CHAPTER 1

INTRODUCTION

A quick return mechanism is a mechanism that converts rotary motion into

reciprocating motion at different rate for its two strokes. When the time required for the
working stroke is greater than that of the return stroke, it is a quick return mechanism. It
yields a significant improvement in machining productivity. Currently, it is widely used in
machine tools, for instance, shaping machines, power-driven saws, and other applications
requiring a working stroke with intensive loading, and a return stroke with non-intensive
loading.
.
By using quick return mechanism in air compressor unit the time of return stroke will
be reduced, therefore the overall efficiency of air compressor will be increased.

Several quick return mechanisms can be found in the literatures including the offset
crank-slider mechanism, the crank-shaper mechanisms, the double crank mechanisms, and
the Whitworth mechanism. All of them are linkages. A linkage has its strengths and
weaknesses. It is inexpensive to make and easy to lubricate; however, it is bulky and
difficult to balance. In situations, if compact space is essential to the design, then a linkage
may not be a good choice.
 CHAPTER 2

QUICK RETURN MECHANISM

 2.1 USAGE OF QUICK RETURN MECHANISM IN AIR COMPRESSOR

Quick return mechanism is used in shaping and slotting machines to cut metals. Here we
used this mechanism in air compressor to reducing the return stroke of the piston. The return stroke
is sucked the air from atmosphere and forward stroke compressed it.

However the power required on return stroke is lesser then, power required to move the
piston in forward. So by reduce time taken of return stroke is increase the efficiency of air
compressor.

2.2 MECHANISM:

Fig 2.1 Quick return mechanism

 Fig 2.2 Slider positions

2.2.1 FORWARD STROKE:

Initially, the slider at point C1, then the point M will be on position of connecting rod
is extremely in left position then the crank rotate at counter clockwise from C1 to C2 by covering of
an angle K. By the results the pistons connecting rod will move M to N in normal speed. The
distance between M and N is called stroke length. And the angle (K) between C1 and C2 called as
forward stroke angle.

2.2.2 RETURN STROKE:

When the crank further rotates counter clockwise from C2 to C1 the slider will be
move N to M now the pistons connecting rod move backward. The angle between C2 to C1 is
known as the return stroke angle. Is denoted at L . The angle L is lesser then the angle k. Due to
this reduction of angle gives the quick return motion comparing to forward motion.

When the driving crank rotates at uniform angular speed (N), we can write,

𝑲
Time for forward stroke=
𝟐𝝅𝑵

𝑳
Time for return stroke=
𝟐𝝅𝑵

Now the ratio of cutting stroke to return stroke time is given by,
 𝑲
𝑻𝒊𝒎𝒆 𝒐𝒇 𝒇𝒐𝒓𝒘𝒂𝒓𝒅 𝒔𝒕𝒓𝒐𝒌𝒆 𝟐𝝅𝑵 𝒂𝒏𝒈𝒍𝒆 𝑲 𝑲 𝟑𝟔𝟎−𝑳
= 𝑳 = = =
𝑻𝒊𝒎𝒆 𝒐𝒇 𝒓𝒆𝒕𝒖𝒓𝒏 𝒔𝒕𝒓𝒐𝒌𝒆 𝒂𝒏𝒈𝒍𝒆 𝑳 𝟑𝟔𝟎−𝑲 𝑳
𝟐𝝅𝑵

Where,

K - Angle of forward stroke

L-Angle of return stroke

CHAPTER 3

GEARS
3.1 GEARS:
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with
another toothed parts to transmit part to transmit torque. Geared devices can change the speed,
torque, and direction of a power source.

Two meshing gears transmitting rotational motion. Note that the smaller gear is rotating
faster. Since the larger gear is rotating less quickly, its torque is proportionally greater. One
subtlety of this particular arrangement is that the linear speed at the pitch diameter is the same on
the both gears.

3.2 TYPES OF GEAR:

There are four principal types of gear,

 SPUR GEARS: The simplest type of gears. The teeth are parallel to the
axis of rotation, as seen in the figure. It transmits rotation between
two straight shafts.

 Helical gears: The teeth are inclined with respect to the axis of
rotation, as seen in the figure. Same as spur gears, it transmits
rotation between parallel shafts, but it is less noisy than spur
gears because of the more gradual engagement of the teeth during
meshing and thus it is more suitable for transmitting motion at
higher speed

 Bevel gears: The teeth are some how similar to those of a spur
gear but they are formed on conical surfaces instead of cylinders.
Bevel gears transmit rotation between intersecting shafts. The gear
shown in the figure has straight teeth where this is the simplest
type. However, there are other types were the teeth form
 circular arcs and it is called spiral bevel gears, as shown in the
figure. With spiral bevel gears, the teeth engagement will be
more gradual and thus it is less noisy and it is suitable for speeds.

