Geneva Mechanism and Powersaw Machine

Prontnicki, Peter Roque, Mario VanRoden, Jack Zicker, Albert March 21, 2014

I pledge my honor that I have abided by the Stevens Honor System.

CONTENTS

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Contents

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1.1

Geneva Mechanism
Introduction

The Geneva Mechanism is a simple example of an intermittent motion device. Intermittent motion is a delayed motion of the output link while there is a continuos motion of the input link. When dealing with the Geneva Mechanism our Geneva Wheel is considered the output link which remains stationary until a pin connected to the crank (input link) enters the slot of the geneva wheel causing the wheel to rotate counterclockwise. This movement ends when the pin leaves the slot which then means that the wheel is again stationary while the crank continues to rotate. The crank also has an angular segment exactly the same size as the space between slots on the geneva wheel that keeps everything in place. This movement repeats dependent on the angular velocity of the crank itself. Although our interpretation of the Geneva Mechanism has four slots, a minimum of three slots in necessary for it to be considered a Geneva Mechanism. Some points that are important when creating a Geneva Mechanism is the detail that is necessary for it to work properly. The interaction between the wheel and the crank has to be as smooth as possible. Although small knowing that one must make sure that when the pin goes through the slot of the wheel, it is tangent from the center of the wheel. The need for close to perfection is important because of the interaction between the wheel and the crank.

1.2

Setup and Analysis

When given the situation where there is constant clockwise angular velocity of the crank at 2 rad/s or Wheel A and we have to determine the counterclockwise angular velocity of the geneva wheel when = 20 . tan = O1 P sin O1 O2 O1 P cos (1)

Since we know the lengths of O1 and O2 and the angle of we were able to solve for which is just the angle relative to the geneva wheel. 1/ 2 sin tan = = 35.8 (2) 1 1/ 2 cos By solving for we are setting ourselves up to solve for the angular velocity. Taking the derivative of the rst equation will give us our relationship between angular velocity and the lengths and angles of the mechanism itself. ) (1/ 2 sin )(1/ 2 sin ) (1 1 / 2 cos )(1 / 2 sec = 1 1/ 2 cos
2

(3)

will give us our angular velocity for the wheel. We just have to plug in = 20 and Solving for = 2 rad/s. = 1.923rad/s 2 = (4)

The angular velocity is negative because it is counterclockwise and we also decided that this result also makes sense. Since our angles was not zero we were going to get something close to but not two. This idea matches our results; the deection of 20 gives us 1.923 rad/s. From this conclusion 3 Geneva Mechanism and Powersaw Machine

1.3

SolidWorks Analysis

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we can also make certain assumptions that in theory would be proved by our SolidWorks analysis. Since there is a linear relationship between the angular velocity of the crank to the angular velocity of the wheel, then we can assume that as the velocity of the crank increases so will the velocity of the wheel. Also if we increase the angular velocity of the crank there will be in the frequency.

1.3

SolidWorks Analysis

The analysis of our SolidWorks design further enforces our data and assumptions.

Figure 1: geneva mechanism Our velocity graphs:

Figure 2: Velocity v. Time at 20 rpm(2.1 rad/s)

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SolidWorks Analysis

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Figure 3: Velocity v. Time at 40 rpm(4.2 rad/s)

Figure 4: Velocity v. Time at 100 rpm(10.5 rad/s) The graphs show an increase in the amplitude which correlates to the velocity. There is also an increase in frequency because angular velocity and frequency are directly related by the equation, = 2f , which is why at 100 rpm there are is an enormous increase in peaks and troughs.

In addition to velocity we analyzed the acceleration of the geneva mechanism.

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SolidWorks Analysis

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Figure 5: Acceleration v. Time at 20 rpm(2.1 rad/s)

Figure 6: Acceleration v. Time at 40 rpm(4.2 rad/s)

Figure 7: Acceleration v. Time at 100 rpm(10.5 rad/s) When looking at the graphs there was confusion because if velocity is constant, then initially you would assume that the acceleration would be zero because the acceleration is just the time derivative of velocity. When the crank makes contact with the slot there is a torque or contact force from the crank that is proportional to a centripetal force on the geneva wheel. Which is also why we believe that the crank has to have a certain weight to assure that it can create a force strong enough to move the wheel. So that is why if we look at the graphs of acceleration there is only acceleration when the crank and wheel make contact. 6 Geneva Mechanism and Powersaw Machine

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Conclusion for the Geneva Mechanism

The Geneva Mechanism was a clear example of intermittent motion and our results and relationships between angular frequency, angular velocity, and angular acceleration agree with basic laws of physics, reassuring that we made no grave error. Again the more exact the design, the clearer the results. As far as recommendations for analyzing a Geneva Mechanism further, one could add more pins on the crank and more slots on the wheel. Physically one could assume that this will change the frequency, but this would also change the design of the mechanism because the crank would have to be completely redesigned thus causing other issues. As seen before the crank needs to force the wheel to move. By changing these factors there are many possibilities to creating variations of a Geneva Mechanism.

