CHAPTER 1

INTRODUCTION
1.1 MOTORIZED HAMMER
Hammering machine is designed with mechanical arrangement in which
movements are controlled by motors with cam arrangements.
When the power is supplied to the 12v Dc wiper motor, Cam arranged is
attached with hammer tool. The rotary motion for the cam is given by the motor
since the cam is coupled with the motor shaft. Hammer. The pin is welded with the
cam eccentrically. When the pin reaches the lower position the hammer is lifted
upwards and when the pin reaches the upper position the hammer is released. Due
to this the impact load will be acting on the hammer table which is clearly shown
as in the above diagram. So the required operation of hammering is easily made.
1.1.1 COMPONENTS
1. DC motor
2. Battery
3. Crank lever mechanism
4. Hinge
5. Hammer
6. Work piece

1. DC MOTOR
1

At the most basic level, electric motors exit to convert electrical

energy into mechanical energy. This is done by way of 2 interacting magnetic
fields- 1 stationary and another attached to a part that can move. High torque
capabilities. There are three major components to a wiper motor:
Motor
Rotary to linear motion converter mechanism
Parking switch
The mechanism to convert rotary motion to linear motion is very straight forward,
and its functionality is apparent from a visual inspection of a disassembled motor
assembly.
A) Normal operation:
In this mode of operation, the dash switch is in the normal, or low speed,
position, and internally, terminal 2 of the switch is connected to terminal 3. Current
flows through the motor as shown by the dotted red line. The operation of the
parking switch has no effect in this mode, as terminal 4 of the dash switch is not
connected to any other terminal.
B) High speed operation:
In this mode, the dash switch is in the high speed position, and current flow
is as shown. This is basically the same configuration as the normal mode, except
the power flows through the high speed brush rather than the normal speed brush.
Internally, terminal 2 of the dash switch is connected to
terminal 1.

Fig 1.1 Dc Motor

C) Wipers off, blades not in the parked position:
With the dash switch off, power is supplied to the motor through the contacts of
the parking switch, and the motor continues to operate. Until the drive gear rotates
to the point where the cam operates the switch plunger, the motor will operate at
the normal, or low speed, just as if the dash switch were still on.
D) Wipers off, blades in the parked position:
When the drive gear has rotated to the point that the blades are in their
parked position, the cam button on the drive gear depresses the parking switch
plunger, operating the switch. Now, rather than the 12 volts as before, ground is
applied to the low speed brush, shorting out the armature windings.
3

The magnetic field that had built up in the windings when 12 volts was
applied will now discharge through the switch contacts, in very much the same
manner as the operation of the primary windings in the ignition coil. This discharge
current, shown as a dotted blue line, will be in the opposite direction as
the normal current flow, and will tend to reverse the rotation of the motor.Because
the windings are now short-circuited, the discharge takes place very quickly, and
the reversing energy lasts just long enough to stop the motor. The energy in the
discharge is such that the motor will stop immediately! In fact, if your are holding
the motor while testing this operation, hold on tight, because it stops so quickly
that it will jump out off your hand if you are not careful.

Earlier models:
Earlier models are a bit simpler than the later models, as you might expect.
Power is applied to the wiper motor at all times when the ignition switch is on, and
the motor is grounded by the operation of the dash switch. As soon as the wiper
blades move to some position other than the park position, the parking switch
inside the wiper applies ground to the motor. Thus, when the dash switch is turned
off, the motor will continue to operate until the blades reach the park position.
There is no field discharge current to assist the parking in this configuration, so the
parking is not as crisp as in the later models.

