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In spring working industry a wide range inspection machines are used. As the industry is a large and growing industry different type of machines are used for different operations.
Our project the spring rolling machine is very simple in operation by using microcontroller with digital display. This machine is used to testing the various types of spring load test in different diameters and length of the spring. This machine can be used in various fields. This machine is simple in construction and working principle.
INTRODUCTION
Spring rolling industry is a large and growing industry. There are many special purposes machines used in this industry to-day. The proper selection of the machines depends upon the type of the work under-taken by the particular industry.
There are many examples of spring, which can be seen in our every day lives. The metals generally used for spring rolling work include iron, copper, tin, aluminium, stainless and brass. Our project the SPRING TESTING MACHINE finds huge application in all spring manufacturing industry.
WORKING PRINCIPLE
The microcontroller receives the signals from power supply unit; the transistor T1, T2, T3 and T4 is used to ON the each letter one by one with respect to the load applying to the spring. The circuit drew the power from the rectified 12 volt supply. This 12 volt is regulated by the 5 volt with the help of 7805. The 12 MHz crystal oscillator is used in this circuit. This oscillator is used to decide the operating speed of the microcontroller. Time = = = 1/frequency 1/ (12 x 10-) 0.08 Microsecond
ADVANTAGES
Low Cost load testing Machine. The total memory requirement for program and data is only 4 kilobytes. Easy to change the program Power drawn the circuit is low
DISADVANTAGES
Additional cost is required
Basic terms.
A tension spring is a helical cylindrical spring with approximate constant stiffness which is able to receive external forces acting away from each other in its axis. Cold formed springs are preferably produced with prestressing, thus with close-coiled active coils. If necessary due to technical reasons, it is possible to use loose-coiled tension springs without prestressing, with gaps between the active coils. Hot formed springs shall be always without inner prestressing. In view of spring function, there are four basic states of springs: State of the spring Description of the spring state free preloaded fully loaded limit the spring is not loaded the spring is exposed to the minimum operational loading the spring is exposed to the maximum operational loading the spring is exposed to the limit operational loading index 0 1 8 9
The above-mentioned indexes are used in the calculation to specify individual parameters of the spring related to the given state of the spring.
With regards to the manner of loading, the springs can be divided for purposes of calculations into springs exposed to static loading or loading with lower variability, with requirements of service life lower than 105 working cycles, and springs exposed to fatigue loading with requirements of service life higher than 105 working cycles. With regards to the considerable effects of the shape and design of fixing eyes on reduction of the spring's service life and impossibility of perfect shot peening of the spring, it is not advisable to use tension springs exposed to fatigue loading.
Process of calculation.
The task of spring design cannot be solved directly and allows considerable freedom in options of the design, dimensions or loading of the spring. Many springs of various designs and dimensions may meet requirements of the desired input parameters of the task. Therefore, it is necessary to proceed iteratively and successively evaluate individual designs of the spring. The calculation solves this problem by creating a table of optimum designs following the chosen qualitative standard. The solution procedure is given in the following items (the square brackets indicate the number of the paragraph). 1. Choose production parameters of the spring [1.1]. 2. Set operational parameters of the working cycle (manner of loading, temperature and aggressivity of the working environment) and the desired level of safety [1.6]. 3. Choose an adequate processing of the spring. [2.1] 4. According to the recommended scope of use [2.3] choose a material for the spring [2.2]. 5. Enter the desired parameters of the working cycle (loading, length and stroke of the spring) [3.1]. 6. Set the necessary filters and marginal conditions of the spring design [3.7]. 7. Choose a method of classification of results [3.18] and press the button to initiate the design calculation [3.19]. 8. Choose a suitable solution from the table [3.20]. 9. Check parameters of the designed spring in chapter [4]. 10. In case of a spring with fixing eyes, check loading of the eye in chapter [6]. 11. In case you need "fine" tuning of some dimensions of the spring, use some of the supplementary calculations [7,8,9] for their modification. After execution of the modifications, transfer the results back to chapter [4] and check again whether the spring meets requirements of the strength check [4.39]. 12. Use chapter [10] for calculation of a spring exposed to fatigue loading. 13. Save the workbook with the designed solution under a new name.
