1.

0
1.1

INTRODUCTION
SLIDER CRANK DEFINITION AND THE MECHANISM

Slider-crank mechanism is an arrangement of mechanical parts made to convert straight-line motion to rotary motion or to convert rotary motion to straight-line motion, A fourbar linkage with output crank and ground member of infinite length. A slider crank (see illustration) is most widely used to convert reciprocating to rotary motion (as in an engine) or to convert rotary to reciprocating motion (as in pumps), but it has numerous other applications. Positions at which slider motion reverses are called dead centers. When crank and connecting rod are extended in a straight line and the slider is at its maximum distance from the axis of the crankshaft, the position is top dead center (TDC); when the slider is at its minimum distance from the axis of the crankshaft, the position is bottom dead center (BDC).

Principal parts of slider-crank mechanism.

1.2

PROJECT OBJECTIVES

Therefore, in this project, the aim is to investigate how to design the best possible slider-crank mechanism based on limitations, measurements, and requirements given. Besides, with this project, students can discover more about ADAMS software which is the main syllabus of software-learning in this course.

1.3

DESIGN REQUIREMENTS

According to the project brief, the requirement of the slider crank we are going to design is as follows: 1. The mechanism required is to produce a linear reciprocating motion of a slider along the horizontal shaft. The piston is denoted as S. 2. The mechanism is to be driven directly by an AC induction motor running at constant speed. 3. The speed of the motor shaft must be in a multiple of 10 rpm. 4. The speed of the working stroke must never exceed VMAX. 5. The time taken by the return stroke should be anywhere between 60% and 95% of the time for the working stroke. 6. The design should aim for the highest number of strokes per unit time as permitted by other parameters. 7. The coupler ratio should be more than 3. 8. The maximum dimension occupied by the working space of the mechanism along the sliding axis should not exceed LMAX while its width should be minimized. 9. For our group, the stroke, the max length and max velocity of the machine required is respectively 300 mm, 580 mm, 1500 mm/s.

S W

LMAX

2.0
2.1

METHODOLOGY
IDENTIFYING REQUIREMENTS & LIMITATIONS

In this section we discuss and list down the limitations and requirements that our design must meet for the crank-slider mechanism. The requirements of our design will be tabulated in order of priority in descending order, the top objects being the highest of priority. Before we go into the requirements, it is important to first look into the limitations of our design.

DESIGN REQUIREMENTS Symbol S W L max V max LIMITATIONS No. 1 2 3 4 5 6 Limitations Vstroke,working < Vmax Angular speed in increments of 10 RPM Time taken by the return stroke should be anywhere between 60% to 95% of the time for the working stroke. Coupler ratio should be more than 3, L3 > 3L2 The horizontal length of working space must not exceed Lmax Stroke must be 300mm for all values of L2 and L3 Definition Stroke Width Max Length Max Velocity Value 300 mm To obtain 580 mm 1500 mm/s

REQUIREMENTS Rank 1 2 3 Requirements Highest number of strokes per unit time. Width W should be minimised. Area of workspace, L X W should be minimized.

2.2

ACQUIRING OPTIMAL VALUE OF ANGULAR SPEED

Referring to the first requirement of the design which is to obtain the highest number of strokes per unit time, it was decided that the angular velocity would play the most important role. However at the same time, we were required to keep the velocity of the working stroke to be at or below the maximum allowable slider velocity. With that in mind, we had come up this table of values that show the significant changes that occur as we change the angular speed.
Angular Speed (rpm) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 t (s) 6.000 3.000 2.000 1.500 1.200 1.000 0.857 0.750 0.667 0.600 0.545 0.500 0.462 0.429 Q 0.071 0.154 0.250 0.364 0.500 0.667 0.875 1.143 1.500 2.000 2.750 4.000 6.500 14.000 B -156.0 -132.0 -108.0 -84.0 -60.0 -36.0 -12.0 12.0 36.0 60.0 84.0 108.0 132.0 156.0 Return stroke (%) 1400.0 650.0 400.0 275.0 200.0 150.0 114.3 87.5 66.7 50.0 36.4 25.0 15.4 7.1

TABLE 1
As you can see weve set the angular speed as an independent variable that will help develop the other values. From angular speed, we can obtain the total time, t by: , where The highest possible number of strokes per revolution of the crank is obtained by increasing the angular speed, which reduced t. The smaller the value of t, the more the number of

strokes obtained per unit time. The optimal value of --------- 1

At the same time,

--------- 2

Therefore to obtain Q is obtained by equating 1 to 2 and rearrange to obtain, With Q found, B = and ( )

