FABRICATION OF SELF LUBRICATION SYSTEM FOR COMPLICATED MACHINES

A PROJECT REPORT

Submitted by

J. GAUTHAM KUMAR K. KARTHIK RAJ M. KARTHIK

in partial fulfillment of the award of the degree of

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

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BACHELOR OF TECHNOLOGY

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ABSTRACT
This system or method for precisely controlling lubricant supply to one or more rotating mechanical gear parts in machines. The pump draws lubricant form a lubricant source and supplies it to a rotating machine. This system is automated by means of a timer device. The sequential time is controlled by using microcontroller, which is fed by a programming language. The time interval can be varied by a controller. Self lubricating system is used to reduce the noise produced inside the machine and to achieve the efficient work.

This system reduces manual errors and prevent from major accidents while lubricating on the complicated machines. It typically delivers a controlled amount

at specific times from a central location. Self lubrication systems offer superior features than

failure, reduced man-hours required for the lubrication task, and increased worker safety, as well as reduced lubricant and cleanup costs.

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manual lubrication. The benefits of self lubrication include less downtime due to bearing

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of lubricant (oil) to multiple, specific locations on a machine while the machine is operating,

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TABLE OF CONTENTS
CHAPTER NO. ABSTRACT LIST OF FIGURES LIST OF TABLES LIST OF ABBREVIATIONS 1 2 3 4 INTRODUCTION LITERATURE REVIEW PROBLEM DESCRIPTION FABRICATION OF EXPERIMENTAL SETUP 4.1 LAYOUT DESCRIPTION 4.2 AC MOTOR 4.2.1 AC Motors Principle and Working 4.2.2 AC Motor Feedback 4.2.3 Basic Types of an AC Motor 4.2.3.1 Induction AC Motor 4.2.3.2 Synchronous AC Motor 4.2.3.3 Industrial AC Motor 4.2.4 Applications 4.2.5 Advantages of an AC Motor 4.2.6 Disadvantages of an AC Motor 4.2.7 Grinder Motor 4.3 DYNAMO 4.3.1 Working 4.3.2 Armatures 4.3.3 Bicycle Dynamo Specification 4.4 TITLE PAGE NO.
ii v vi vii

1 2 6 7 8 9 9 9 10 10 10 11 11 11 11 12 13 13 15 15 16 18 18 18 19 19 19

4.5

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12V DC PUMP 4.4.1 Features 4.4.2 Applications 4.4.3 Limitations RECHARGABLE BATTERY 4.5.1 Specification 4.5.2 Applications

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iv 4.6 4.7 SUMP LUBRICATING OIL 4.7.1 Motor Oil 4.7.2 Uses 4.7.3 Non-Vehicle Motor Oils 4.7.3 Properties 4.7.4 Grades TIMER CIRCUIT 4.8.1 Microcontroller
4.8.2 4.8.1.1 Applications Capacitor

4.8

20 20 20 21 23 23 24 25 26
26 27

5.1 5.2 5.3

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MICROCONTROLLER 8051 ARCHITECTURE PROGRAM FED IN MICROCONTROLLER

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4.8.2.1 Working Principle of Capacitor 4.8.2.2 Applications 4.8.3 Resistor 4.8.3.1 Working of Resistor 4.8.3.2 Applications 4.8.4 Diode 4.8.4.1 Working of Diode 4.8.4.2 Applications 4.8.5 Relay ROLE OF MICROCONTROLLER IN TIMER CIRCUIT

27 27 28 28 28 29 29 29 30 31
31 32 33

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DISCUSSION CONCLUSION REFERENCE

38 39 40

LIST OF FIGURES

FIGURE No.

TITLE

PAGE No.

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5.1 6.1

Layout Rotor Magnets interaction with Stator AC Motor Armature Dynamo 12V DC Pump Rechargeable battery Motor oil

8 9 12 14 15 16 19 20

8051 Microcontroller Relay

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Timer Circuit

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26 30 32 38

8051 Microcontroller Architecture

Comparison between Manual vs Automated Lubrication

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LIST OF TABLES

TABLE No. 4.1

TITLE 12V DC Pump specification

PAGE No. 17

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LIST OF ABBREVIATIONS
AC DC HP RPM ISO SAE LCD I/O RAM ROM Alternating Current Direct Current Horse Power Revolutions Per Minute International Standards Organization Society of Automotive Engineers Liquid Crystal Display Input and Output Random Access Memory Read Only Memory

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CHAPTER 1 INTRODUCTION
Machines produce more heat and noise due to the motion of rotating and reciprocating parts. Lubrication will minimize the noise produced by the machine components. Lubrication systems and equipment are essential components of manufacturing and industrial machinery and technology. To ensure reliable and efficient operation of such equipment, these moving parts often need a constant supply of lubricating fluids, and the lubrication system is able to provide this at the proper temperature, viscosity, flow rate and pressure. Lubrication allows smooth continuous operation of equipment, with only mild wear, and without excessive stresses or seizures at bearings. When lubrication breaks down, metal or other components can rub destructively over each other, causing destructive

reservoir, pump and filter. The reservoir is the area in which the lubricant is stored after

system and into areas that need to be lubricated.

OBJECTIVES

To fabricate the self lubricating setup with timer circuit To lubricate the complicated machine components

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coming back from the area it lubricates. The pump is used to move the lubricant through the

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damage, heat, and failure. The most important components of a lubricating system are the

CHAPTER 2 LITERATURE REVIEW

Nathan E. McIntire and Zelma M. Porter proposed on automatic lubrication system. An automatic lubrication system for conveyors and the like, said system comprising means for initiating a lubrication cycle whereby a lubricant agitator and pump are sequentially actuated to deliver lubricant to a dispensing passageway, a timer and relay arrangement effective to open a lubrication solenoid valve to permit a quantity of lubricant to flow into the dispensing passageway and subsequently open a gas solenoid valve to blow gas through the passageway and expel substantially all of the lubricant there from onto the member being lubricated, in such a manner that dripping of the excess lubricant or clogging of the passageway is eliminated. Richard W.dochterman and Fort Wayne were invented the lubrication system for electric machine. A lubrication system which serves both to lubricate bearings and to occlude the primary airflow path through a machine. The system includes a capillary seal (spaced apart plates with or without wick material there between) serving both as a capillary air seal

pressure differential across an electric motor. This invention relates generally to lubrication systems for bearing supported shaft members , and more particularly to improved air sealing lubrication systems for supplying lubricant to the bearing journaling surfaces in electric machines while also preventing air flow there through . In current refrigeration systems having at least one refrigerated compartment and a compartment open to the ambient area and housing such systems components as a condenser and compressor, a motor driven fan is usually mounted in each compartment for purposes of circulating air. In such systems, it has been the practice to mount a separate motor and fan within each compartment. In order to reduce cost and yet retain the air circulation benefits, it is quit desirable to use only one motor to drive a number of fans since this obviously will cost less than a separate motor for each fan. It is also desirable in order to accomplish this end that this one motor be

