a second body called follower, with which it
is in contact.
The length of times spent for the rotation is depending on the shape
of the cam.
Part that lowers the
follower, its profile
determining how Part that drives the
quickly the cam follower upwards, its
follower will fall. profile determining how
quickly the cam
Part that allows the follower will lifted.
follower to remain at
the same lever for a
significant period of
time and where its
circular with a radius
that does not change.
 Cams
The cam shape required to produce a particular motion of the
follower will depend on the shape of the cam and the type of
follower used.

Displacement diagram for an eccentric cam

 Cams
Figure below shows the types of follower displacement diagrams
that can be produced with two other different shaped cams and
either point or knife followers.

(constant rate,
Heart uniform speed)
shape

(rise and fall

Pear
symmetrically)
shape
 Cams
Figure below shows a number of examples of different types of cam
followers.
Point Knife Roller

Lower friction than

sliding contact but
can be more
expensive
 Cams
Figure below shows a number of examples of different types of cam
followers.
Sliding and oscillating Flat Mushroom

Often used because

cheaper and can be
made smaller than roller
follower.
 Gears
Gear trains are mechanisms which are very widely used to transfer
and transform rotational motion. They are used when a change in
speed or torque of a rotating device is needed. For example, the car
gearbox enables the driver to match the speed and torque
requirements of the terrain with the engine power available.

(a) Parallel gear axes, (b) axes inclined to one

another, (c) axial teeth, (d) helical teeth, (e)
 Gears
Two meshed gears.

Gear ratio,
ωA = number of teeth on B = dB
ωB number of teeth on A dA

Angular velocity Diameter

 Gears
Gear trains – a series of intermeshed gear wheels.
Simple gear train – used for a system where each shaft carries only
one gear wheel.

Ratio of the angular velocities,

G = ωA = ωA ωB
x
ωC ωB ωC
 Gears
Compound gears trains – two wheels are mounted on a common
shaft.

Ratio of the angular velocities,

G = ωA = ωA
ωD ωB
x ωB
ωC
x ωC = ωA
ωD ωB
x ωC
ωD
 Gears
Rotational to translational motion – two intermeshed gears
with one having a base circle of infinite radius. Such gear can be
used to transform either linear motion to rotational motion or
rotational motion to linear motion.
Eg: The rack-and-pinion.
X = α r , α in radians ( gear travelled angle)
r : raduis of the gear
X: linear distance travelled

Effective gear ratio= ,w (rev/sec)

𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝑙𝑖𝑛𝑒𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
 Example
for rack and pinion configuration if the raduis of
the pinion is 2 cm and it rotates 5
revolutions ,calculate the linear distance
travelled.
Solution.
X = α r = 5(2π) X 2 cm
= 20π cm= 62.8 cm
(if the 5 rev were made in 2 sec) what will be the
linear velocity) = 31.4 cm/s
 Gear Types
Spur gears have straight
teeth
Helical Gears
Bevel gears are used to transmit
power between two non-
parallel, intersecting shafts,
often at 90 degrees.
Worm Gears
 Defects of gears
Tooth breakage is generally caused by excessive
wear or an unexpectedly high load being placed
on the gear teeth.
Pitting takes place when little pieces of metal
break and fall out of the teeth, and is caused by
metal fatigue.
Scoring generally occurs under heavy loading
and lack of lubrication.
 Chain Drives
Chains are flexible machine elements, usually
made of metal, that are designed to transfer
power between parallel shafts. They are
especially useful in situations where the shafts
are too far apart to use gears
 Chain and Sprocket Fundamentals
If a chain is wrapped around a driving sprocket
with 15 teeth and a driven sprocket with 30
teeth, the 30 tooth sprocket will rotate ½ of the
way around for each full rotation of the 15 tooth
sprocket.
the 30 tooth sprocket will have double torque
 Advantages of chain drives
1) They are immune to damage by oil and grease
2) They can operate under relatively high temperatures
3) They do not slip
4) They do not require initial tension
5) They are highly efficient
6) Chain installation is relatively easy
7) They can run with looser tolerances than gears or belts
8) Chains can accomodate long center distances between shafts (up
to 4 meters)
9) Depending on the chain type, both sides of the chain may be used
to drive shafts
10) Sprockets are subject to less wear than gear teeth because the
driven load is spread across more sprocket teeth.
11) For the same power conditions, chains and sprockets are much
less expensive than timing belts and pulleys.
 Disadvantages of chain drives
1) They can be noisy
2) Chains need lubrication
3) Chains elongate when they wear
4) Chordal action causes vibration and
uneven driven speed ( wear of teeth)
 Chain Types and Applications
Roller chains and silent chains

silent chains
Roller chain
 Belt and Chain Drives
Pair of rolling cylinders with the motion of one cylinder being
transferred to the other by a belt.

