Design badminton equipment feather planting machine for manufacturing badminton ball

- Don’t need to adjust the speed control parameters Servo -High intermittent torque - The current consuming does not depend on load - Limit size - No response to probable errors - High c

Hanoi University of Science and

Technology School of Mechanical Engineering Center for Training of Excellent Students

**********  **********

Instructor: Ph.D Trương Hoành Sơn

Students: Nguyễn Huy Bắc

Topic: Design badminton equipment feather

planting machine for manufacturing badminton ball

Ph.D Truong Hoanh Son Students: Nguyen Huy Bac-Truong Thanh Cong

Hanoi University of Science and Technology

School of Mechanical Engineering SOCIALIST REPUBLIC OF VIETNAMIndependence-Freedom-Happiness Center for Training of Excellent Students

Hanoi, June , 2016

HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

SCHOOL OF MECHANICAL ENGINEERING CENTER FOR TRAINING OF EXCELLENT STUDENTS

-FINAL THESIS REMARK

Trương Thành Công

PROJECT

Design badminton equipment feather planting machine for

manufacturing badminton ball

CONTENTS

Chapter 1 – Introduction Chapter 2 – Mechanical structure Chapter 3 – Design driving system Chapter 4 – Design control system Appendix A: Codes for MCU ATmega8

1. Remark of Instructor

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INSTRUCTOR

2. Remark of Reviewer

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REVIEWER

Actually, there are several shuttlecock manufacturing facility in Viet Nam But almost of them use the machines which are composed of all mechanical elements In this project we use the microcontroller to build a machine because of microcontroller brings high performance in space, time, economic value and very convenient for using

to suit to the development of society In this project we will design and make a

shuttlecock manufacturing machine which has almost automatically work This

machine will need only one worker to realize these process as drilling hole, putting leather and the productivity of this machine will be increased Therefore, we will save money, time and labour

After 6 months of study and research reference material with a sense of personal effort, we succeeded in designing and making the shuttlecock manufacturing machine;Building the control system of this machine using Atmega16.Since in the process of working, with young on the level of professional knowledge, practical experience and time constraints of the project so we cannot avoid mistakes Therefore, we are lookingforward to more help of the teacher, and the contribution of friends

This thesis is constant effort to learn new things, and almost importantly to excel at what we know Throughout 1 year, this work was never to see the light without a greathelp from people around us and people in our mind We would like to thank Ph.D Trương Hoành Sơn for his great effort and help, also, we would like to thank Dr Nguyễn Trọng Thanh for his great effort and great tips every day Not forget many thank to teachers in practical center, our parents, our friends they made great help to our project

TABLE OF CONTENTS

Table List

Table of Figures

Fig 3.9 Relation between frequency of pulse and the rotated angle of

step motor

28

Fig 4.9 Schematic diagram of electric control system 52

CHAPTER I: INTRODUCTION 1.1 History

Badminton is played almost throughout the world by both men and women andalso by the Children This game is also very popular in our country and is beingpatronized by the Government and Non-Government agencies and clubs etc Withthe increase in popularity of the badminton, the demand for good qualitybadminton ball is also increasing The life of each badminton ball is generallyshort after it is used in the game Hence, the consumption pattern is quitefrequent The badminton ball is one of the simplest items of sports goodsmanufacture with lesser investment of capital and can be produced in tiny andsmall-scale sector

There exists a very good market potential for badminton ball in Viet Nam andabroad However, most of the badminton ball manufactured are used internallywith the exports being very negligible due to poor quality and high per unit cost

of production compared to the international standards There exists a hugedemand for badminton ball in Viet Nam

1.2 Structure of a badminton ball

divided to 2 small stage:

1.4 Define the problem

From this analysis, we can see that the machine will has 2 main function is drill 16 holes on the cork base as the drawing:

56.0000 50.0000

R1.5000 30.0000

A-A 10.0000

Fig 1.2: Drawing of cork base Fig 1.3: Feather

And plant the feather on that holes

1.5 Basic and presumption

This project profile is prepared on the basis of the following presumption:

1 Working Hours 8 hours per day

2 No of shifts 1 shift per day

3 No of working 25 days per month

4 Total working 300 days

5 Total working 2400 hours per year

6 Working 75% to 80% efficiency

7 Time period 3 years after for achieving commencement the max of

commercial Capacity run utilization

8 Labour charge as per the rates existing in the locality

9 Margin Money 25% of capital investment

10 Rate of interest 15% on Capital

11 All the rates and estimates have been provided on the basis of the

prevailing market price

12 It is envisaged that very good quality shuttle cocks of high standard would

be produced

13 Payback period 2½ year (approx.)

Quality Control and Standards

Production Volume (per month): 1000 Rolls (Each roll contains ten pieces of badminton ball)