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and as portion of lubricant transfer path. This system is especially effective to support a

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mounted exteriorly of the refrigerated compartment so that motor heat will not be introduced in to the refrigerated compartment during operation of the motor. However, this approach introduces certain difficulties since there is a pressure differential between the interior of a refrigerated compartment and the ambient area about the compartment. Thus, when a refrigerated compartment is cooled, the pressure and the temperature in the compartment are lowered, and a pressure differential is created between the compartment and the surrounding area such an s the room or the condenser compartment. It is well known that in commercial refrigerator units for example, pressure differentials ranging between three and six inches of water occur during at least the first portion of the each cooling cycle. Normal leakage through the door seal, electrical conduit openings etc, equalizes the pressure within and without the refrigerated compartment after some period of time. It would be desirable to place externally mounted fan motor in sealed engagement

through the opening into the compartment for mounting the fan with the shaft also being accessible in order to drive a second fan in another compartment. However, if there is an air

motor into the refrigerated compartment due to the initial pressure differential across the motor. this air flowing through the motor into the compartment deposits its moisture on to the first cold object it conducts, which is the motor shaft, fan blades, fan enclosure is will results in ice forming on the shaft and blades and the motor may then over load and eventually burn out, damage to the motors used in this application is especially undesirable as this motors are normally mounted in relatively inaccessible locations and thus are difficult to repair and replace. I have found that the usual fan motor is unacceptable for the discussed application as it will not support a pressure differential without at least some air leakage. The primary path of air flowing through the usual totally enclosed fan motor when it is mounted across a pressure differential occurs in the bearing lubrication system.

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flow path through the motor, relatively warm, moist ambient air will be drawn through the

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within an opening in the wall of a refrigerated compartment with the motor shaft extending

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Accordingly it would be highly desirable to provide a fan motor which may be mounted externally of a refrigerated compartment in communication both with the interior of the compartment and with the surrounding locations such as the room in which the refrigeration apparatus is present or the compressor compartment. In this regard, it would be advantageous to provide an inexpensive fan motor having a highly dependable air sealing lubrication system which prevents air flow through the motor and especially through the primary air flow path of the motor. It is therefore, a general object of this invention to provide an electric machine having a lubrication system which alleviates the problems and incorporates the desired result mentioned above. It is a more specific object of the present invention to provide an improved lubrication system for an electric machine having a bearing supported rotatable shaft which incorporates an air flow sealing arrangement for occluding the primary air flow path through

lubrication arrangement for an electric machine which is inexpensive to produce and highly dependable in operation, and which nonetheless provides adequately controlled lubricant

Hermann Werner, Erich Lessol and Burkard Mueller were invented the bicycle dynamo having a rotary-current generator. Bicycle dynamo having a rotary-current generator having stator and a rotator which can be rotated relative to the stator. The stator or the rotor has radially extending pole fingers which are wound individually with one surrounding magnetic coil winding respectively. The ratio of the number of poles of the rotor to the number of poles of the stator is a non-integer value, this permits the implementation of a bicycle dynamo of a high efficiency event at a relatively low riding speed, which may be used, for an example, to power bicycle lighting systems. Cheng-Hsien Wu and Yu-Tai Kung proposed journal of a parametric study on oil/air lubrication of a high-speed spindle. The ball-bearing is widely used on many high-speed spindles due to its low starting friction and high load capacity. However, heat generation and dynamic loading caused by high-speed rotation have been obstacles for increasing the speed

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feed to the motor bearing shaft area.

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A further object of the present invention is the provision of a capillary sealed

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the machine.

limit in many high-speed ball-bearing applications. Applying an appropriate lubrication and preload cannot be overemphasized. Recently, oil/air lubrication has been used on high-speed spindles because of its accuracy in oil quantity control and high cooling efficiency. However, an oil/air supply with inadequate parameters is undesirable. In this study, the performance of a high-speed spindle under different lubrication parameters and preloads was investigated. The Taguchi method was applied to study the effects of design parameters on the lubrication efficiency. This method can also be used to obtain the optimum lubrication conditions. The optimum operating conditions that create the smallest temperature increase were established. The effects of preload on the temperature increase, the thermal deformation and the static stiffness of an oil/air lubricated spindle were studied. The results provide a useful tool in designing a high-speed spindle with a small increase in temperature and sufficient static stiffness.

programmable timer circuit includes a counter that contains a plurality of sequentially

counter stage to accept the output signal from the preceding stage and to the input signal from the preceding stage and to issue an input signal to the succeeding counter stage. The

determined by the state of a fuse associated with the program stage. The logic state of the program signal is determined by the state of a fuse associated with the program stage. Selected fuses can be blown by a programming routine to adjust the time delay between the initiation signal and issuance of the output signal. This sets the counter stages at power-up to a predetermined logic state in which the output signal will be produced with a predetermined time delay when the initiation signal is applied to the integrated circuit. The program routine includes activating the counter stages that will be active at the desired count and issuing a programming signal to burn the fuse associated with the active counter stage.

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logic state of the input signal is determined by the logic state of the program signal is

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arranged counter stages. A toggle logic gate is disposed between each sequential pair of

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James C. Gwynn proposed paper on programmable electronic timer circuit. A

CHAPTER 3 PROBLEM DESCRIPTION

In some major industries, machine runs continuously for their production. Due to continuously running process of machines leads to more tear and wear. For this problem, some industries employed labours to lubricate the machine. Manual lubrication typically produces inconsistent lubrication. The uneven lubrication cycle leads to wasted lubricant and allows contaminants to enter the bearing producing premature wear. Even though labours are equipped with safety features, during manual lubrication many accidents are happened in industries. Many machines are dangerous to lubricate while running. Under lubrication will cause bearing damage and premature failure. This project describes a fabrication of self lubrication system which automated by timer that works by dynamo. Dynamo gets power by rotational motional for ac motor which is coupled with belt.