Belt drives use the friction that develops between the pulleys
attached to the shaft and the belt around the arc of contact
in order to transmit a torque.
The transmitted torque is due to the differences in tension
that occur in the belt during operation. This difference
results in a tight side and a slack side for the belt.
 Belt and Chain Drives
– As a method of transmitting power between two
shafts, belt drives have the advantage that the length
of the belt can easily be adjusted to suit a wide range
of shaft to shaft distance and the system is
automatically protected against overload because
slipping occurs if the loading exceeds the maximum
tension that can be sustained by frictional forces.

– If the distance between shafts is large, a belt drive is

more suitable than gears, but over small distances
gears are to be preferred.

– Different size pulleys can be used to give a gearing

effect. However, the gear ratio is limited to about 3
because of the need to maintain an adequate arc of
contact between the belt and pulleys.
 Belt and Chain Drives
– Figure below shows two types of reversing drives.
– With both forms of drive, both side of the belt comes
into contact with the wheels and so V-belts or timing
belts cannot be used.

Cross belt

Open belt
 Belt and Chain Drives
Types of belts
Flat.
Has rectangular cross section.
Has an efficiency about 98% and produces little noise.

Round.
Has a circular cross section and is used with grooved pulleys.
 Belt and Chain Drives
–V
• V – belts are used with grooved pulleys and are less
efficient that flat belts but a number of them can be used
on a single wheel and so give multiple drive.

– Timing.
• Require toothed wheels, having teeth which fit into the
grooves on the wheel.
• Unlike the other belts, timing belt does not stretch or slip
and consequently transmits power at a constant angular
velocity ratio.
• The teeth make it possible for the belt to be run at slow or
fast speeds.
Bearings
A bearing is a machine element
that constrains relative motion
and reduces friction between
moving parts to only the desired
motion
 Bearings
– Whenever there is relative motion of one surface in contact with
another, either by rotating or sliding, the resulting frictional
forces generate heat which wastes energy and results in wear.

– The function of bearing is to guide with minimum friction and

maximum accuracy the movement of one part relative to
another.

– Give suitable support to rotating shaft.

– The term thrust bearing is used for bearings that are designed to
withstand forces along the axis of a shaft when the relative
motion is primarily rotation.
 Loads on bearing

An axial load, also known as a thrust load, is a

force applied along the axis of the shaft, such as
by a spring or clutch connected to the end of the
shaft. A radial load is a load along the radial
direction of the shaft, which could be due to the
force between the teeth of a gear mounted on
the shaft and the teeth of another gear on a
parallel shaft, or even due to the weight of the
shaft itself
There are at least 6 common
principles of operation:
• Plain bearing, also known by the specific styles: bushing,
journal bearing, sleeve bearing, rifle bearing
• Rolling-element bearing such as ball bearings and roller
bearings
• Jewel bearing, in which the load is carried by rolling the
axle slightly off-center
• Fluid bearing, in which the load is carried by a gas or liquid
• Magnetic bearing, in which the load is carried by a
magnetic field
• Flexure bearing, in which the motion is supported by a
load element which bends.
Motions
Common motions permitted by bearings are:
 axial rotation e.g. shaft rotation
 linear motion e.g. drawer
 spherical rotation e.g. ball and socket joint
 hinge motion e.g. door, elbow, knee
 Friction
Reducing friction in bearings is often important
for efficiency, to reduce wear and to facilitate
extended use at high speeds and to avoid
overheating and premature failure of the
bearing.
Reducing friction

By shape, gains advantage usually by using

spheres or rollers
• By material, exploits the nature of the
bearing material used.
• By fluid, exploits the low viscosity of a layer
of fluid, such as a lubricant
• By fields, exploits electromagnetic fields,
such as magnetic fields, to keep solid parts from
touching
 Bearings
Plain journal bearings
Used to support rotating shafts which are loaded in a radial
direction (journal – shaft).
Consists of an insert of some suitable material which is fitted
between the shaft and the support.
Rotation of the shaft results in its surface sliding over that of
the bearing surface.
The bearing may be a dry rubbing bearing or lubrication.
 Bearings
Ball and roller bearing
With this type of bearing, the main load is transferred from
the rotating shaft to its support by rolling contact rather than
sliding contact.
A rolling element bearing consists of 4 main elements : an
inner race, an outer race, the rolling element either balls or
rollers, and a cage to keep the rolling elements apart.
The inner and outer races contain hardened tracks in which
the rolling elements roll.
 Bearings
Ball and roller bearing
Types of ball bearings.

a) Deep-groove
b) Filling-slot
c) Angular contact

d) double-row
e) Self-aligning
e) Thrust, grooved
race
 Bearings
Ball and roller bearing
Types of roller bearings.