Since it is impossible to obtain a Q value of Q < 1, we reduce the table of values to:
Angular Speed (rpm) 80 90 100 110 130 140 80 t (s) 0.750 0.667 0.600 0.545 0.462 0.429 0.750 Q 1.143 1.500 2.000 2.750 6.500 14.000 1.143 B 12.0 36.0 60.0 84.0 132.0 156.0 12.0 Return stroke (%) 87.5 66.7 50.0 36.4 15.4 7.1 87.5

TABLE 2
From this smaller table of values, we can now start to pick the most optimal angular speed to ensure the most number of strokes per unit time while at the same time keeping to the limitations of set for the design. We have decided to take Angular Speed, of 360RPM with the smallest t while having a

tstroke,return, (%) value of 66.7% which fits within the 60-95% limitation. At the same time, we must look closely to the B value of 36 obtained at that angular velocity for it will be a value to aid us in the next step.

2.3

OBTAINING WIDTH, CRANK RADIUS AND COUPLER LENGTH

The next step in the design of our crank-slider mechanism is to choose the appropriate crank radius, coupler length and workplace width. In this, we start off with setting an arbitrary radius of the crank. At this radius, we would start off with having the coupler length (L3) to be a multiple of crank radius (L2) at 3.05. In other words, first value of L3 for that radius is L3 = L2 * 3.05. With both the crank radius (L2) and coupler length (L3) set, we move on to find the B angle as well as the offset length and whether at these values of L2 and L3, we are still able to keep within the length limitations. For each L2, we experiment by changing L3 to achieve the B angle previously obtained in the previous step. Once the desired B angle is achieved for that radius, we repeat these steps again for different radius values until the desired B angle is no longer achievable. Below is the first list of values to help us obtain the optimal crank radius.
Radius (mm) L3 (mm) 244 280 320 360 418 274.5 300 350 399 450 305 375 400 450 500 335.5 348 400 450 500 366 380 400 420 440 L2 + L3 (mm) 324.0 360.0 400.0 440.0 498.0 364.5 390.0 440.0 489.0 540.0 405.0 475.0 500.0 550.0 600.0 445.5 458.0 510.0 560.0 610.0 486.0 500.0 520.0 540.0 560.0 L3 - L2 (mm) 164.0 200.0 240.0 280.0 338.0 184.5 210.0 260.0 309.0 360.0 205.0 275.0 300.0 350.0 400.0 225.5 238.0 290.0 340.0 390.0 246.0 260.0 280.0 300.0 320.0 B () 66.8 56.4 48.3 42.4 36.0 55.1 49.6 41.6 36.0 31.6 45.7 36.0 33.6 29.5 26.4 37.5 36.0 30.8 27.0 24.1 30.2 28.9 27.3 25.8 24.6 m () 97.0 90.2 85.1 81.4 77.5 85.4 81.8 76.7 73.2 70.5 74.9 68.7 67.1 64.6 62.7 64.8 63.8 60.4 58.0 56.3 54.5 53.7 52.6 51.7 50.9 L1 (mm) 162.8 200.0 239.1 276.8 330.0 183.9 207.8 253.0 295.8 339.4 197.9 256.2 276.4 316.2 355.5 204.0 213.5 252.1 288.4 324.3 200.3 209.5 222.5 235.4 248.2 n () 30.2 33.7 36.7 39.0 41.5 30.3 32.2 35.1 37.2 38.9 29.3 32.6 33.6 35.1 36.3 27.3 27.8 29.6 31.0 32.1 24.3 24.8 25.3 25.8 26.3 Test of Limitation (mm) 219.9 200.7 179.3 158.0 127.1 175.3 160.0 130.0 100.6 70.0 126.7 80.0 63.3 30.0 -3.3 74.0 64.8 26.7 -10.0 -46.7 17.2 6.0 -10.0 -26.0 -42.0

120

110

100

90

80

TABLE 3

Below are the equations related to the table. A) OBTAINING B ANGLE To obtain B angle, we had to use the cosine rule, where S is is the angle C. Cosine Rule This equation was rearranged to become, B) OBTAINING n and m To obtain n, we use the sin rule which states This equation was rearranged to become, As for m, m = B + n C) OBTAINING L1 To obtain L1, we simple use this equation: D) OBTAINING TEST OF LIMITATION VALUE First off, test of limitation would let us know whether the combination of L2 and L3 are within the workplace length limit. If it is negative then that means weve surpassed the limit. ( ) , L3 L2 is , L3 + L2 is and B