Benefits of an Automatic Lubrication System

Lubrication occurs while the machinery is in operation causing the lubricant to be equally distributed within the bearing and increasing the machines availability Less wear on the components means extended component life, fewer breakdowns, reduced downtime, reduced replacement costs and reduced maintenance costs Safety - no climbing around machinery or inaccessible areas

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All critical components are lubricated, regardless of location or ease of access

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CHAPTER 4 FABRICATION OF EXPERIMENTAL SETUP

The experimental apparatus of our project consists of major parts like ac motor, dynamo, pump, sump, timer circuit and rechargeable battery. First of all the materials were brought to fabricate the ac motor and dynamo, and then the major parts of the system that is pump, timer circuit and rechargeable battery. The whole experimental setup made into rectangular steel frame with supported bars. AC motor is mounted on the steel frame and in other end dynamo is mounted. The top surface of the steel frame is covered by sheet metal where other components like timer circuit and pump are placed on it. Sump contains lubricating oil, which placed in bottom of steel frame. For our convenience, we have used AC motor of 1440 rpm converted to dynamo by

programmed microcontroller, which performs further operations based upon the preset value. Thus relay gets activated by the signal instructed from the timer. Based the relay function,

from sump to supply on gear parts which needs to be lubricate.

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pump gets power supply from rechargeable battery. Whereas pump draws lubricating oil

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means of belt. Dynamo produces 5V ac voltage which is used for timer circuit. With

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4.1 LAYOUT DESCRIPTION Dynamo produces electric energy by rotation motion of AC motor. Power produced by dynamo used to run the timer circuit. Relay switch is activated by timer circuit which incorporates microcontroller. Relay switch is placed between the rechargeable battery and pump. Lubricating oil can be pumped from sump and distributed to varies complicated components of machines.

To lubricating parts

DYNAMO

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MAIN MOTOR

TIMER CIRCUIT

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RECHARGABLE BATTERY

RELAY

PUMP

SUMP
(Lubricating Oil)

Figure 4.1 Layout

4.2 AC MOTOR 4.2.1 AC Motors Principle and Working The standard definition for an AC Motor is an electric motor that is driven by alternating current. The AC Motor is used in the conversion of electrical energy into mechanical energy. This mechanical energy is made from utilizing the force that is exerted by the rotating magnetic fields produced by the alternating current that flows through its coils. The AC Motor is made up of two major components: the stationary stator that is on the outside and has coils supplied with AC current, and the inside rotor that is attached to the output shaft. The fundamental operation of an AC Motor relies on the principles of magnetism. The simple AC Motor contains a coil of wire and two fixed magnets surrounding a shaft.

generating a magnetic field. Simply described, when the magnets interact, the shaft and the coil of wires begin to rotate, operating the motor.

4.2.2 AC Motor Feedback AC Motor products have two options for feedback controls. These options are either an AC Motor resolver or an AC Motor encoder. Both the AC Motor resolver and the AC Motor encoder can sense direction, speed, and the position of the output shaft. While both the AC Motor resolver and AC Motor encoder offer the same solution in multiple applications, they are greatly different.

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Figure 4.2 Rotor Magnets interaction with Stator

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When an electric (AC) charge is applied to the coil of wire, it becomes an electromagnet,

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AC Motor resolvers use a second set of stator coils called the transformer to provoke rotor voltages across an air gap. Since the resolver lacks electronic components, it is very rugged and operates over a large temperature range. The AC Motor resolver is also naturally shock resistant, due to how it is designed. The resolver is often used in harsh environments. The type of application will establish whether a resolver or an encoder is desired. AC Motor encoders are easier to implement and more precise, so they should be the primary preference for any application. A resolver should only be chosen if the environment in which it will be used requires it. 4.2.3 Basic types of an AC Motor The AC Motor comes in three different types known as Induction, Synchronous, and Industrial. These AC Motor types are determined by the rotor design used in the construction. Anaheim Automation carries all three types in its product line.

Induction AC Motor is referred to as asynchronous motors or rotating transformers. This type of AC Motor uses electromagnetic induction to power the rotating device which is usually the shaft. The rotor in Induction AC Motor products typically turns slower than the frequency that is supplied to it. Induced current is what causes the magnetic field that envelops the rotor of these motors. This Induction AC Motor is designed in one or three phases. 4.2.3.2 Synchronous AC Motor

The Synchronous Motor is typically an AC Motor that has its rotor spinning at the same rate as the alternating current that is being supplied to it. The rotor can also turn at a sub multiple of the current it is supplied. Slip rings or a permanent magnet supplied with current is what generates the magnetic field around the rotor.

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4.2.3.1 Induction AC Motor

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4.2.3.3 Industrial AC Motor Industrial AC Motors are designed for applications requiring a three-phase, highpower induction motor. The power ratings of an industrial motor exceed those of a standard single-phase AC induction motor. Anaheim Automation offers Industrial AC Motors from 220W to 2200W, in 3-Phase operation at 220VAC or 380VAC. 4.2.4 Applications AC Motors are primarily used in domestic applications due to their relatively low manufacturing costs, and durability, but are also widely used in industrial applications. They can also be found in industrial applications: Pumps

Conveyors Compressors

4.2.5 Advantages of an AC Motor Low Cost

Long Lifespan

High-Efficiency and Reliability Simple Construction High Starting Torque (Induction) No Slip (Synchronous)

4.2.6 Disadvantages of an AC Motor Frequency Causes Rotation Slips (Induction) Starting Switch Needed (Induction)

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4.2.7 Grinder Motor

Figure 4.3 AC Motor Capacity: 0.5 HP Speed: 1440 RPM Phase: Single Phase

Features

Stampings: Stator consists of thin lamination of high quality low core loss silicon steel Copper Wire: Super enamel insulated high conductivity copper wire of an ISO 9002 company Rotor: Dynamically balanced pressure die cast rotor for complete vibration free operation Shaft: High graded mild steel machined and centrelex grinding to close tolerance. Insulation: Class B insulation specially treated to withstand a maximum temperature of 120C. Bearings: Sealed ball bearings are used at both ends to ensure smooth running.