Tension springs are usually fixed using fixing eyes of several types (A .. J) with different heights of the eyes and differing properties. Fixing eyes are the best solution in the technological aspect, however, this brings certain problems in view of loading capacity of the spring. Loading of the spring creates a concentration of stress on the fixing eyes and this may be substantially higher than the calculated stress in the spring coils. This fact should be taken into account when designing the spring. When using fixing eyes it is advisable to design the spring with a sufficient level of safety [1.10] and check the loading capacity of the eyes in chapter [6]. The amount of concentration of the stress depends on the type, design and dimensions of the eye and it is very difficult to calculate it theoretically. In view of bending stress appearing in the fixing eye [6.1], small eyes (type I, J) or double eyes (type D, E) are the best solution. In view of concentration of stress in torsion at the point of transition of the coil into the loop [6.2] the full loops on the side (type C,E,I) are the best solution. With regards to the above-mentioned facts, it is not recommended to use tension springs with fixing eyes exposed to fatigue loading in any case.
For individual designs of fixing eyes, the following values of eye height are prescribed: A) Half loop: LH = {0,55 .. 0,8} Di B,C) Full loop: LH = {0,8 .. 1,1} Di D,E) Double twisted full loop: LH ~ Di F) Inside full loop: LH = {1,05 .. 1,2} Di G,H) Raised hook: 1,2 Di < LH < 30 d I,J) Small eye: 2 d < LH < 0,6 Di K) Inclined full loop: LH = {0,35 .. 0,9} Di With designs without fixing eyes (M .. O) the spring is fixed using end coils whose pitch does not change during functional deformation of the spring. These types of tension springs are suitable for possible use with fatigue loading.
Note: Hot formed springs (see [2.1]) shall be usually used without fixing eyes (design N). Warning: If the automatic design of the spring [3] has the filter in row [3.13] disabled, the program designs the type of the eye upon calculated height of the eye regardless of the design of the ends of the spring chosen in this row.
Note: In view of strength check of a spring exposed to static loading, using the correction coefficient from Bergstrsserr gives the best results. Hint: With springs exposed to static loading, corrections are usually not executed.
design the spring with a sufficiently overdesigned level of safety [1.10] and then check the spring in chapter [10].
Note: If this filter is disabled and the filter in row [3.12] is enabled, all designed solutions will very probably use the small eye (type I), which is the best solution in view of bending stress of the fixing eye.
3.14 Keep to the desired level of safety with the strength check.
If this filter of solutions is set to "Yes", the resulting design eliminates all solutions with calculated levels of safety ss lower than the desired level of safety given in row [1.10]. If the filter is disabled, the resulting design includes all solutions with calculated levels of safety higher or equal to 1. Due to the fact that the desired levels of safety are usually more or less accurate estimations and only rarely reflect the accurately determined value, whose exceeding could lead to damage to the spring, experienced users can disable this filter during execution of the design and consider the level of safety of the designed spring directly in the table of the design or in the chapter of results in row [4.43].
Hint: If the filter is disabled, it may often be advantageous to set the standard of quality in row [3.15] to the value "Deviation from the desired level of safety".
Incorrectly entered parameters of the working cycle or limit diameters of the spring resp.: Some input data in paragraph [3.1] or rows [3.8, 3.9] are entered incorrectly. An incorrect entering is indicated as a change in color of the parameter value to red. Incorrectly set limit dimensions of the spring: Some data in chapter [3.0] in the sheet "Options" are entered incorrectly. Incorrect entering is indicated as a change in color of the parameter value to red. The desired diameters of the spring do not correspond with its the limit dimensions: Some of the desired diameters in rows [3.8, 3.9] are outside the marginal conditions given in chapter [3.0] in the sheet "Options". For the chosen wire and desired diameters of the spring, no suitable solution can be found : This problem can probably be resolved by selection of another wire material which is delivered in different diameters (see row [2.8]) or less strict limitation of the spring diameter in rows [3.8, 3.9] if possible. The problem may also be caused due to too limiting a setting of marginal conditions in rows [3.1, 3.2] in the sheet "Options". For the chosen wire and desired parameters of the working cycle or diameters of the spring resp., no suitable solution can be found: The problem probably has similar causes and solution as the previous problem. Another possible cause can be found in low strength of the material with regards to the desired value of the maximum working loading in row [3.2]. The solution can be found in a material with higher strength or possibly disabling of the control of the desired level of safety in row [3.14].
