Final semester Project

Lukhdhirji Engineering College, Morbi (634)
Diploma Mechanical Engineering Department
Year: 2014-15
:WORK REPORT:
RANK KRUNAL M.-126340319027
YADAV PARAS J.-126340319033
SOLANKI VISHAL V.-126340319043
PATEL PIYUSH K.-126340319060
PATEL SACHIN M.-136348319008
:submission:
Submitted- Vth
Sem. : / /2014

This is to certify that
Has satisfactorily completed his term work in the subject Project-I (3351908) within
the prescribed time limit and prescribed boundary.
Date: Student
Date: Industrial/Institute Guide
Date: Head Of Dept.
CERTIFICATE

I would like to thank Head of the Diploma Mechanical Engineering Department, Prof. P.V.
JETHVA for giving Mechanical Department students the opportunity to prepare a project on a topic
relevant to mechanical engineering, thereby making possible for us to get a great insight on a topic
chosen by us.
I would like to sincerely thank to MR. K.C.PARMAR, my batch in charge and guide, for
guiding me wonderfully guidance on my topic, thereby making possible for me to learn a great deal
on the topic and making a very systematic project report.
Yours Faithfully,

TOPIC
NO.
TITLE OF CHAPTER PAGE NO.
1. Abstract 4
2. Introduction 5
3. Literature review 6
4. Methodology 8
5. Constable idea 10
6. Various type and speed parameters 18
7. Classification of coupling 21
8. Future work 26
9. Conclusion 27
10. Reference 28
11. Day To day log book 29
INDEX

ABSTRACT
In present world there is a lots of coupling which required laser alignment which is very costly so
magnetic disc coupling provide a best way to couple driving shaft of motor to pump driven shaft without any
physical contact.
There is a no any requirement of laser alignment so magnetic disc coupling have advantage to work
with angular and linear misalignment so it is very useful in various industries easily. This deal with design
and development of magnetic disc coupling. Because of various industrial problems on alignment of driving
shaft to driven shaft magnetic disc coupling provide best way to connect them without any physical contact.
This project is about to construct the magnetic disc coupling that can transmit high torque. This project
involves the process of sketching and drawing. After design had completed next step is fabrication of
attachment to transform the paperwork into real work. This project is mainly about a generating a new
concept for transforming torque

INTRODUCTION
Because of enhance application of transmitting torque in industries and inherent limitation of non-
flexible coupling in terms of inaccuracy and non-optimum operation need felt for an attachment or a system
which can at least minimize inaccuracy for transmitting torque by minimizing backlash.
To study and understand further this replacement of magnetic coupling we have selected to work
upon design and development of magnetic coupling as final year project for Diploma in mechanical semester
5th examination to be held by GTU.
Magnetic Disc Coupling
Magnetic disc coupling which connect shafts without any direct mechanical contact. Good for
system processing highly volatile liquids or for transferring motion with in vacuum chambers without the
need for expensive and vulnerable shaft seals.
This coupling is simple construction and better flexibility than other coupling. It can work easily in
angular and linear misalignment areas.

PROBLEM STATEMENT
In industries there is lot of problem about misalignment while transmitting torque from driving shaft
to the driven shaft. To overcome this problem and obtaining maximum efficiency of system we are working
on,
“Modification of magnetic coupling”
Which can transmit up to 8 Nm torque in no load condition using 1 hp motor running at 960 rpm?
 PROJECT OBJECTIVES:-
 Design an attachment for magnetic coupling which can increase torque transmission efficiency.
 Develop the magnetic disc coupling which can transmit torque without any physical contact.
 Design and development of magnetic disc coupling which transmit torque from 7 Nm to 8 Nm.
 ADVANTAGES:-
 Smooth running.
 Overload protection to 110%.
 High torsion rigidity.
 Maintenance and wear free
 Maximum torque transmitted is 53.1 NM
 Use in application with high operation temperature greater than 423 K
 It can work with angular misalignment up to 3 degree and parallel misalignment up to ¼.
 No Wearing Parts.
 No wearing parts - wear free transmission of torque
 Synchronous design
 No slip at any speed
 protecting mechanical components in the drive-line from damage
 No physical contact between driving and driven parts