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4.3 DYNAMO A dynamo is an electrical generator that produces direct current with use of commutator. It converts mechanical power to electrical power. It converts the mechanical motion of the driven wheel into electrical energy, with the aid of a magnet. A dynamo is an electrical generator that produces direct current with the use of a commutator. Dynamos were the first electrical generators capable of delivering power for industry, and the foundation upon which many other later electric-power conversion devices were based, including the electric motor, the alternating-current alternator, and the rotary converter. Today, the simpler alternator dominates large scale power generation, for efficiency, reliability and cost reasons. A dynamo has the disadvantages of a mechanical commutator. Also, converting alternating to direct current using power rectification devices (vacuum tube or more recently solid state) is effective and usually economic. In electricity generation, an electric generator is a device that converts mechanical

to flow through an external electrical circuit. The source of mechanical energy may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an

of mechanical energy.

The reverse conversion of electrical energy into mechanical energy is done by an electric motor, and motors and generators have many similarities. Many motors can be mechanically driven to generate electricity and frequently make acceptable generators. 4.3.1 Working It converts the mechanical motion of the driven wheel into electrical motion, with the aid of a magnet. Many scientists say that the full circle of energy that keeps the world spinning, grows crops, and paints the sky with the Aurora Borealis, begins and ends with magnetism that the suns rays are magnetic rays. Magnetism is the force that keeps the compass needle pointing north and south. Take a steel rod and hold it along the north and south line, slightly inclined towards the earth, and strike it a sharp blow with a hammer, and it becomes a magnet feeble, it is true, but still a magnet.

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internal combustion engine, a wind turbine, a hand crank, compressed air, or any other source

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energy to electrical energy. A generator forces electric charge (usually carried by electrons)

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4.3.2 Armatures This experiment gives the theory of the dynamo. Instead of passing only one wire through the field of force of a magnet, we have hundreds bound lengthwise on a revolving drum called an armature. Instead of one magnetic pole in a dynamo we have two, or four, or twenty according to the work the machine is designed for always in pairs, a North pole next to a South pole, so that the lines of force may flow out of one and into another, instead of escaping in the surrounding air.

If we could see these lines of force, they would appear in countless numbers issuing from each pole face of the field magnets, pressing against the revolving drum like hair brush bristles trying to hold it back. This drum, in practice, is built up of discs of annealed steel, and the wires extending lengthwise on its face are held in place by slots to prevent them from flying off when the drum is whirled at high speed. The drum does not touch the face of the magnets, but revolves in an air space. If we give the electric impulses generated in these wires a chance to flow in a circuit flow out of one end of the wires, and in at the other, the drum will require more and more power to turn it, in proportion to the amount of electricity we permit to flow. Thus, if one electric light is turned on, the drum will press back with certain strength on the water wheel; if one hundred lights are turned on it will press back one hundred times as much. Providing

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Figure 4.4 Armature winding in Dynamo

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there is enough power in the water wheel to continue turning the drum at its predetermined speed, the dynamo will keep on giving more and more electricity if asked to, until it finally destroys itself by fire. We cannot take more power, in terms of electricity, out of a dynamo that we put into it, in terms of mechanical motion. In fact, to insure flexibility and constant speed at all loads, it is customary to provide twice as much water wheel, or engine, power as the electrical rating of the dynamo. 4.3.3 Bicycle Dynamo Specification The max diameter of the dynamo body is: 40.5mm, the longest length of the main body is: 94.5mm. Maximum Output: 12V

Components of Dynamo 1. Friction roller 2. The dynamo body 3. Magnetic steel 4. Winding support 5. Spring housing 6. Coil 7. Wrench 8. Lug plate 9. Rear Cover

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Figure 4.5 Dynamo

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4.4 12V DC PUMP This is a brushless DC motor-driven centrifugal pumps, use special design closed impeller. Main features: High water head, moderate flow rate, long life (use fine ceramic bearing), continues work, low noise, stable performance.

Figure 4.6 12V DC Pump

can be guaranteed no leak forever, completely avoid the presence of traditional DC motor pumps' liquid leakage. If the mining epoxy resin package, you can Brushless motor circuit design optimization using a large movement of lowtemperature, stable performance, long life. Closed impeller simple structure, with less water loss, pump output high efficiency, can effectively enhance higher water head. Impeller/rotor shaft with ceramic materials, enhance the wear resistance, high accuracy, precision with resistance to shock, to extend the life of the pump. Bearing sleeve with graphite self-lubricating properties, reduce noise at work. Low noise down to 35dB, smaller consumption pump even down to 30 decibels, almost silent operation. Pump chamber seal can withstand 5 bar pressure without leakage. Each pump in the production line has to go through stress tests, which can effectively prevent the leakage of product defects.

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completely and totally waterproof diving use.

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Pump chamber and the motor is absolutely isolated, magnetic drive technology

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Pump uses high-strength engineering plastics, PPS PPE, PA66, etc., can be used for hot water circulation, strong endurable capacity, resistance to weak acid corrosion. Can be recycled with a small impurity of the liquid; do not plug the pump chamber.

For our project, we have used 12V DC pump and specification below: Table 4.1 12V DC Pumps Specification No. Items 1 Sizes and weight 2 Dimension of inlet 3 Dimension of outlet 4 Driving method 5 Pump material 6 Condition of use 7 Fluids Specifications 83x63x48; 250g 5mm

Brushless, Magnetic , 2 phase or 3 phase

8 Max working temp

9 Power consumption 10 Rated voltage 11 Voltage used 12 Max rated current 13 Power supply

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1.2A

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Continuously 2.5W~26.4W 12Vdc 5Vdc ~ 12Vdc

PA66+GF30% (optional)

Water, oil, gasoline, acid and alkali solution etc 60 degree (2 phase)or 100 degree (3 phase)

Solar panel; DC electric source; battery

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4.4.1 Features 1. Durable magnetic rotor and ceramic /stainless steel shaft 2. Long life brushless pump, ideal life for 30000 hours 3. Low noise: 42dB far from 1m distance 4. Low or no maintenance 5. Low power consumption 4.4.2 Applications 1. Circulation system 2. Solar energy panel 3. Aquarium 4. Cooling system 5. Water heater and so on 4.4.3 Limitations

1. Power to DC Power Supply, reverse polarity is strictly prohibited, generally red positive power supply, black to negative.