Production Volume (per annum) 12000 rolls Turnover (per annum) 12000 x

375 = 4500000 Motive Power 1 HP

Pollution Control There is no pollution hazard from this type of industry either

in air or in water Hence, there is no need of taking any pollution control

measures

Energy Conservation The scope for energy conservation in the shuttle cock manufacturing industry is very little, since most of the operations are carried out manually except few operations like boring etc However, the workers and staff members should be trained properly to make optimum use of power like fuel, electricity etc to save energy

CHAPTER II: MECHANICAL STRUCTURE 2.1 Block for holding and pushing the cork base

Fig2.1: Block for holding and pushing the cork base

The cork base is hold on a cylinder part and is push by a 3- bar 2 revolute jointmechanism 4 blocks like this is spaced 90 degrees away, around a shaft on a 15mmthick plate

2.2 Drilling mechanism

Fig 2.2: Drilling mechanism

For drilling motor, we use a 24V-DC motor combine with a collet to put the Ø3countersink

2.3 Planting feather mechanism

Fig 2.3: Feather planting mechanism

A base has the same deformation with feather shaft is created and move up and downbased on the motion of an air cylinder

2.4 Other parts

Fig 2.4: The mechanism create in-out motion Fig 2.5: Pushing support

To synchronous drilling motion and planting motion, we need a mechanism that candrill and plant feather at the same time and same position on 2 cork base Then wechoose crank mechanism and belt transmission

We use a cylinder to push the cork base out of holding part

CHAPTER III: DRIVING SYSTEM DESIGN 3.1 The dynamic diagram of the machine

STEP MOTOR

Mantit mechanism Ratchet

mechanism

Crank mechanism Slider

Pulley

Fig 3.1: The dynamic diagram of the machine3.2 Select the motor

turning continuously-Use for devices whichneed a RPM speed such as shaft of the axle of car, fan’s wing

- low cost

- can work in an open loop,

no feedback required-Good at maintaining the moment (without brakes, variables speed)

- High torque at low speed

- low maintenance, brushless

- Positioning accuracy

- Don’t need to adjust the speed control parameters

Servo -High intermittent torque

- The current consuming does not depend on load

- Limit size

- No response to probable errors

- High cost

- Do not work in an open mode control circuit, requires a feedback system

- Required to adjust the controller parameters

- Maintenance more expensive especially

DC servo motors

Tab 3.1: The comparison between step, servo and DC motor

In our design, we need a motor that can control easily the angle or speed Themovement of the milling and inserting leather must be precise so we need the motorwhich has high positioning precision In other hand, we need a high holding torque forthe main disk to remain the position when it turn 90 degree From the requirements,

we consider the stepping motor and servo motor But the servo motor has high cost,high maintain cots and more difficult to control So finally we choose the steppingmotor for this machine

3.2.1 Stepping motor

■ Introduction

Stepping motors are digitally controlled motors used for precise positioning Theyenable simple, accurate control of rotation angle and rotation speed, so they aresuitable for wide variety of applications Oriental Motor has brought hybrid steppingmotors into its product line to provide better levels of precision and performance whencompared to other stepping motors These motors have been used in manyapplications ranging from industrial equipment to office automation

Oriental Motor also provides a complete product line with everytype or product, aswell as optional equipment that a stepping motor might need, from dedicated drivers,

to controllers, precision gears and more

■ Features

- Easy angle and speed control

Stepping motors move by rotating in steps of predetermined degrees called stepangles The degrees rotated and the speed of rotation are easily controlled usingelectrical signals called pulses

Fig 3.2: Some step revolutions

- High torque/ good response

Stepping motors are compact, but produce high torque This provides excellentacceleration and fast movement

- High Resolution/High Positioning Precision

There are two types of stepping motors: the 5-phase stepping motor, which rotates0.72˚ for each pulse, and the 2-phase stepping motor, which rotates 1.8˚ for eachpulse The angular distance moved corresponds to the number of pulses input, with astopping accuracy of ±3 arc minutes (0.05˚ with no load) [±5 arc minutes for the

PMU and PMC series (0.08˚ with no load).]