2. BATTERY
A series, parallel or series-parallel grouping of cells is called a battery.
Generally, a cell can deliver a small current at low voltage. If higher voltage is
required- a battery containing number of cells connected in series.If higher current
is required a battery containing number of cells connected in parallel.If large
current at high voltage is required- a battery containing number of cells in series
and further connected in parallel.Usually a no. of cells connected in series placed
in single container is called a battery.
Working:
Lead acid batteries used in the RV and Marine Industries usually consist of
two 6-volt batteries in series, or a single 12-volt battery. These batteries are
constructed of several single cells connected in series each cell produces
approximately 2.1 volts.
A six-volt battery has three single cells, which when fully charged produce
an output voltage of 6.3 volts. A twelve-volt battery has six single cells in series
producing a fully charged output voltage of 12.6 volts.
A battery cell consists of two lead plates a positive plate covered with a paste of
lead dioxide and a negative made of sponge lead, with an insulating material
(separator) in between. The plates are enclosed in a plastic battery case and then
submersed in an electrolyte consisting of water and sulfuric acid Each cell is
capable of storing 2.1 volts.

Fig 1.2 Battery

Above a fully charged battery is connected to a load (light bulb) and the chemical
reaction between sulfuric acid and the lead plates produces the electricity to light
the bulb. This chemical reaction also begins to coat both positive and negative
plates with a substance called lead sulfate also known as sulfation (shown as a
yellow build-up on plates). This build-up of lead sulfate is normal during a
discharge cycle. As the battery continues to discharge, lead sulfate coats more and
more of the plates and battery voltage begins to decrease from fully charged state
of 12.6-volts
One disadvantage of recharging a lead acid battery at a fixed voltage of
13.6-volts is the recharge time is very long. A typical 125-AH RV or Marine
battery will take approximately 80 hours to recharge at 13.6 volts. Increasing the
charge voltage to 14.4-volts will reduce battery recharge time for a 125-AH battery
to 3-4 hours. Once a battery reaches 90% of full charge, the voltage must be
reduced from 14.4-volts to 13.6-volts to reduce gassing and water loss.
The optional Charge Wizard automatically senses when a battery has a very
low state of charge and automatically selects its boost mode of operation. Boost
mode increases the voltage of a PD9100 Series converter/charger to 14.4 volts.
When the battery reaches the 90% charge level, the Charge Wizard automatically

reduces the charge voltage down to 13.6 volts to complete the charge. Again, this is
a standard feature on our Marine Chargers.
Another disadvantage of recharging a lead acid battery at a fixed voltage of
13.6-volts is that once it is fully charged, 13.6 volts will cause considerable gassing
and water loss. To prevent this from occurring the charging voltage must be
reduced to 13.2-volts. The Charge Wizard will automatically select its storage
mode of operation (13.2-volts) once the battery reaches full charge and remains
unused for a period of 30 hours. This feature is standard on all of Progressive
Dynamics Marine Battery Chargers.
At a charging voltage of 13.2 volts, the converter/charger will maintain a full
charge, reduce gassing and water loss. However, this lower voltage does not
provide enough gassing to prevent a battery condition called Battery Stratification.
Battery Stratification is caused by the fact that the electrolyte in the battery is a
mixture of water and acid and, like all mixtures, one component, the acid, is
heavier than water. Therefore, acid will begin to settle and concentrate at the
bottom of the battery.
3. CRANK LEVER MECHANISM
Mechanism
A mechanism is a device designed to transform input forces and movement
into a desired set of output forces and movement. Mechanisms generally consist of
moving

components

such

as gears and gear

trains,

belt

and

chain

drives, camand follower mechanisms, and linkages as well as friction devices such
as brakes and clutches, and structural components such as the frame, fasteners,
bearings, springs, lubricants and seals, as well as a variety of specialized machine
elementssuch as splines, pins and keys