2. Pumps in addition to immersible work can be identified, the rest cannot be immersed in water, or they will cause a short circuit burned. 3. Pumps is prohibited by the strong shock, fall from a height on the ground and other external damage. 4. Pumps cannot take strong acid and other corrosive liquids and granular solids with a tiny hard. 5. Pumps were not long-time stall, causing the motor burned. 6. Pumps cannot withstand high voltage shock.

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4.5 RECHARGEBLE BATTERY The rechargeable batteries are lead-lead dioxide systems. The dilute sulfuric acid electrolyte is absorbed by separators and plates and thus immobilized. Should the battery be accidentally overcharged producing hydrogen and oxygen, special one-way valves allow the gases to escape thus avoiding excessive pressure build-up. Otherwise, the battery is completely sealed and is, therefore, maintenance-free, leak proof and usable in any position.

Figure 4.7 Rechargeable Battery Voltage: 6V

Capacity: 4ah

Dimensions (mm): 70(L)*45(W)*99(H)*104(TH) Approx Weight (Kgs): 0.7

4.5.2 Application Power: Electric tools, toys, portable suction fans, Robots, electric bicycle Speakers: Insert earphones, cassette decks, portable CD players Video: Cameras, portable TV sets, lap-tops Correspondence: Car telephone, mobile system, portable radio transmitter Survey: Measuring instruments

Medical treatment: Blood-pressure meters, electric wheelchairs

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4.5.1 Specification

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4.6 SUMP The oil is used to lubricate the machine's moving parts and it pools in a reservoir, known as a sump. Use of a sump requires the engine to be mounted slightly higher to make space for it. Often though, oil in the sump can surge during hard cornering starving the oil pump. 4.7 LUBRICATING OIL 4.7.1 Motor Oil Motor oil or engine oil is an oil used for lubrication of various internal combustion engines. The main function is to lubricate moving parts; it also cleans, inhibits corrosion, improves sealing, and cools the engine by carrying heat away from moving parts. Motor oils are derived from petroleum-based and non-petroleum-synthesized chemical compounds.

Motor oils today are mainly blended by using base oils composed of hydrocarbons, polyalphaolefins (PAO), and polyinternal olefins (PIO), thus organic compounds consisting

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Figure 4.8 Motor Oil

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entirely of carbon and hydrogen. The base oils of some high-performance motor oils however contain up to 20% by weight of esters. 4.7.2 Uses Motor oil is a lubricant used in internal combustion engines. These include motor or road vehicles such as cars and motorcycles, heavier vehicles such as buses and commercial vehicles, non-road vehicles such as go-karts, snowmobiles, boats (fixed engine installations and outboards), lawn mowers, large agricultural and construction equipment, locomotives and aircraft and static engines such as electrical generators. In engines, there are parts which move against each other causing friction which wastes otherwise useful power by converting the energy to heat. Contact between moving surfaces also wears away those parts, which could lead to lower efficiency and degradation of the engine. This increases fuel consumption, decreases power output and can lead to engine failure. Lubricating oil creates a separating film between surfaces of adjacent moving parts to minimize direct contact between them, decreasing heat caused by friction and reducing wear, thus protecting the engine. In use, motor oil transfers heat through convection as it flows through the engine by means of air flow over the surface of the oil pan, oil cooler and through the buildup of oil gases evacuated by the Positive Crankcase Ventilation (PCV) system. In petrol (gasoline) engines, the top piston ring can expose the motor oil to temperatures of 160 C (320 F). In diesel engines the top ring can expose the oil to temperatures over 315 C (600 F). Motor oils with higher viscosity indices thin less at these higher temperatures. Coating metal parts with oil also keeps them from being exposed to oxygen, inhibiting oxidation at elevated operating temperatures preventing rust or corrosion. Corrosion inhibitors may also be added to the motor oil. Many motor oils also have detergents and dispersants added to help keep the engine clean and minimize oil sludge build-up. The oil is able to trap soot from combustion in itself, rather than leaving it deposited on the internal surfaces. It is a combination of this, and some singeing that turns used oil black after some running.

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Rubbing of metal engine parts inevitably produces some microscopic metallic particles from the wearing of the surfaces. Such particles could circulate in the oil and grind against moving parts, causing wear. Because particles accumulate in the oil, it is typically circulated through an oil filter to remove harmful particles. An oil pump, a vane or gear pump powered by the engine, pumps the oil throughout the engine, including the oil filter. Oil filters can be a full flow or bypass type. In the crankcase of a vehicle engine, motor oil lubricates rotating or sliding surfaces between the crankshaft journal bearings (main bearings and big-end bearings), and rods connecting the pistons to the crankshaft. The oil collects in an oil pan, or sump, at the bottom of the crankcase. In some small engines such as lawn mower engines, dippers on the bottoms of connecting rods dip into the oil at the bottom and splash it around the crankcase as needed to lubricate parts inside. In modern vehicle engines, the oil pump takes oil from the oil pan

bearings holding the crankshaft up at the main journals and camshaft bearings operating the valves. In typical modern vehicles, oil pressure-fed from the oil galleries to the main bearings enters holes in the main journals of the crankshaft. From these holes in the main journals, the oil moves through passageways inside the crankshaft to exit holes in the rod journals to lubricate the rod bearings and connecting rods. Some simpler designs relied on these rapidly moving parts to splash and lubricate the contacting surfaces between the piston rings and interior surfaces of the cylinders. However, in modern designs, there are also passageways through the rods which carry oil from the rod bearings to the rod-piston connections and lubricate the contacting surfaces between the piston rings and interior surfaces of the cylinders. This oil film also serves as a seal between the piston rings and cylinder walls to separate the combustion chamber in the cylinder head from the crankcase. The oil then drips back down into the oil pan. Motor oil may also serve as a cooling agent. In some constructions oil is sprayed through a nozzle inside the crankcase on the piston to provide cooling of specific parts that underly high temperature strain. On the other hand the thermal capacity of the oil pool has to be filled up, i.e. the oil has to reach its designed temperature range until it can protect the engine under high load. This typically takes longer than heating the main cooling agent - water or mixtures thereof - up to its operating temperature.