 Disadvantages of magnetic coupling:-
 Magnetic flux from the surroundings (such as other wires) may diminish or enhance the field the
Hall probe intends to detect, rendering the results inaccurate.
 Also, as Hall voltage is often on the order of millivolts, the output from this type of sensor cannot be
used to directly drive actuators but instead must be amplified by a transits based circuit.
 Magnetics are usually bulkier and more expensive.
 Magnetics don't pass DC.
 If you need to pass a low frequency signal, then you have to modulate it onto a carrier somehow.

LITERATURE REVIEW
Every industrial product has its own importance that is used for various purposes and to make the
industrial jobs easy and hassle-free. Industrial products can be in any form from a very small screw to large
and heavy machineries. High end couplings are also the most demanding industrial product used to connect
two different moving parts or connect two shafts together at their ends to transmit power for further use.
The most vital and demanding industrial products are used for a number of purposes in machineries to make
them more productive and workable.
As far as the use of innovative coupling is concerned, they are used to endow with the misalignment
of the shafts or to introduce mechanical flexibility. There are different types of couplings available in the
market and used for a number of purposes. Among a wide range of couplings, rigid coupling is one of the
main couplings available in the market that is utilized for the connection between two separate systems like
motor and generator.
A part from all this advantages, it has certain demerit also. It cannot work under overload condition.
It causes vibration problem while transmitting power at high speed also it has backlash problem.

To overcome this disadvantages magnetic coupling is invented by JOHN A. MACKEN. After this it is primary
examined by Ramon M. Barrera. In this they used stainless steel (SS) hub in which magnets are fixed.
This arrangement gives better running compare to rigid coupling. It can work under overload
condition and also overcome the vibration problem at high speed.

METHODOLOGY
 PROJECT PLANNING:-
In process to develop magnetic coupling there is planning of overall project for completing project
on its schedule. Based on planning first we get the project title for final year project then make a literature
review. Made a lot of investigation about magnetic coupling. This investigation involves the advantages and
disadvantages of magnetic coupling in market. This task is done through the information got from the
internet, books and our guide.
After gathering all the information we started to select the best idea for it. To achieve this we
discussed with our guide about the design. After several design sketched design consideration was made
and we develop the one of the new design where this design called final concept. This all activity is
represented as a flow chart below.

 CONCEPTUAL IDEA:-
There is a simple mechanism in magnetic coupling based on motion transmission from one
shaft to another shaft by magnets.
One shaft is driving shaft which is operated by motor while other one is idle shaft where the
rotating motion is transferred due to magnetic field produced between them. All this arrangement
is mounted on bed.
So main parts of magnetic coupling are:
1. Motor
2. Magnets
3. Driving shaft
4. Driven shaft
5. Hub
6. Bed
Component Material No. of component
Motor - 01
Magnets Rare earth magnet 08
Driving shaft Mild steel 01
Driven shaft Mild steel 01
Pulley Aluminum 02
Ball bearing Cast iron 02
Bed Cast iron 01

 Following activities carried out in our project planning process for
development of hand power punching press :
1. Literature Review
2. Identification of Problem
3. Experimental Setup Preparation
4. Experimental Setup
5. Conclusion
 ARRANGEMENT OF MAGNETS IN PULLEY:-
Magnetic coupling consists of two pulleys. These pulleys are fitted with permanent magnets,
hermetically sealed from the liquids, in a multiple arrangement. The inner and outer magnetic rotors are
locked together by magnetic forces and work as a synchronous coupling. The permanent-permanent
magnetic couplings create neither slippage nor induction current during rotation. When excessive torque is
applied, the magnets will decouple, they will not recouple.
These magnets are arranged in method called HALLBACH ARRAY. This method is as follows
A Halbach array is a special arrangement of permanent magnets that augments the magnetic field
on one side of the array while cancelling the field to near zero on the other side. This is achieved by having a
spatially rotating pattern of magnetization.
The rotating pattern of permanent magnets (on the front face; on the left, up, right, down) can be
continued indefinitely and have the same effect. The effect of this arrangement is roughly similar to many
horseshoe magnets placed adjacent to each other, with similar poles touching.
The effect was discovered by John C. Malison in 1973, and these "one-sided flux" structures were
initially described by him as a "curiosity", although he recognized at the time the potential for significant.
This is shown in figure.