a) Straight roller
b) Taper roller
c) Needle roller
Bearings
Bearings
Bearings
Bearings
Bearings
Bearings
Loads
Bearings vary greatly over the size and
directions of forces that they can support.
Forces can be predominately
radial,
axial (thrust bearings)
or bending moments perpendicular to the
main axis.
Bearings – Axial and Thrust Loading
Bearings – Axial and Thrust Loading
 Speeds
Plain bearings typically handle only lower
speeds, rolling element bearings are
faster, followed by fluid bearings and
finally magnetic bearings.
 Service life

Rolling element bearing life is

determined by load, temperature,
maintenance, lubrication, material
defects, contamination, handling,
installation and other factors
External Factors

bearing mounting, temperature, exposure

to external environment, lubricant
cleanliness and electrical currents through
bearings etc
Maintenance and lubrication
 - Bearings can be lubricated by a
metal ring that rides loosely on the
central rotating shaft of the
bearing
- Splash lubrication
- Pressure lubrication
 COUPLINGS
• Mechanical component for connecting
two shafts together

• Transfers torque from one shaft to the other

• Allows two shafts to rotate with some misalignment

 COUPLINGS – uses
• To provide for the connection of shafts of units that are
manufactured separately such as a motor and generator and to
provide for disconnection for repairs or alterations.

• To provide for misalignment of the shafts or to introduce

mechanical flexibility.

• To reduce the transmission of shock loads from one shaft to

another.

• To introduce protection against overloads.

• To alter the vibration characteristics of rotating units.

• To connect driving and the driven part

 COUPLINGS – Two Main Types
1.RIGID/SOLID Couplers
-used to join two shafts within a motor system
-must be strong enough to hold the two shafts ends
together AS IF they were one shaft
-clamp onto each shaft tight enough to transmit the
torque from one shaft to the other
- precise alignment

2. FLEXIBLE Couplers
- allow for misalignment and/or axial displacement
- used when two shafts are already running on
their own bearings
- for vibration damping or noise reduction
 COUPLINGS – Rigid/Solid Couplers
Two main types.
1.Rigid Cylinder
-easiest to use
-cheapest
-single tube with inner diameter equal to size of shaft
2. Clamped/Rigid Flanges
- come in two parts fit around the shaft to form a
sleeve
or flange
- flanges are bolted together
This Flange coupling is most accurate and rigid and provide
a strong connection .
COUPLINGS – Rigid/Solid Types

Rigid Cylinder Couplers

COUPLINGS – Rigid/Solid Types

Clamped Rigid Couplers

COUPLINGS – Rigid/Solid Types

Clamped Rigid Couplers

COUPLINGS – Rigid/Solid Types

Clamped Rigid flanges

 COUPLINGS – Flexible Couplings
Flexible couplings are used to transmit torque from one
shaft to another when the two shafts are slightly
misaligned
Advantages
• Easy to install and disassemble
• they can also be used for vibration damping
• Stay rigidly attached to the shaft.
• Withstand temperatures of environment or
heat of friction
Increasing number of coils allows for greater angular misalignment
COUPLINGS – Flexible Couplers
1.Mechanical Element
Gear Couplers
Metal Ribbon Couplers
2. Elastomeric Element

3. Metallic Membrane/Disk Type

COUPLINGS – Gear Couplers
The gear coupling consists of two hubs with external
gear teeth that are attached to the shaft

A hub cover or sleeve with internal gear teeth engage

with the shaft hubs to provide the transmission of
power

Lubrication of gear teeth is required

COUPLINGS – Gear Couplers
COUPLINGS – Gear Couplers
Typical Specifications:

Capacity : up to 70,000 hp

Max Speed : up to 50,000rpm

Coupling guards should be air

tight
COUPLINGS – Gear Couplers
Advantages:
Allows freedom of axial movement
Capable of operating at high speeds
Good balance characteristics.
Long history of successful applications

Disadvantages:
Requires lubrication.
Separation of greases into soaps and oils.
Centrifugal effect on oils / sludge formation.
Temperature limitation due to lubricant
 COUPLINGS – Metal Ribbon Couplers
Consist of two hubs with axial ‘grooves’ on the outer
diameter of the hub

A continuous ‘S’ shaped grid meshes into the grooves.

Misalignment and axial movement is achieved by flexing

and sliding of the grid member

Lubrication of gear teeth is required.

COUPLINGS – Metal Ribbon Couplers
Typical Specifications:

Capacity : up to 70,000 hp

Max Speed : up to 6,000rpm

Coupling guards should be air

tight
COUPLINGS – Metal Ribbon Couplers
COUPLINGS – Metal Ribbon Couplers
Advantages:
Easy to assemble and disassemble
Torsionally Soft (twisting)
Long history of successful applications

Disadvantages:
Requires lubrication.
Temperature limited.
Speed limited
COUPLINGS – Elastomeric Coupling
An elastomeric medium (called ‘spider’) is used to
transmit torque and accommodate misalignment.