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and sends it through the oil filter into oil galleries, from which the oil lubricates the main

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4.7.3 Non-Vehicle Motor Oils An example is lubricating oil for four-stroke or four-cycle internal combustion engines such as those used in portable electricity generators and "walk behind" lawn mowers. Another example is two-stroke oil for lubrication of two-stroke or two-cycle internal combustion engines found in snow blowers, chain saws, model airplanes, gasoline powered gardening equipment like hedge trimmers, leaf blowers and soil cultivators. Often, these motors are not exposed to as wide service temperature ranges as in vehicles, so these oils may be single viscosity oils. In small two-stroke engines, the oil may be pre-mixed with the gasoline or fuel, often in a rich gasoline: oil ratio of 25:1, 40:1 or 50:1, and burned in use along with the gasoline. Larger two-stroke engines used in boats and motorcycles will have a more economical oil injection system rather than oil pre-mixed into the gasoline. The oil injection system is not used on small engines used in applications like snowblowers and trolling motors as the oil

equipment. The oil properties will vary according to the individual needs of these devices. Non-smoking two-stroke oils are composed of esters or polyglycols. Environmental

based two cycle oil. 4.7.4 Properties

Most motor oils are made from a heavier, thicker petroleum hydrocarbon base stock derived from crude oil, with additives to improve certain properties. The bulk of typical motor oil consists of hydrocarbons with between 18 and 34 carbon atoms per molecule.[6] One of the most important properties of motor oil in maintaining a lubricating film between moving parts is its viscosity. The viscosity of a liquid can be thought of as its "thickness" or a measure of its resistance to flow. The viscosity must be high enough to maintain a lubricating film, but low enough that the oil can flow around the engine parts under all conditions. The viscosity index is a measure of how much the oil's viscosity changes as temperature changes. A higher viscosity index indicates the viscosity changes less with temperature than a lower viscosity index.

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legislation for leisure marine applications, especially in Europe, encouraged the use of ester-

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injection system is too expensive for small engines and would take up too much room on the

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Oil is largely composed of hydrocarbons which can burn if ignited. Still another important property of motor oil is its flash point, the lowest temperature at which the oil gives off vapors which can ignite. It is dangerous for the oil in a motor to ignite and burn, so a high flash point is desirable. At a petroleum refinery, fractional distillation separates a motor oil fraction from other crude oil fractions, removing the more volatile components, and therefore increasing the oil's flash point (reducing its tendency to burn). Another manipulated property of motor oil is its Total Base Number (TBN), which is a measurement of the reserve alkalinity of an oil, meaning its ability to neutralize acids. The resulting quantity is determined as mg KOH/ (gram of lubricant). Analogously, Total Acid Number (TAN) is the measure of a lubricant's acidity. Other tests include zinc, phosphorus, or sulfur content, and testing for excessive foaming. The NOACK volatility (ASTM D-5800) Test determines the physical evaporation loss of lubricants in high temperature service. A maximum of 15% evaporation loss is

specifications require lower than 10%. 4.7.5 Grades

The Society of Automotive Engineers (SAE)

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allowable to meet API SL and ILSAC GF-3 specifications. Some automotive OEM oil

system for grading motor oils according to their viscosity characteristics. SAE viscosity grading includes the following, from low to high viscosity: 0, 5, 10, 15, 20, 25, 30, 40, 50 or 60. The numbers 0, 5, 10, 15 and 25 are suffixed with the letter W, designating their winter (not "weight") or cold-start viscosity, at lower temperature. The number 20 comes with or without a W, depending on whether it is being used to denote a cold or hot viscosity grade. The document SAE J300 defines the viscometrics related to these grades. Kinematic viscosity is graded by measuring the time it takes for a standard amount of oil to flow through a standard orifice, at standard temperatures. The longer it takes, the higher the viscosity and thus higher SAE code. The SAE has a separate viscosity rating system for gear, axle, and manual transmission oils, SAE J306, which should not be confused with engine oil viscosity. The higher numbers of a gear oil (e.g., 75W-140) do not mean that it has higher viscosity than an engine oil.

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has established a numerical code

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4.8 TIMER CIRCUIT Timer circuit will create and maintain the on and off time delay to do the specific job or task. The sequential time is controlled by using microcontroller, which is fed by a programming language. The time interval can be varied by push type switches in circuit. Timer circuit consists of general circuit elements like capacitors, diode, resistor, voltage regulator, LCD display, microcontroller and relay.

Initially the power produced from dynamo is rectified using a rectifier and output supplied to microcontroller. Microcontroller is then control the signal to actuate the pump using relay switch. LCD displays OFF and ON time, and changes can be performed by push type switches. LCD displayed by additional power. By setting the value, OFF TIME tends to work the pump and ON TIME tends to delay interval for further operations. While off timing condition, power supplies from rechargeable battery to pump by means of relay circuit.

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Figure 4.9 Timer Circuit

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4.8.1 Microcontroller A micro controller is an integrated circuit or a chip with a processor and other support devices like program memory, data memory, I/O ports, serial communication interface etc integrated together. Unlike a microprocessor (ex: Intel 8085), a microcontroller does not require any external interfacing of support devices. Microcontrollers are usually dedicated devices embedded within an application. Since microcontrollers are powerful digital processors, the degree of control and programmability they provide significantly enhances the effectiveness of the application. The 8051 is the first microcontroller of the MCS-51 family introduced by Intel Corporation at the end of the 1970s. The timer function is one of the basic features of a microcontroller. Although some compilers provide simple macros that implement delay routines, in order to determine time elapsed and to maximize use of the timer, understanding the timer functionality is necessary.

4.8.1.1 Applications Microcontrollers are used in products that are controlled automatically. The various products that make use of microcontrollers in our everyday life are given below: Home: Television, DVD player, Telephone, Fax machine, Cellular phones, Security systems, Camera, Sewing machine, Musical Instrument, Exercising machine, Video games, Computer, Microwave oven.

Office: Computers, Printers, Telephones, Fax machine, Security systems.

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Figure 4.10 8051 Microcontroller

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4.8.2 Capacitors The capability of a capacitor to store electricity is known as capacitance of that capacitor. It is denoted by C. The measuring unit of capacitance is Farad, but Farad is very large unit. Its smaller units are Kilo Micro Farad (KMFD), Micro Farad (MFD), Kilo Pico Farad (KPF) or Nano Farad (NF) and Pico Farad (PF).