 DETAIL DESIGN:-
We are developing the magnetic disc coupling which uses 1 HP motor and the maximum amount of
the torque transmitted with the help of 8 rare earth magnet whose total magnetic field will be around 3.2
tesla around 7.93 Nm.
For obtaining all these specification the design and specification of all the components which are
used in magnetic disc coupling are below:
 HUB:-
Sectional View of hub
Where,
D1 Internal diameter of working hub
D2 Internal diameter of idle hub
D External diameter of hub
L Distance between working and idle hub
S Overall diameter of hub
Gap Air gap between two hubs

 PULLEY:-
 Here we are using disc aluminum pulleys which have a disc for connecting rim to the shaft instant of
arms as a hub in magnetic disc coupling. This is shown in figure below, Magnets are arranged inside
of this pulley
 Motor:-

An electric motor is an electric machine that converts electrical energy into mechanical energy. The
reverse conversion of mechanical energy into electrical energy is done by an electric generator.
In normal motoring mode, most electric motors operate through the interaction between an electric
motor's magnetic field and winding currents to generate force within the motor. In certain applications, such
as in the transportation industry with traction motors, electric motors can operate in both motoring and
generating or braking modes to also produce electrical energy from mechanical energy.
Electric motors are used to produce linear or rotary force (torque), and should be distinguished from
devices such as magnetic solenoids and loudspeakers that convert electricity into motion but do not
generate usable mechanical powers, which are respectively referred to as actuators and transducers.
 Magnet:-
A magnet (from Greek "Magnesian stone") is a material or object that produces a magnetic field.
This magnetic field is invisible but is responsible for the most notable property of a magnet: a force that
pulls on other ferromagnetic materials, such as iron, and attracts or repels other magnets.
A permanent magnet is an object made from a material that is magnetized and creates its own
persistent magnetic field. An everyday example is a refrigerator magnet used to hold notes on a refrigerator
door. Materials that can be magnetized, which are also the ones that are strongly attracted to a magnet, are
called ferromagnetic (or ferrimagnetic). These include iron, nickel, cobalt, some alloys of rare earth metals,
and some naturally occurring minerals such as lodestone. Although ferromagnetic (and ferrimagnetic)
materials are the only ones attracted to a magnet strongly enough to be commonly considered magnetic, all
other substances respond weakly to a magnetic field, by one of several other types of magnetism.

 Drive shaft:-
A drive shaft, driveshaft, driving shaft, propeller shaft (prop shaft), or Card an shaft is a mechanical
component for transmitting torque and rotation, usually used to connect other components of a drive train
that cannot be connected directly because of distance or the need to allow for relative movement between
them.
As torque carriers, drive shafts are subject to torsion and shear stress, equivalent to the difference
between the input torque and the load. They must therefore be strong enough to bear the stress, whilst
avoiding too much additional weight as that would in turn increase their inertia.
To allow for variations in the alignment and distance between the driving and driven components,
drive shafts frequently incorporate one or more universal joints, jaw couplings, or rag joints, and sometimes
a splined joint or prismatic joint.