- High holding Torque

Stepping motors produce high holding torque even while stopped The stop positioncan be held without relying on a mechanical brake

■ Applications

-Factory Automation:

X-Y plotters, laser processors, electric discharge processors, CNC machines, sewingmachines, etc

-Semiconductor fabrication equipment:

Wafer processing devices, wafer conveyors, IC bonders, dicing machines, ICinspection devices, etc

-Automation and labor-saving devices:

ATMs, ticket machines, postal sorters, laboratory systems, bill counters, vendingmachines, etc

■ The basic of stepping motor

Structure

Fig 3.3: Structure of a step motor

The figures above show two cross-sections of a 5-phase hybrid stepping motor.Hybrid Stepping motors are composed primarily of two parts, the stator and the rotor.The rotor in turn is comprised of three components: rotor 1, rotor 2 and the permanentmagnet The rotors are magnetized in the axial direction, with rotor 1 polarized northand rotor 2 polarized south

The stator contains 10 magnet poles with small teeth, each of which is wrapped inwire to form a coil The coil is connected to the facing magnet pole and is wound so itbecomes magnetized to the same pole when current is run through it (Running acurrent through a given coil magnetizes the facing poles to the same magnetism, eitherNorth Pole or South Pole.) The two facing poles form a single phase Since there arefive phases, A through E, the motor is called a 5-phase stepping motor There are 50teeth on the outside of the rotor, with the teeth of rotor 1 and rotor 2 mechanicallyoffset from each other by half a tooth pitch

■ Principal Operation

Fig 3.4: Operation principle of step motor

When phase A is excited, its poles are magnetized south and attract the teeth of rotor

1, which are magnetized north, while repelling the teeth of rotor 2, which aremagnetized south, which balances it to a stop The teeth of the phase B poles, whichare not excited, are misaligned with the south-polarized teeth of rotor 2 so they areoffset by 0.72˚

When the excitation switches from phase A to phase B, the phase B poles aremagnetized north, attracting the south polarity of rotor 2 and repelling the northpolarity of rotor 1 In other words, when excitation switches from phase A to phase B,the rotor rotates 0.72˚ As excitation shifts from phase A, to phase B, to phase C, tophase D, to E, to phase A, the stepping motor rotates in precise 0.72˚ steps To rotate it

in reverse, reverse the excitation order to phase A, phase E, phase D, phase C, phase

B, phase A

The high (0.72˚) resolution is created by the mechanical offset of the stator and rotorstructures, which is why positioning can be performed accurately without the use of

an encoder or other sensor Since the only factors that might decrease stoppingprecision are variations in the processing precision, assembly precision, and DCresistance of the coil, a high stopping precision of ±3 arc minutes (with no load) isachievable The driver performs the role of switching the phases, and its timing issupplied by the pulse signal input to the driver

In the example above, excitation proceeds one phase at a time, but for the mosteffective use of the coils, four or five phases should be excited simultaneously

■ Characteristics

 Dynamic

-Speed and Torque

This is the most common characteristic for expressing stepping motor performance

On the graph of this characteristic, the horizontal axis expresses pulse speed while thevertical axis expresses torque

Pulse speed equals the pulse rate, which is the number of pulses per second Instepping motors, the number of revolutions per minute is proportional to pulse speed

Fig 3.5: Torque and speed relationship of step motor

The speed vs torque characteristics are determined by the motor and driver, so theyvary greatly based upon the type of driver used

-Holding Torque

The holding torque is the maximum holding power (torque) the stepping motor haswhen power is being supplied but the motor is not rotating (rated current)

-Pullout Torque

Pullout torque is the maximum torque that can be output at a given speed Whenselecting a motor, be sure the required torque falls within this curve

-Maximum response frequency (FR)

This is the maximum pulse speed that the motor can be operated at when graduallyincreasing or decreasing the speed, when the frictional load and inertial load of thestepping motor are zero

-Maximum starting frequency (FS)

This is the maximum pulse speed at which the motor can start or stop instantly(without an acceleration or deceleration period) when the frictional load and inertialload of the stepping motor are 0 Driving the motor at greater than this pulse speedrequires gradual acceleration or deceleration This frequency drops when there is aninertial load on the motor

• Inertial Load vs Starting Frequency Characteristics

The figure below illustrates the changes in starting frequency caused by inertial load.Since the stepping motor rotor and the equipment have their own inertia, lags andadvances occur on the motor axis during instantaneous starts and stops These valueschange with the pulse speed, but the motor cannot keep up with pulse speeds beyond acertain point and missteps result The pulse speed just before a misstep occurs iscalled the maximum starting frequency

Fig 3.6: Pulse rate and inertial load relationship of step motor

Changes in maximum starting pulse rate with load inertia may be approximated by thefollowing formula.