3
3.1

Powersaw Mechanism
Introduction

The power saw mechanism is supplied all of its power through the input link (link 2). The velocity of the saw blade is strongly connected to angular velocity of the input link. = a2 sin 3 2 d cos 3 (5)

is the Above is the mathematical equation that models the velocity of the slider. In this equation d velocity of the slider, a is the length of the input crank, is the angular velocity of the input crank, and 3,4 are the relative angles the other links form. As you can see from the equation above, a direct increase in either the size or speed of the input crank will increase the velocity of the slide. This relationship can also be modeled graphically as seen below.

Figure 8: Input Angular Velocity = 1 rad/s

Figure 9: Input Angular Velocity = 100 rad/s

The rst gure shows the saw with an input angular velocity of 1 rad/s, while the second gure models the same saw at 100 rad/s. Both of them appear to have similar velocity proles, but a closer look will reveal that the second gure, at a higher angular acceleration yielded a result that was nearly 100x greater than that of the rst gure. The two mechanisms had the exact same dimensions. Because they were that same size at every independent input angle both of the mechanisms would have the same 3 and 4 . The only variable in the equation above was the angular velocity, and because of where it lies in the equation, an increase in the angular velocity of the input link would lead to an increase in the slider velocity.

Geneva Mechanism and Powersaw Machine

3.2

Setup and Analysis

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3.2

Setup and Analysis

Figure 10: Band Saw Threshold Above is an example of band saw cutting speed thresholds for various materials. All of these materials are fairly common in many industries, and it would be reasonable to assume that a power saw, like the one that was modeled, would be used to cut materials similar to these. For safety, and to preserve the life on the cutting blade, and other parts of tool, there are usually maximum speeds to which dierent material can be cut. Using the equation mentioned above that related the slider velocity to the input angle velocity we are able to approximate a safe and ecient angular velocity for the input crank to cut each one of these materials. At every dierent maximum slider velocity the 3 ,4 and length of th crank were always the same values. Knowing the maximum cutting speed, of the maximum speed of the blade/slider, the only unknown was the input crank angular velocity which could easily solved for using the slider-crank equation.

Material Aluminum Bakelite Brass Soft Brass Hard Brass Sheets Bronze Cast Iron Monel Metal Rubber Hard Steel Alloy Steel High Carbon Steel Sheet Steel Stainless Steel Tool

Average Cutspeed (fpm) 1100 550 237.5 112.5 550 112.5 75 75 200 75 75 70 62.5 100

Average Cutspeed(mm/s) 5588 2794 1206.5 571.5 2794 571.5 381 381 1016 381 381 355.6 317.5 508

Max Crank Velocity (rad/s) 57.755 28.878 12.47 5.907 28.878 5.907 3.938 3.938 10.501 3.938 3.938 3.675 3.282 5.25

3.3

SolidWorks Analysis

Below are our gures for the bandsaw in dierent positions.

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Figure 11: Band Saw Figure

Figure 12: Band Saw Figure 2

Figure 13: Band Saw Displacement

Figure 14: Band Saw Velocity

Figure 15: Band Saw Acceleration As expected the displacement and the velocity are both sinusoidal which agrees with our initial equation analysis.

Comparison

Below are all our gures for the analytical model and analysis of the PowerSaw. The analytical model and the SolidWorks simulation output were both illustrated the linear velocity correctly. The maximum and minimum points are the same for both systems however they were just the inverse of each other ( the maximum of the SolidWorks output was the minimum of the Linkages output and vice versa). This is arbitrary because it is only caused by the rotational direction of the power saw when simulated. Additionally, the SolidWorks output illustrates the power saw over a ve second time period (roughly three full rotations), while the Linkages software just illustrates one full, 360 rotation. However, the graphs are identical when only looking at one full rotation in the SolidWorks graph. The main point was to illustrate that the rotation causes the same minimum and maximum vales, and produces the same path when graphed. The same reversed minimum and maximum event occurred for the acceleration graph as well, but again is only due to the motor rotating in the opposite direction. They are still identical, just inversely. The graphs follow the same path as one another for the most part, so the behavior of the acceleration is clearly correct for the model. The displacement graphs were slightly dierent in displacement value; however this is to be expected because the spots chosen for the graph in SolidWorks was dierent from that of the one chosen

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in the Linkages program. The graphs do show and identical path though, which proves that the models were accurate because the pieces portrayed graphically were moving in the same motion.

Figure 16: Simple Analysis Image

Figure 17: Displacement Analysis

Figure 18: Velocity Analysis

Figure 19: Acceleration Analysis

Conclusion for the PowerSaw

The PowerSaw mechanism we created was a correct representation as proven not only by our SolidWorks motion analysis and also through basic mathematics. We were able to prove the correct displacement, velocity and acceleration through the motion analysis and by knowing that the derivative of the displacement is velocity and derivative of velocity is acceleration.

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Geneva Mechanism and Powersaw Machine