 Worms and worm gears: Transmit rotation between

perpendicular shafts (not intersecting, there is an offset between
them). The worm resembles a screw which can be right handed or left
handed. Worm gear sets are usually used when high reduction in
speed is desired (speed ratios of 3 or higher). It transmits rotation
from the worm to the worm gear, but not the opposite.

Fig3.1

Nomenclature

Since spur gears are the

simplest type, it will be used for
illustration and to define the
primary parameters of gears and
their relations. The figure
illustrates the terminology of
spur gears.

 Pitch circle:

A circle upon which

all gear calculations are based
and its diameter is called the
“pitch diameter”.

Fig3.2
 .

 Addendum and Dedendum circles:

The circles defining the top and bottom faces of the teeth.

 Addendum :
The radial distance from the pitch circle to the top surface of the teeth.

 Dedendum:
The radial distance from the pitch circle to the bottom surface of the
teeth.
 CHAPTER 4

PNEUMATIC CYLINDER
4.1 PNEUMATIC CYLINDERS:

Many industrial applications require linear motion during their operating

sequence. One of the simplest and most cost effective ways to accomplish this is with
a pneumatic actuator, often referred to as an air cylinder. An actuator is a device that
translates a source of static power into useful output motion.

It can also be used to apply a force. Actuators are typically mechanical devices
that take energy and convert it into some kind of motion. That motion can be in any
form, such as blocking, clamping, or ejecting.

Pneumatic actuators are mechanical devices that use compressed air acting on a
piston inside a cylinder to move a load along a linear path. Unlike their hydraulic
alternatives, the operating fluid in a pneumatic actuator is simply air, so leakage
doesn’t drip and contaminate surrounding areas.

Fig4.1
4.2 SINGLE ACTING CYLINDER:

A single-acting cylinder in a reciprocating engine is a cylinder in which

the working fluid acts on one side of the piston only. A single-acting cylinder relies on
the load, springs, other cylinders, or the momentum of a flywheel, to push the piston
back in the other direction.

Single-acting cylinders are found in most kinds of reciprocating engine. They

are almost universal in internal combustion engines (e.g. petrol and diesel engines)
and are also used in many external combustion engines such as Stirling engines and
some steam engines. They are also found in pumps and hydraulic rams.

Fig4.2
 CHAPTER 5

ELECTRIC MOTOR
5.1 MOTOR:

An AC motor is an electric motor driven by an alternating current (AC). The

AC motor commonly consists of two basic parts, an outside stator having coils
supplied with alternating current to produce a rotating magnetic field, and an
inside rotor attached to the output shaft producing a second rotating magnetic field.
The rotor magnetic field may be produced by permanent magnets, reluctance saliency,
or DC or AC electrical windings.

Less common, AC linear motors operate on similar principles as rotating

motors but have their stationary and moving parts arranged in a straight line
configuration, producing linear motion instead of rotation.

5.1.1 WORKING PRINCIPLE OF MOTOR:

The two main types of AC motors are induction motors and synchronous
motors. The induction motor (or asynchronous motor) always relies on a small
difference in speed between the stator rotating magnetic field and the rotor shaft speed
called slip to induce rotor current in the rotor AC winding.

As a result, the induction motor cannot produce torque near synchronous speed
where induction (or slip) is irrelevant or ceases to exist. In contrast, the synchronous
motor does not rely on slip-induction for operation and uses either permanent
magnets, salient poles (having projecting magnetic poles), or an independently excited
rotor winding.

The synchronous motor produces its rated torque at exactly synchronous speed.
The brushless wound-rotor doubly fed synchronous motor system has an
independently excited rotor winding that does not rely on the principles of slip-
induction of current. The brushless wound-rotor doubly fed motor is a synchronous
motor that can function exactly at the supply frequency or sub to super multiple of the
supply frequency.

Other types of motors include eddy current motors, and AC and DC

mechanically commutated machines in which speed is dependent on voltage and
winding connection.

5.1.2 MOTOR DETAILS:

2.4.5 ‘C’ CHANNEL:
Fig 2.9 ‘c’ channel