ƒS: Maximum starting pulse rate (Hz) of the motor

ƒ: Maximum starting pulse rate (Hz) when applying load inertia

J O: Rotor inertia (oz-in2) [kg·m2] J L: Load inertia (oz-in2) [kg·m2] (J = GD2/4)

• Vibration Characteristics

When no pulse signal is input to driver, the stepping motor stops with a holding brakeforce equivalent to the maximum value of holding torque As pulses are input, themotor operates in a repeating stepwise manner as shown below

Fig 3.7: Single step response

-When a pulse signal is input, the motor accelerates towards the next step angle-Due to the influence of the rotor inertia and the load inertia,

The motor overshoots a certain angle, returns in the opposite direction, and thenrepeats this action

-After the motor has repeated sufficient damping oscillations, it stops at the setposition

A step-like movement that produces this kind of damped vibration is the cause ofvibration at low speeds The graph of vibration characteristics below shows thecharacteristics indicating the extent of vibration while the stepping motor is running

• Torque and angle characteristics

Torque-angle characteristics are the relationship between the angular displacement ofthe rotor and the torque which is applied to the shaft when energizing the motor withrated voltage The curve for this characteristic is shown below

Fig 3.8: Torque and angle characteristics of step motor

• Step angle accuracy

Under no-load conditions the stepping motor can maintain a step angle accuracy

within ±3 arc minutes (0.05˚) [For PMU and PMC series, ±5 minutes (0.08˚)] This

slight error arises from difference in the mechanical precision of the stator and rotorteeth and variations in the electrical precision of the DC re sistance of the stator coil

The step angle error is ±3 arc minutes (0.05˚) [For PMU and PMC series, ±5 minutes

(0.08˚)], but only under no load In actual applications, there is always frictional load.The angle precision in such cases is produced by the angular displacement caused byangle-torque characteristics based upon the frictional load If frictional load isconstant, the angle of displacement is constant for rotation in one direction Whenoperating from both forward and reverse, however, double the displacement angle isproduced by the round trip When stopping precision is required, always position fromone direction only

■Using stepping motor

Stepping motors rotate according to the number of pulse signals, so speed of rotation can be controlled by the speed (frequency) of the pulse signal

Fig 3.9: Relation between frequency of pulse and the rotated angle of step motor

A specialized driver circuit is needed to run the stepping motor Oriental Motor’sdrivers are designed for easy connection

3.2.2 Choosing motor

a Specifications and Operating conditions of the drive mechanism

b Determine the operating pattern

d Select motor

e Check the data of motor

■ For the 1 st motor (motor to drive drilling and feather planting blocks):

 Specifications and Operating conditions of the drive mechanism

– Feed 200mm

– Desired resolution 1mm (mm/step)

– Load m1=m2=5kg

– Coefficient of ball and slider 0.05

– Gear and belt coefficient 0.8

s

θ = × =

Choose the stepping motor with resolution is 1.8 angle

Calculate the number of operating pulse:

360 200 1.8

 Calculate the required Torque

-Calculate the load torque:

Force of moving direction:

(sin cos )

A

F F = + mg θ µ + θ

= ×5 9.807 0.05 2.452× =

Load Torque:

32.452 2 50 10

0.3060.8

L

F D T

1.8 266.67 ( 10.632 10 )

0[0.306 (40 J 0.420)] 2

0

80 J 1.452

 Select the motor:

(

2.

kg m

)

Required Torque (N.m)

43 10 × − 3.1

Fig 3.10: Parameter of the first step motor

■ For the second motor:

 Specifications and Operating conditions of the drive mechanism

Index table diameter 350mm

Index table thickness 10mm

Friction coefficient between matl structure 0.6

Malt diameter of the 16mm

Positioning angle 90 degree

Positioning time 1.5s

We use the malt structure at the output shaft of the motor with the transmissioncoefficient Z=4 so the positioning angle of motor is 360 and the positioning time is 6s

 Determining the operating pattern

For the second motor, we also use the stepping motor with resolution is 1.8 degree :

-Calculating the number of pulse:

360 200 1.8

A= =

An acceleration time (deceleration) time of 25% of the positioning time of is appropriate

-Calculating the operating pulse speed

N = ×f θ × = × × = rev

 Calculating the required Torque T M [N.m]

Calculating the load Torque:

Calculating the moment of load inertia:

1 6 0.25 1.5

+Inertia of malt disk 1:

The load inertia

1.8 44.45 ( 16.79 10 )

 Selecting the motor:

(N.m)

2.

kg m

)

Fig 3.11: Parameter of the second step motor

 Checking the motor

3.3 Bevel gear transmission

Fig 3.12: Bevel gears

Fig 3.13: Bevel gear Terminology Fig 3.14: Bevel gear force

Straight bevel gear:

WW

W W tan sin

W W tan cos

t ave

T r

2

'

p d o v s m t

Ko and Kv are defined as for spur gears

The load distribution factor is:

2 w

6 2 w

0.0036 (5.6 10 )

mb m