4.8.2.1 Working Principle of Capacitor There are different results produced by giving DC & AC supply to a capacitor. The working of a capacitor in both the conditions is as follows: When any capacitor is connected between an AC supply sources, one plate is at a negative potential and the other plate is at a positive potential (due to the voltage source). Hence opposite charges develop on the both the plates. The time when the plates of capacitor are charging there is flow of current from the

capacitor becomes equal to maximum input voltage to the capacitor, this flow of current stops. In this way, we can say that at the time of charging of capacitor the flow of current stores charges in the both of the plates. It is known as charging state of capacitor.

Its function is to store the electrical energy and give this energy again to the circuit when necessary. In other words, it charges and discharges the electric charge stored in it. Besides this, the functions of a capacitor are as follows: It blocks the flow of DC and permits the flow of AC. It is used for coupling of the two sections. It bypasses (grounds) the unwanted frequencies. It feeds the desired signal to any section. It is used for phase shifting. It is also used for creating a delay in time. It is used as motor starter.

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4.8.2.2 Applications

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supply source into the capacitor, and when the value of voltage across the two plates of the

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4.8.3 Resistor A resistor is a two-terminal electrical or electronic component that resists the flow of current, producing a voltage drop between its terminals in accordance with Ohm's law. The electrical resistance is equal to the voltage drop across the resistor divided by the current that is flowing through the resistor.

4.8.3.1 Working of Resistor The working of a resistor can be explained with the similarity of water flowing through a pipe. Consider a pipe through which water is allowed to flow. If the diameter of the pipe is reduced, the water flow will be reduced. If the force of the water is increased by increasing the pressure, then the energy will be dissipated as heat. There will also be an enormous difference in pressure in the head and tail ends of the pipe. In this example, the force applied to the water is similar to the current flowing through the resistance. The

4.8.3.2 Applications

Resistors are used as part of electrical networks and electronic circuits. All resistors dissipate heat. This is the principle behind electric heaters. In general, a resistor is used to create a known voltage-to-current ratio in an electric circuit. If the current in a circuit is known, then a resistor can be used to create a known potential difference proportional to that current. Conversely, if the potential difference between two points in a circuit is known, a resistor can be used to create a known current proportional to that difference.

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pressure applied can be resembled to the voltage.

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4.8.4 Diode A diode is the simplest two-terminal unilateral semiconductor device. It allows current to flow only in one direction and blocks the current that flows in the opposite direction. The two terminals of the diode are called as anode and cathode. 4.8.4.1 Working of Diode The diode operates when a voltage signal is applied across its terminals. The application of a DC voltage to make the diode operate in a circuit is called as Biasing. As already mentioned above the diode resembles to that of a one way switch so it can either be in a state of conduction or in a state of non conduction. The ON state of a diode is achieved by Forward biasing which means that positive or higher potential is applied to the anode and negative or lower potential is applied at the cathode of the diode. In other words, the ON state of diode has the applied current in the same direction of the arrow head. The OFF state of a diode is achieved by Reverse biasing which means that positive or higher

the diode. In other words, the OFF state of diode has the applied current in the opposite direction of the arrow head. During ON state, the practical diode offers a resistance called

condition which is called Cut-in-voltage. The diode starts conducting in reverse biased mode when the reverse bias voltage exceeds its limit which is called as the Breakdown voltage. The diode remains in OFF state when no voltage is applied across it.

4. 8.4.2 Applications Rectification The rectification means converting AC voltage into DC voltage. Clipper- Diode can be used to clip off some portion of pulse without distorting the remaining part of the waveform. Clamper A clamping circuit restricts the voltage levels to exceed a limit by shifting the DC level. The peak to peak is not affected by clamping. Diodes with resistors and capacitors are used to make clamping circuits. Sometimes independent DC sources can be used to provide additional shift.

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as the Forward resistance. The diode requires a forward bias voltage to switch to the ON

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potential is applied to the cathode and negative or lower potential is applied at the anode of

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4.8.5 Relay Relay is an electromagnetic device which is used to isolate two circuits electrically and connect them magnetically. They are very useful devices and allow one circuit to switch another one while they are completely separate. They are often used to interface an electronic circuit (working at a low voltage) to an electrical circuit which works at very high voltage. For example, a relay can make a 5V DC battery circuit to switch a 230V AC mains circuit. Thus a small sensor circuit can drive, say, a fan or an electric bulb. A relay switch can be divided into two parts: input and output. The input section has a coil which generates magnetic field when a small voltage from an electronic circuit is applied to it. This voltage is called the operating voltage. Commonly used relays are available in different configuration of operating voltages like 6V, 9V, 12V, 24V etc. The output section consists of contactors which connect or disconnect mechanically. In a basic relay there are

input state, the COM is connected to NC. When the operating voltage is applied the relay coil gets energized and the COM changes contact to NO. Different relay configurations are available like SPST, SPDT, DPDT etc, which have different number of changeover contacts. By using proper combination of contactors, the electrical circuit can be switched on and off.

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Figure 4.11 Relay

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three contactors: normally open (NO), normally closed (NC) and common (COM). At no

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CHAPTER 5 ROLE OF MIRCOCONTROLLER IN TIMER CIRCUIT

5.1 MICROCONTROLLER

Microcontrollers are usually dedicated devices embedded within an application. For example, microcontrollers are used as engine controllers in automobiles and as exposure and focus controllers in cameras. In order to serve these applications, they have a high concentration of on-chip facilities such as serial ports, parallel input/output ports, timers, counters, interrupt control, analog-to-digital converters, random access memory, read only memory, etc. The I/O, memory, and on-chip peripherals of a microcontroller are selected depending on the specifics of the target application. Since microcontrollers are powerful digital processors, the degree of control and programmability they provide significantly enhances the effectiveness of the application.

The microcontroller incorporates all the features that are found in microprocessor. The microcontroller has built in ROM, RAM, Input Output ports, Serial Port, timers, interrupts

Microcontrollers are usually dedicated devices embedded within an application. For example, microcontrollers are used as engine controllers in automobiles and as exposure and focus controllers in cameras. In order to serve these applications, they have a high concentration of on-chip facilities such as serial ports, parallel input output ports, timers, counters, interrupt control, analog-to-digital converters, random access memory, read only memory, etc. The I/O, memory, and on-chip peripherals of a microcontroller are selected depending on the specifics of the target application. The 8051 family with its many enhanced members enjoys the largest market share, estimated to be about 40%, among the various microcontroller architectures. The microcontroller has on chip peripheral devices. In this unit firstly we differentiate microcontroller from microprocessor then we will discuss about Hardware details of 8051 and then introduce the Assembly level language in brief.