For the given entry data, no suitable solution was found: In this case, it is very difficult to determine the source of the problem. It is advisable to use several common procedures to localize and resolve the problem. One of the options of how to find causes of the problem is to initiate a design with differently set filters of solution in rows [3.8 .. 3.14]. A greater permissible deviation from the desired parameters of the working cycle in paragraph [3.1] is another option. The last option is to choose a material with higher strength or a wider range of delivered diameters of wire. If even these procedures do not bring any sufficient solution, the problem can probably be found in too high loading of the designed spring and the problem could be solved using several springs arranged in parallel. For the chosen type of fixing eye, no suitable solution was found: In this case, the application can find some suitable springs, however, not with the chosen type of eye [1.3]. The solution can be found in a design with another type of fixing eye or by disabling the filter in the row [3.13].
ss m LH
Level of safety of a spring exposed to static loading Weight of the spring Height of the fixing eye. The letter at the beginning indicates the type of eye design.
A comparative value showing the quality of the solution with regards to the chosen quality qualitative standard [3.15]. The lower the given value, the higher the quality of the design.
If it is necessary to tune some parameters of the designed spring (e.g. rounding of the designed dimensions), use some of the supplementary calculations [7,8,9] for this purpose.
Parameters of designed spring for specific working load or spring length. [5]
This paragraph can be used for calculation of the spring parameters (designed in paragraph [4]) which is in specific operating conditions. The paragraph [5.1] is designed for the purpose of calculations of the length Lx of a spring loaded with a given operational
force Fx. The paragraph [5.6] enables users to find the operational force which is necessary to extend the spring to the given length Lx.
parameter value to red. Any possible exceeding of the tensile strength Rm of the spring material is then indicated by a change in color of the whole field to red.
Note: Double-twisted full loops in design D or E resp. [1.3] need not be checked in view of bending stress.
Hint: If the fixing eye does not meet any checks, modify the radii [6.2, 6.6] or use a more suitable type of eye or a spring of greater dimensions.
designed spring can be transferred to the calculation using the button in row [7.1]. In the course of modification, you are informed on any possible exceeding of the recommended values of some of the parameters of the spring by a change in color of this parameter to red. The modified data can now be transferred back to the chapter of results [4] using the button in row [7.29]. It is advisable to visually check in the chapter of results whether the modified spring meets all needed checks, including a possible check of loading of the fixing eye [6]. All check boxes in rows [7.9, 7.18, 7.21, 7.24] must be disabled in the course of the calculation. C. Manual design of the spring. This calculation enables experienced users to make a design of a spring for the given parameters of the working cycle manually. When designing the spring, it is recommended to proceed as follows: diameter of the spring, diameter of the wire, number of coils, length of the spring [7.7,7.9, 7.21, 7.24]. After entering one parameter, the recommended values of the following parameters are calculated automatically. When designing a spring, it is good to enable check boxes of these parameters. The application then automatically determines the given parameters following a change in the higher positioned parameter. To simplify the design, the input boxes of the spring diameter and number of coils are completed with roll-up strips which quicken entering and change in values of these parameters. In the course of the design, you are informed on any possible exceeding of the recommended values of some of the parameters of the spring by a change in color of this parameter to red. The data on the designed spring can be transferred using the button in row [7.29] to the chapter of results [4], where some other parameters of the spring are calculated additionally. In cases of springs with fixing eyes, it is recommended to also perform a check of loading of the eye [6].
button in row [10.1]. The resulting data can then be transferred using the button in row [10.38] to the chapter of results [4], where some other parameters of the spring are calculated additionally. The springs designed in chapter [3], which are optimized in view of the static strength check, will not probably meet requirements of the dynamic check. If you also wish to use the automatic design [3] for a spring exposed to fatigue loading, proceed as follows:
use a material with the highest possible strength, suitable for dynamic loading (see [2.3]) design the spring with overdesigned level of static safety [1.10], double the required dynamic safety [10.5]). design the spring with as small a difference between the maximum and minimum loading [3.2, 3.3] as possible
Warning: The calculation used here performs a strength (fatigue) check of the spring only for stress in active coils, and does not take into consideration any possible stress concentrations in the fixing eye.
of working cycles. In the field of unlimited service life (the desired service life of the spring is higher than 107 working cycles), the fatigue limit of the material and thus the strength of the spring remains approximately constant.
"Setting calculations,
Note: In the calculation itself, any exceeding of limit dimensions is indicated in the chapter of results by a change in color of the parameter to red.
3.5 Ratio between pitch and spring diameter in the free state.
Not prescribed by the standard; with commonly produced springs without prestressing, made of a wire strengthened by drawing or heat, usually 0.2*D < t < 0.4*D.
Note: This marginal condition is meaningful only for tension springs without prestressing [1.2]. In case of springs with prestressing, the coils adjoin each other, thus the pitch is equal to the wire diameter.
"Workbook (calculation)
modifications".