Torsionally ‘soft’ to absorb high starting torques.

The spider is generally natural or synthetic rubber,

urethane, nylon and teflon

Capacity : up to 67,000 hp / 1000 rpm

Max Speed : approx. 5000rpm

COUPLINGS – Elastomeric Coupling
COUPLINGS – Elastomeric Coupling
COUPLINGS – Elastomeric Coupling
Advantages:
Minimal wear in coupling
Acts as a vibration damper and isolator
Acts as electrical current insulator
Torsionally soft
No lubrication required

Disadvantages:
Speed limited. Cannot be balanced perfectly
Corrosive attack/oxidation of elastomer
Undesirable axial forces
COUPLINGS – Elastomeric Coupling
Failure Modes:
Abrasion (skin)
Temperature deformation
Aging/Drying
Consumption of organic material

Disadvantages:
Speed limited. Cannot be balanced perfectly
Corrosive attack/oxidation of elastomer
Undesirable axial forces
Braking and Clutch
 Purpose
This chapter describes the principles of
electromagnetic force and magnetic
circuits.
It outlines typical applications of
electromagnetic force in mechanical
actuation.
 Solenoids
A solenoid is a simple electrical machine that consists of a coil and
a movable magnetic core.
The coil acts as an electromagnet, which causes movement of the
core (plunger).
 Solenoids (continued)
An electric actuator is a device that moves a mechanism from one
position to another.
 Solenoids (continued)

The operating force of a solenoid depends on the

current, the number of turns and the material in
the magnetic path.
The larger air gap that exists when the solenoid is
open requires a greater current to cause enough
force so that the solenoid 'pulls in'.
 Solenoids (continued)
When the solenoid is closed, the air gap is
smaller and the current required to 'hold in' the
solenoid is smaller.
 Electromagnet applications
Electromagnets are used in a range of
applications.
The benefit of using electromagnets is that
control of the current through the coil can
control the magnitude of the electromagnetic
force applied.
 Electromagnetic brake
The use of a remotely controlled solenoid to operate a
braking mechanism is known as electromagnetic braking.
This braking system may be arranged to provide braking on
application or removal of current flow in the solenoid.
 Electromagnetic clutch
An electromagnetic clutch can be used to control
coupling of a machine driven flywheel to a
mechanical load.
 Lifting electromagnet
Scrap metal dealers use large electromagnets
on cranes to allow the safe movement of large
amounts of jagged and dangerous iron and
steel.
The magnet is lowered onto the scrap metal
pile, the magnet is energised and the scrap
metal is moved to the desired location at which
point the electromagnet is turned off causing
the metal to fall from the crane.
Lifting electromagnet (continued)
 Electromagnetic Clutch
EM Clutches – operate electrically but transmit
torque mechanically

Basic Components for EM Brakes and Clutch:

a. Coil in a shell (Field)
b. Hub
c. Armature
Electromagnetic Clutch
 Electromagnetic Clutch
Coil shell – usually carbon steel for strength
and magnetic properties

Coil – copper wire (sometimes aluminum)

Activating the electric circuit = coil energized = magnetic field

Magnetic field overcomes air gap = armature is pulled =

Hub is connected with the rotor
 Sample Test Questions
1) Which statements about the installation and adjustment of the synchronous belt drive shown
below are correct?

X a) If both pulleys are properly aligned, all four edges of the pulleys (1, 2, 3, and 4) should be touching the
straight edge.

b) After installation, it is important to check the tension of the belt while the machine is running.
c) Loosening of both pulleys is always required to properly align the belt.
X d) If the pulleys are not aligned, the belt will run up against the pulley flanges causing excessive belt
wear.
e) If the pulleys are not aligned, the belt still remains perfectly centered on the pulleys.
 Sample Test Questions
2) The internals of an automotive gearbox are shown below. What condition must hold true if
any two gears of the type shown are to mesh properly?

X a) The teeth of both gears must be the same size.

b) Both gears must have the same outer diameter.

X d) The shafts must be parallel.

e) None of the above .

 Sample Test Questions
3) An image of the internals of an automotive differential are shown below. The pinion gear with
14 teeth is driving the ring gear with 42 teeth. If the pinion turns at 420 rpm, what will be the
speed of the ring gear?

a) 42 rpm.

X b) 140 rpm.

c) 160 rpm.

d) 110 rpm.

e) 1260 rpm.
 Sample Test Questions
4) The builder of the automotive racing engine shown in the picture decided to use socket head
cap screws to attach the valve covers. What is the pitch of the screws used?

X a) 2mm.

b) 12mm.

c) 34mm.

d) 54mm.

e) 18mm.
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