 VARIOUS TORQUE AND SPEED PARAMETER:-
KW
@960
RPM
Max.
Speed
Weight
per hub
Torque
Normal
Torque
PEAK
A B D E G
HP RPM Kg Nm Nm Mm mm mm mm Mm
0.02 42500 0.05 0.12 0.16 26.9 21 15.9 15.9 3.2
0.05 26000 0.1 0.5 0.6 43.7 21 15.0 15.0 4.80
0.10 23000 0.1 0.7 0.9 50.3 28 15.0 15.0 4.80
0.15 19000 0.3 1.0 1.4 60.0 38 19.1 19.1 4.80
0.28 15500 0.6 1.7 2.3 72.6 51 25.4 25.4 4.80
0.62 12000 1.0 4.1 4.5 93.5 70 25.4 25.4 6.35
1.23 10500 1.2 8.1 9.0 107 70 25.4 25.4 6.35
1.85 9000 2.0 12.2 13.5 130 76 38.1 31.8 6.35
3.08 9200 2.2 20.3 22.6 125 70 38.1 31.8 6.35
4.63 9200 3.1 30.5 34.0 125 108 47.5 41.4 6.35
6.17 7800 4.1 40.6 45.2 147 108 52.6 46.0 6.35
8.02 7800 3.2 53.1 61.0 147 60 41.7 31.8 6.35
Various torque and speed

 HOW IT’S WORK:-
Magnetic couplings consist of an outer and an inner drive. The two drives do not touch each other –
the coupling works via the non-contact transfer of power, which means that the magnetic solution – in
contrast to traditional solutions – does not experience any wear. The magnetic coupling is thus
maintenance-free.
Between the two rotating units it is possible to place a can such that two different media can be kept
separate. With the hermetic enclosure of the coupling in a stainless steel housing, corrosion is avoided and
the coupling can operate directly as a wet runner in different liquids and aggressive environments.
The outer drive is normally connected to the drive unit and the inner drive is, for example,
connected to a pump. If a can is placed between the two contact-free rotating units, a standard air-cooled
norm motor can for example be connected
to a pump without the use of gaskets and seals.
Magnetic couplings are also called torque couplings because they can transfer a certain maximum
mechanical torque through the air. If the torque exceeds this maximum value, the coupling will “slip”, which
means that the rotational speed between the two coupled units is no longer the same. This prevents wear
and tear and the magnetic coupling provides a built-in safety feature that protects against damage.
There are two main types of couplings. One type has a radial design – similar to an ordinary electric
motor – whilst the other is axially oriented such that it can transfer forces through a surface.
 FOR MAXIMUM TORQUE:-
All important internal clearances are ground to tolerances of less than .001 in. (0.025 mm). Magnet
assemblies surround hysteresis assembly. When like poles face each other, they produce maximum
magnetic saturation of the hysteresis disc, forcing lines of flux to travel circumferentially through the
hysteresis disc.

 FOR MINIMUM TORQUE:-
When opposite poles face each other they produce minimum saturation of the hysteresis disc. The
lines of flux travel through the hysteresis disc. Combinations of adjustment angles between the two
extremes give infinite adjustability. Because there are no contacting surfaces, the setting can be maintained
indefinitely.
 TOOLS AND TECHNIQUES USED
 Sketching: All the ideas for magnetic coupling are first sketched on paper to ensure that advantages
can be obtained.
 Pro engineering software: the final design is drawn with the help of this software.
 LIST OF MACHINE TOOLS:-
 Lathe machine
 Drilling machine
 Grinding machine
 Welding machine
 MANUFACTURING PROCESSES INVOLVED:-
 Measuring and marking
 Cutting process
 Grinding process
 Turning

Classification of coupling
 Rigid Coupling:-
A rigid coupling is a unit of hardware used to join two shafts within a motor or mechanical system. It
may be used to connect two separate systems, such as a motor and a generator, or to repair a connection
within a single system. A rigid coupling may also be added between shafts to reduce shock and wear at the
point where the shafts meet.
When joining shafts within a machine, mechanics can choose between flexible and rigid couplings.
While flexible units offer some movement and give between the shafts, rigid couplings are the most
effective choice for precise alignment and secure hold.
By precisely aligning the two shafts and holding them firmly in place, rigid couplings help to
maximize performance and increase the expected life of the machine. These rigid couplings are available in
two basic designs to fit the needs of different applications. Sleeve-style couplings are the most affordable
and easiest to use.

