際際滷

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Design and Development of
New loading component for
braking application
Note : This work of mine showcases
engineering skills used to develop new product
based on our necessity.
Presentation by KANDHAN.S
BE Mechanical Engineering ,
Rajalakshimi Institute of Technology
Methodology
Modeling and drafting of machine
elements
Analytical modeling
As an application in gear testing rig
Benchmarking
Problem statement
Working principle
Problem statement
Conventional loading device
These are IC engines test rig. Here, for testing engine performance a external torque load is applied by
this conventional loading device
Disadvantages : size is not compact and application of constant torque is difficult
Benchmarking
Shaft adapter sleeve as a benchmark
Nut Tapered Sleeve
Nut
Tightened Tapered Sleeve
Nut
Tapered Sleeve
Housing
Modeling and rendering
key
Tapered Sleeve
Housing
Nut
All dimensions are in mm
Tapered Sleeve
key
Housing
Nut
Oil seal
LOADING COMPONENT EXPLODED VIEW
DISASSEMBLED LOADING COMPONENT
key
Tapered Sleeve
Housing
Nut
Loading shaft
NutNut
HousingHousing
Oil seal
Tapered Sleeve
LOADING COMPONENT
Working principle
Parts of loading component
The main parts of this system is composed of
 Tapered sleeve or tapered bush with 6 degree of taperness, partial external
thread and a through cut
 Housing which contains inner tapered bore to accommodate the bushs taperness
and Internal step on left face
 Nut contains internal thread to match the external thread of the bush and
external step to match the internal step of the housing
Bush nomenclature
Tapered bush with 6 degree of taperness and partial external
thread and through cut made of gun metal
external thread
through cut
Housing nomenclature
a housing contains inner tapered bore to accommodate the
bushs taperness. Internal step on left face is machined to
accommodate nut.
Inner tapered bore
Internal step
Nut nomenclature
Nut contains internal thread to match the
external thread of the bush and external step to
match the internal step of the housing made of
mild steel
Internal thread
External step
Tapered Sleeve
NutHousing
Oil seal
key
Oil seal
Tapered Sleeve key
Housing
Oil seal
Oil seal
Nut
Working of the loading component
 The tapered bush is inserted inside the housing such way that the treaded part of
the bush alone is expelled out of the housing
Working of the loading component
 The nut is made to travel over the external thread of the bush. As nut is rotated,
it get advanced forward till the external step on nut meets the internal step of
the housing beyond which the forward travel of nut is restricted. still as when
keep on rotating the nut, the tapered bush containing a through cut on other
hand shrinks itself and comes out by closing the gap between it. Therefore the
inner diameter of the bush is reduced thus tightening the shaft, loading torque is
applied.
forward travel of nut
travel of Bush
Working of the loading component
Before tightening After tightening
inner diameter of the bush is reduced by tightening
Analytical modeling
Analytical modeling of loading component
This loading device is modeled such a way that it exhibits sequential
combination of three mechanisms
1. Nut and bolt mechanism (achieving tightening force by interaction
between nut, housing and tapered bush )
2. Cone clutch mechanism (achieving contact pressure between
housing and tapered bush )
3. External shoe brakes (achieving braking torque by tapered bush on
loading shaft )
Design and development of New loading component for braking application
Tightening force
contact pressure
braking torque
Design and development of New loading component for braking application
Design and development of New loading component for braking application
Design and development of New loading component for braking application
Design and development of New loading component for braking application
Design and development of New loading component for braking application
Design and development of New loading component for braking application
Force flow chart
APPLIED FORCE ON
LEVER, [F]
TIGHTINIG FORCE, [W]
BY BOLD AND NUT
MECHANISM
CONTACT PRESSURE,
[Pn] BY CONE CLUCH
MECHNISM
BRAKING TORQUE,
[Tb] BY EXTERNAL
BRAKES
Design and development of New loading component for braking application
Design and development of New loading component for braking application
BRAKING TORQUE PRODUCED LOADING
COMPONENT (Tb)
Influencing parameters
Thus the braking torque of this device depends on three parameters
1. Coefficient of friction, l
2. Force applied F on lever of length L
3. Nut factor, K
 =


 .
Loading component providing braking torque
Ideal gear
RPM sensor
Arduino Board
Data from Arduino is linked with MS excel
Test gear
3phase, 2HP
induction motor
APPLICATION OF LOADING COMPONENT
Design and development of New loading component for braking application
No more slides
THANKS FOR YOUR PATIENCE !

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