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and clock circuit. A microcontroller is an entire computer manufactured on a single chip.

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Microcontrollers Microcontroller (MC) may be called computer on chip since it has basic features of microprocessor with internal ROM, RAM, Parallel and serial ports within single chip. Or we can say microprocessor with memory and ports is called as microcontroller. This is widely used in washing machines, vcd player, microwave oven, and robotics or in industries. Microcontroller can be classified on the basis of their bits processed like 8bit MC, 16bit MC. 8 bit microcontroller means it can read, write and process 8 bit data. Ex. 8051 microcontroller. Basically 8 bit specifies the size of data bus. 8 bit microcontroller means 8 bit data can travel on the data bus or we can read, write process 8 bit data.

It is 8-bit microcontroller, means MC 8051 can Read, Write and Process 8 bit data. This is mostly used microcontroller in the robotics, home appliances like mp3 player, washing machines, electronic iron and industries.

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Figure 5.1 8051 Architecture

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5.2 MICROCONTROLLER 8051 ARCHITECTURE

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5.3 PROGRAM FED IN MICROCONTROLLER This coding fetched into microprocessor to perform delay timing operation CODING: // Lcd module connections sbit LCD_RS at P2_0_bit; sbit LCD_EN at P2_1_bit; sbit LCD_D4 at P2_2_bit; sbit LCD_D5 at P2_3_bit; sbit LCD_D6 at P2_4_bit; sbit LCD_D7 at P2_5_bit; sbit led at P3_0_bit; sbit alt at P1_0_bit;

sbit inc at P1_1_bit;

sbit dec at P1_2_bit; sbit set at P1_3_bit;

sbit inp at P1_4_bit; void Vdelay_ms(unsigned time_in_ms); long int on=1000,off=1000,j,k; unsigned int a,d,c; void main() {

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P1=0XFF; P3=0; Lcd_Init(); // Initialize Lcd // Clear display // Cursor off

Lcd_Cmd(_LCD_CLEAR); Lcd_Cmd(_LCD_CURSOR_OFF); Lcd_out(1,1," ON TIME:000"); Lcd_out(2,1," OFF TIME:000"); while(1) { while(set==0) { led=0; if(inp==0) { if(inc==0) { on=on+1000;delay_ms(200); if(on>99999) {on=999999;} } if(dec==0)

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{ if(on<=1000) {on=1000;} else {on=on-1000;delay_ms(200);} } j = on/1000; a = j/100; d = j%100; c = d%10; d = d/10; Lcd_Chr(1, 11, a+48); Lcd_Chr(1, 12, d+48); Lcd_Chr(1, 13, c+48); } /////////////////// if(inp==1) { if(inc==0) { off=off+1000;delay_ms(200);

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if(off>99999) {off=999999;} } if(dec==0) { if(off<=1000) {off=1000;} else {off=off-1000;delay_ms(200);} } k = off/1000; a = k/100; d = k%100; c = d%10; d = d/10; Lcd_Chr(2, 11, a+48); Lcd_Chr(2, 12, d+48); Lcd_Chr(2, 13, c+48); } } //////////////////////////

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while(set==1) { Vdelay_ms(on); led=1; Vdelay_ms(off); led=0; } } }

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CHAPTER 6 DISCUSSION
Many machines are dangerous to lubricate while running. So safety is an issue when lubricating hard-to-reach bearings. Under lubrication will cause bearing damage and premature failure. Over lubrication can cause product spoilage, bearing seal damage and cleanup issues. Manual lubrication typically produces inconsistent lubrication. The uneven lubrication cycle leads to wasted lubricant and allows contaminants to enter the bearing producing premature wear.

Figure 6.1 Comparison between Manual vs Automated Lubrication

Advantages of an Automatic Lubrication System Lubrication occurs while the machinery is in operation causing the lubricant to be equally distributed within the bearing and increasing the machines availability. All critical components are lubricated, regardless of location or ease of access. Proper lubrication of critical components ensures safe operation of the machinery. Less wear on the components means extended component life, fewer breakdowns, reduced downtime, reduced replacement costs and reduced maintenance costs. There is no climbing around machinery or inaccessible areas by the use of this system.

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CHAPTER 7 CONCLUSION

This self lubrication systems offer superior features than manual lubrication. This system eliminates productions loss where as manual lubrication requires machine shut down. It provides effective and clean lubrication. Self lubrication system will improve safety features and prevents accidents that occur during manual lubrication. It provides consistent lubrication that extends bearing life and prevents unplanned downtime. This system can be used complicated machines in small scale industries.

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CHAPTER 8 REFERENCES

1. C. James Erickson, Charles D. Potts, Byron M. Jones Electrical and Electronics Engineering 2. Muhammad Ali Mazidi, Janice Gillispie Mazidi and Rolin D. McKinlay The 8051 Microcontroller and Embedded Systems Using Assembly and C Second EditionNathan E. McIntire and Zelma M. Porter (1972) Automatic Lubrication System 3. Hermann Werner, Erich Lessol and Burkard Mueller (1996) Bicycle Dynamo having a rotary-current generator US patent 4. Richard W. Dochterman and Fort Wayne (1967) Lubrication System for Electric

5. Cheng-Hsien Wu, Yu-Tai Kung A parametric study on oil/air lubrication of a highspeed spindle Precision Engineering, Volume 29, Issue 2, April 2005, pp 162-167 6. James C. Gwynn (1995) Programmable Electronic Timer Circuit - US patent 7. Willam Bolton Mechatronics (2011) Fourth Edition - Microprocessor pp 336-372 8. www.wikipedia.org 9. www.wikitronics.com 10. www.interlubesystem.co.uk 11. www.electronicsforu.com 12. www.engineergarage.com

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Machines

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PHOTO: FABRICATION SETUP

FABRICATION OF SELF LUBRICATION SYSTEM FOR COMPLICATED MACHINES

WORKING OF SYSTEM - VIDEO LINK YOUTUBE http://youtu.be/TLBIh9-gpkY or http://www.youtube.com/watch?v=TLBIh9-gpkY&feature=youtu.be