 Flange coupling:-
This coupling has two separate cast iron flanges. Each flange is mounted on the shaft end and keyed
to it. The two flanges are coupled together with the help of bolts and nuts. The projected portion of one of
the flanges and corresponding recess on the other flange help to bring the shaft into line and to maintain
alignment. A flange which is provided with a shroud which shelters the bolts heads and nuts is called
protected type flange coupling

 Clamp or split-muff coupling:-
In this coupling, the muff or sleeve is made into two halves parts of the cast iron and they are join
together by means of mild steel studs or bolts. The advantages of this coupling is that assembling or
disassembling of the coupling is possible without change the position of the shaft. This coupling is used for
heavy power transmission at moderate speed.
 Magnetic coupling:-

A Magnetic Coupling is a means of transferring torque from one shaft to another without a
physical mechanical connection. Magnetic shaft couplings are most often used for liquid pumps and
propeller systems, since a static, physical barrier can be placed between the two shafts to separate the fluid
from the motor operating in air.
Magnetic shaft couplings preclude the use of shaft seals, which eventually wear out and fail from
the sliding of two surfaces against each another. Magnetic couplings are also used for ease of maintenance
on systems that typically require precision alignment, when physical shaft couplings are used, since they
allow a greater off axis error between the motor and driven shaft.
 Requirements of Good Magnetic Coupling Setup:-
 It should be easy to connect or disconnect the coupling.
 It does allow some misalignment between the two adjacent shaft rotation axes.
 Its goal should be to minimize the remaining misalignment in running operation so as to maximize
power transmission and to maximize machine runtime (coupling, bearing and sealing's lifetime).
 It should have no projecting parts.
 It is recommended to use manufacturer's alignment target values to set up the machine train to a
defined non-zero alignment, due to the fact that later, when the machine is at operation temperature,
the alignment condition is perfect

FUTURE WORK
In a next SEM we are going to present magnetic coupling. We will create proper design of magnetic
coupling in 2D AutoCAD drawing. After it we assemble all part of the model. After all we will run magnetic
coupling by joint electric supply.

CONCLUSION
 After constructing and performing all required experiment on magnetic disc coupling we can say
that it is no slip coupling it transmits equal number of revolution as that of motor with minimum air
gap.
 The torque transmitted has direct relation with the air gap as we increase the air gap the torque will
reduce and vice versa.
 This is one best try to connect driving shaft to drive shaft without any physical contact. In various
industries there is a lots of time waste on alignment of pump shaft to motor shaft and there is no
possibilities of accuracy so by applying this technology one can get more benefit.
 There is no any need of alignment instrument so this technology provide best way of time saving
and money plus man power saving

REFERENCES
 Machine design by R.S.KHURMI.
 Elements of machine design by BHANDARI.
 www.wikipediya.com
 www.ac-tech.com

Day to Day Log Book
ENROLLMENT NUMBER OF THE STUDENT :
126340319027
NAME OF THE STUDENT : RANK KRUNAL M.
INSTITUTE :
L.E.COLLEGE
DATE DETAILS OF WORK CARRIED OUT INITIAL OF STUDENT INITIAL OF
INDUSTRY/INSTITUTE
GUIDE &
INSTRUCTOR/WORK
MAN
15/07/2014 SELECTION OF THE PROJECT V.V. SOLANKI
16/07/2014 COLLECTION OF INFORATION V.V. SOLANKI
19/07/2014 START WORKING ON REPORT V.V. SOLANKI
20/07/2014 WORKING ON INDEX V.V. SOLANKI
21/07/2014 WORKING ON
ACKNOWLEDGEMENT&
CERTIFICATE
V.V. SOLANKI
22/07/2014 TYPING OF THE PROJECT V.V. SOLANKI
23/07/2014 INSERTING THE IMAGE OF
AUTOMATIC LATHE
V.V. SOLANKI
26/07/2014 CONCLUSION OF THE PROJECT V.V. SOLANKI
2/08/2014 VISIT TO INDUSTRY V.V. SOLANKI
14/11/2014 CORRECTION OF THE PROJECT V.V. SOLANKI