Planar mechanism
A planar mechanism is a mechanical system that is constrained so the
trajectories of points in all the bodies of the system lie on planes parallel to a
ground plane. The rotational axes of hinged joints that connect the bodies in the
system are perpendicular to this ground plane.
Spherical mechanism
A spherical mechanism is a mechanical system in which the bodies move in
a way that the trajectories of points in the system lie on concentric spheres. The
rotational axes of hinged joints that connect the bodies in the system pass through
the center of these spheres.
Spatial mechanism
A spatial mechanism is a mechanical system that has at least one body that
moves in a way that its point trajectories are general space curves. The rotational
axes of hinged joints that connect the bodies in the system form lines in space that
do not intersect and have distinct common normals.
Crank lever mechanism
`A crank is an arm attached at right angles to a rotating shaft by
which reciprocating motion is imparted to or received from the shaft. It is used to
convert circular motion into reciprocating motion, or vice versa. The arm may be a
bent portion of the shaft, or a separate arm or disk attached to it. Attached to the
end of the crank by a pivot is a rod, usually called a connecting rod. The end of the
rod attached to the crank moves in a circular motion, while the other end is usually
constrained to move in a linear sliding motion.The term often refers to a humanpowered crank which is used to manually turn an axle, as in a bicycle crankset or
a brace and bit drill.

. In this case a person's arm or leg serves as the connecting rod, applying
reciprocating force to the crank. There is usually a bar perpendicular to the other
end of the arm, often with a freely rotatable handle or pedal attached.
4. HINGE
A jointed or flexible device that allows the turning or pivoting of a part, A
device for holding together two parts such that one can swing relative to the other,
typically having two interlocking metal leaves held by a pin about which they
pivot.Stainless steel does not respond to any coating materials, however, and so
finishes will not adhere to a stainless steel hinge. As a result, stainless steel is more
common for hidden hinges, while brass, bronze, and brass- and bronze-plated
hinges are more common for doors. Brass and bronze, both copper-based alloys,
are very sturdy metals that can withstand less-than-ideal weather conditions like
rain, salt air, smog, and can form thicker hinges than stainless steel.
Brass requires extra treatment to withstand salt water, but bronze is
incredibly weatherproof, and used frequently in marine applications. They also
respond well to finishes, so they can be affixed with a broad array of colors to
complement many different paint coats. Copper: Copper makes up the base metal
of solid bronze and brass alloys, or that used in bronze- and brassplating.Galvanized: This electrochemical finishing process coats steel to protect it
from rust.Japanned: This is a kind of lacquer from Italy, named after fashionable
Asian embossments in the 17th century.Blued:

This is a finishing

process

involving the passive oxidization of steel, which gives the material a bluish hue.

Fig 1.3 Hinges

5. HAMMER
A hammer is a handheld tool used to strike another object.Forging is a
manufacturing process involving the shaping of metal using localized compressive
forces. The blows are delivered with a hammer(often a power hammer) or a die. It
consists of a handle to which is attached a heavy head, usually made of metal, with
one or more striking surfaces. There are dozens of different types of hammers. The
most common is a claw hammer, which is used to drive and pull nails. Other
common types include the ball-peen hammer and the sledge hammer.
Certain specialty hammers may have Dead-blow hammers have a hollow
head filled with small steel shot to give maximum impact with little or no rebound.
Steel and composite handles usually have a contoured grip made of a synthetic
rubber or other elastomer. Wood handles do not have a separate grip. Steel and
composite handles may also be encased in a high-impact polycarbonate resin. The
addition of this material around the handle increases shock absorption, improves
chemical resistance, and offers protection against accidental overstrikes. An
overstrike is when the hammer head misses the nail and the handle takes the
impact instead. This is a common cause of handle failure.
10

Fig 1.4 Hammer

CHAPTER 2
11

DESIGN CALCULATION
2.1 DESIGN OF MOTOR
Motor power : 60 kw
Speed of the power : 440 rpm
Motor speed is directly proportional to the input voltage, E,
applied to the motor terminals.
s = E/Ke
where,
s = Shaft speed, rad/sec
E = Input voltage applied to motor terminals, V
Ke = Motor voltage constant, V/(rad per sec)
1. Torque
T = 60P/2n
= 60*60/2*440
= 1302.17 N-mm