TEST OF LIMITATION =

) , >= 0

By observing the first table 2, as we increase the crank radius, L2, the value of L1 becomes smaller and the desired B angle is achievable at smaller coupler lengths, L3 but becomes impossible after a certain value for L2. Once L2 reaches 120mm, B angle becomes unachievable at the limit of L3 > 3 x L2. However, at 110mm, B angle becomes increasing close at values of L3 close to the value of 3 x L2. We decided to increase the radius by 1mm from there on.

Radius (mm)

L3 (mm) 335.5 348 360 380 400 339 345 360 375 390 342 360 380 400 420 345 360 375 390 415

L2 + L3 (mm) 445.5 458.0 470.0 490.0 510.0 450.0 456.0 471.0 486.0 501.0 454.0 472.0 492.0 512.0 532.0 458.0 473.0 488.0 503.0 528.0

L3 - L2 (mm) 225.5 238.0 250.0 270.0 290.0 228.0 234.0 249.0 264.0 279.0 230.0 248.0 268.0 288.0 308.0 232.0 247.0 262.0 277.0 302.0

B () 37.5 36.0 34.6 32.6 30.8 36.7 36.0 34.3 32.7 31.3 36.0 33.9 31.9 30.1 28.5 35.2 33.5 32.0 30.6 28.6

m () 64.8 63.8 62.9 61.5 60.4 63.7 63.3 62.1 61.1 60.2 62.7 61.4 60.1 58.9 57.9 61.7 60.6 59.6 58.7 57.4

L1 (mm) 204.0 213.5 222.5 237.4 252.1 204.5 209.0 220.1 231.2 242.1 204.4 217.7 232.2 246.7 261.0 204.3 215.2 226.0 236.7 254.5

n () 27.3 27.8 28.3 29.0 29.6 27.0 27.3 27.9 28.4 28.9 26.8 27.5 28.2 28.8 29.4 26.5 27.1 27.6 28.1 28.8

Test of Limitation 74.0 64.8 56.0 41.3 26.7 68.1 63.7 52.6 41.5 30.4 62.6 49.2 34.3 19.3 4.4 57.1 45.8 34.5 23.2 4.4

113

112

111

110

TABLE 4
As you can see from the table above, when the radius becomes 112mm with an L3 of 342 (which is exactly 112 * 3.05), the B angle is exactly 36.0. Hence, the most suitable crank radius, L2, for our design and its coupler length, L3, are 112mm and 342mm respectively. These set of values comply with all requirements and limitations that have been previously stated.

3.0
3.1

METHODOLOGY
THE CRANK RADIUS AND LENGTH OF THE COUPLER

By trial and error, we have obtained the value of the crank radius, L2 to be 112mm. The length of the coupler is obtained by multiplying the radius by the given requirement of L3 > 3L2. For this we have taken the minimum value possible by multiplying L2 with 3.05. This gives us the length of the coupler, L3 = 453.6.

3.2

THE CYCLE TIME, TIME FOR WORKING AND RETURN STROKE, TIME RATIO & IMBALANCE ANGLE

The cycle time was calculated by testing a set of angular speed and choosing the value with shortest time but with the return stroke between 60% to 95% of the time for the working stroke.
From the table, we obtained an angular speed of 360 and the cycle time is calculated:

The time taken for the working stroke is then calculated by the following equation :

Using the two values obtained above, we can obtain the return stroke :

We can then calculate the time ratio using the working stroke and return stroke :

In order to obtain the imbalance angle, we first calculate the value of Q using the equation:

By using the value of Q obtained, we then calculate the value of the imbalance angle:

3.3

THE CRANKSHAFT SPEED IN RPM

From the trial and error, we obtained the crankshaft speed of 360rpm.

3.4

THE WORKING AREA REQUIRED BY THE MECHANISM (L X W)

The maximum length given to our group was 580mm. From the data, we have obtained maximum value of the length, L for the given angle to be 453.6mm. This value obtained is in the range given. For a safer working area, we can round of this value to 455mm The height, W is obtained by adding L1 and L2,

We also round of this value to 317mm and the working are is :

3.5

THE MAXIMUM FORCE EXERTED BY THE SLIDER ALONG ITS AXIS OF MOTION