126340319027
INSTITUTE :
L.E.COLLEGE
INDUSTRY/INSTITUTE
GUIDE &
INSTRUCTOR/WORK
MAN
15/07/2014 SELECTION OF THE PROJECT S.M. PATEL
16/07/2014 VISIT TO INDUSTRY S.M. PATEL
19/07/2014 START WORKING ON REPORT S.M. PATEL
20/07/2014 WORKING ON INDEX S.M. PATEL
ACKNOWLEDGEMENT&
CERTIFICATE
S.M. PATEL
22/07/2014 TYPING OF THE PROJECT S.M. PATEL
AUTOMATIC LATHE
S.M. PATEL
26/07/2014 CONCLUSION OF THE PROJECT S.M. PATEL
2/08/2014 VISIT TO INDUSTRY S.M. PATEL
14/11/2014 CORRECTION OF THE PROJECT S.M. PATEL

126340319027
INSTITUTE :
L.E.COLLEGE
INDUSTRY/INSTITUTE
GUIDE &
INSTRUCTOR/WORK
MAN
15/07/2014 SELECTION OF THE PROJECT P.K. PATEL
16/07/2014 VISIT TO INDUSTRY P.K. PATEL
19/07/2014 START WORKING ON REPORT P.K. PATEL
20/07/2014 WORKING ON INDEX P.K. PATEL
ACKNOWLEDGEMENT&
CERTIFICATE
P.K. PATEL
22/07/2014 TYPING OF THE PROJECT P.K. PATEL
AUTOMATIC LATHE
P.K. PATEL
26/07/2014 CONCLUSION OF THE PROJECT P.K. PATEL
2/08/2014 VISIT TO INDUSTRY P.K. PATEL
14/11/2014 CORRECTION OF THE PROJECT P.K. PATEL

126340319027
INSTITUTE :
L.E.COLLEGE
INDUSTRY/INSTITUTE
GUIDE &
INSTRUCTOR/WORK
MAN
15/07/2014 SELECTION OF THE PROJECT P.J. YADAV
16/07/2014 COLLECTION OF INFORMATION P.J. YADAV
19/07/2014 START WORKING ON REPORT P.J. YADAV
20/07/2014 WORKING ON INDEX P.J. YADAV
ACKNOWLEDGEMENT&
CERTIFICATE
P.J. YADAV
22/07/2014 INDUSTRIAL VISIT P.J. YADAV
AUTOMATIC LATHE
P.J. YADAV
26/07/2014 CONCLUSION OF THE PROJECT P.J. YADAV
2/08/2014 VISIT TO INDUSTRY P.J. YADAV
14/11/2014 CORRECTION OF THE PROJECT P.J. YADAV

126340319027
INSTITUTE :
L.E.COLLEGE
INDUSTRY/INSTITUTE
GUIDE &
INSTRUCTOR/WORK
MAN
15/07/2014 SELECTION OF THE PROJECT K. M. RANK
16/07/2014 INFORMATION COLLECTION K. M. RANK
19/07/2014 START WORKING ON REPORT K. M. RANK
20/07/2014 WORKING ON INDEX K. M. RANK
ACKNOWLEDGEMENT&
CERTIFICATE
K. M. RANK
22/07/2014 VISIT TO INDUSTRY K. M. RANK
AUTOMATIC LATHE
K. M. RANK
26/07/2014 CONCLUSION OF THE PROJECT K. M. RANK
2/08/2014 VISIT TO INDUSTRY K. M. RANK
14/11/2014 CORRECTION OF THE PROJECT K. M. RANK

Final semester Project

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