2. Synchronous speed
Ns = 120*f/Pn
= 120*50/6
12

= 2000rpm
Pn no . of poles 6
3. Slip
= Ns-N/Ns
= 2000-440/2000
= 0.78
4. Diameter
T=/16D
=1302.17*10/45*(/16) = D
D = 52mm
5. Horse power
1 HP = 0.746 KW
1 /0.746 HP = 1KW
HP = 60/0.746
= 44.76 KW
6. Locked rotor current
IL = 577*HP*KVA/E
= 577*44.76N*5.6 / 440
= 361 Amps
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kva code F motor constant 5.6

CHAPTER 3
FABRICATION DETAILS
3.1 MATERIAL SELECTION
Hammer:
Hammer heads are made of high carbon, heat-treated steel for strength and
durability. The heat treatment helps prevent chipping or cracking caused by
14

repeated blows against other metal objects.Heads are made up of copper, brass,
babbet metal, and other materials.Steel and composite handles usually have a
contoured grip made of a synthetic rubber or other elastomer.
Hinge:
Copper: Copper makes up the base metal of solid bronze and brass alloys, or
that used in bronze- and brass-plating.
Galvanized: This electrochemical finishing process coats steel to protect it
from rust.
Brass and bronze, both copper-based alloys, are very sturdy metals that can
withstand less-than-ideal weather conditions like rain, salt air, smog, and can form
thicker hinges than stainless steel.
Cam mechanism:
The rotary motion for the cam is given by the motor since the cam is
coupled with the motor shaft. Iron casting with steel and phosphor bronze.Medium
speed with automatic generation is applicable.Very accurate machining is
required.3

3.2 LIST OF MATERIALS

S.NO

COMPONENTS

MATERIALS

QUANTITY

Hammer

Steel & Composite

Head

Copper & Babbet Metal

15

Hinge

Galvanized Steel

Circular disc

Mild Steel & Phosphor Bronze

D.c motor

Table no 3.1 List of Materials

3.3 MOTORISED HAMMER CONSTRUCTION
The motor is fixed at the bottom of the frame. The distance between the
motor and hammer is adjusted in such a way to avoid slip and to make a proper
power transmission to the hammer. The cam mechanism mounted with the shaft.
The electrical hammer is a device used for forging the metal, bend removing for
steel bars and also used for sheet metal works.

16

Fig 3.1 Motorized Hammer 2D Diagram

3.3.1 WORKING PRINCIPLE

When the power is supplied to the 12v Dc wiper motor, Cam arranged
is attached with hammer tool. The rotary motion for the cam is given by the motor
since the cam is coupled with the motor shaft. Hammer. The pin is welded with the
cam eccentrically. When the pin reaches the lower position the hammer is lifted
upwards and when the pin reaches the upper position the hammer is released. Due
to this the impact load will be acting on the hammer table which is clearly shown
as in the above diagram. So the required operation of hammering is easily made.

17

3.3.2 CAD DIAGRAM

Fig 3.2 Motorized Hammer 3D Diagram

3.4 ADVANTAGES

Automatic process
Easy to operate
Maintenance is less
Implementation is easy

DISADVANTAGE
Large size of specimens cannot be hammered.

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APPLICATIONS
It is applicable in forging process and also applicable in seed crushing
process etc.
3.5 COST ESTIMATION
S.NO
1
2
3
4
5
6
7
8
9

No of
QUANTITY
1
1
1
1
1
1
4
1

COMPONENTS

Hammer
Head
Hinge
Circular disc
D.c motor
battery
Bolt & nut
welding
Stand
Total
Table no 3.2 List of Materials

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Cost in Rs
300
300
250
250
1550
1000
50
500
1000
Rs.4200

CHAPTER 4
CONCLUSION

This project is to increase the productivity & time saving for forging the
work piece. In this project cam mechanism is used to convert the motion. It
reduces the man power requirement. It is a simple machine, easy to operate and
also transfer from one place to another. Maintained cost is less . its widely used in
small scale industry , workshop, etc

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REFERENCE
Theory of machines by r. S. Khurmi, j.k. gupta eurasia publishing house,
2005
Electric motors and drives: fundamentals, types and applications by austin
hughes, bill drury

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