IES ALJANADIC .

POSADAS (CORDOBA)

Maria Dolores García Fernández

http://www.petervaldivia.com/technology/mechanisms/index.php

http://www.bbc.co.uk/schools/gcsebitesize/design/systemscontrol/mechanismsrev1.shtml

MECHANISMS
Mechanism
A mechanism is simply a device which takes an input motion and force, and outputs a
different motion and force. The point of a mechanism is to make the job easier to do.
The mechanisms most commonly used in mechanical systems are levers, cams, gears,
and pulleys.

You need to know how to calculate the mechanical advantage obtained by using levers,
the velocity ratio in levers and pulley systems, and gear ratio and output speed when
using gears.

Levers:
Levers. Give me the place to stand, and I shall move
the earth
(Arquimedes)

A lever is the simplest kind of mechanism. There are three different types of lever.
Common examples of each type are the crowbar, the wheelbarrow and the pair of
tweezers.

All levers are one of three types, usually called classes. The class of a lever depends on
the relative position of the load, effort and fulcrum:

• The load is the object you are trying to move.

• The effort is the force applied to move the load.
• The fulcrum (or pivot) is the point where the load is pivoted.

Class 1 levers
A class 1 lever has the load and the effort on opposite sides of the fulcrum, like a
seesaw. Examples of a class-one lever are a pair of pliers and a crowbar.
Class 2 levers
A class 2 lever has the load and the effort on the same side of the fulcrum, with the load
nearer the fulcrum. Examples of a class-two lever are a pair of nutcrackers or a
wheelbarrow.

In the diagram below, the wheel or fulcrum on the wheelbarrow is helping to share the
weight of the load. This means that it takes less effort to move a load in a wheelbarrow
than to carry it.

Class 2 lever

Mechanical advantage
Class 1 and class 2 levers both provide mechanical advantage. This means that they
allow you to move a large output load with a small effort. Load and effort are
forces and are measured in Newtons (N). Mechanical advantage is calculated as
follows:

Mechanical advantage = load ÷ effort

For example, if the load=500N and the effort=100N, the mechanical advantage would
be:

500N ÷ 100N = 5

Class 3 levers
A class 3 lever does not have the mechanical advantage of class-one levers and class-
two levers, so examples are less common. The effort and the load are both on the same
side of the fulcrum, but the effort is closer to the fulcrum than the load, so more force is
put in the effort than is applied to the load. These levers are good for grabbing
something small, or picking up something that could be compressed or broken if too
much pressure is applied. The common example of class 3 levers is a pair of barbeque
tongs or a pair of tweezers. The latter are shown in the diagram below.

Class 3 lever

Lever at equilibrium .

The principle of the lever tells us that the lever is in static equilibrium, with all forces
balancing, if F1D1 = F2D2. In order to lift a bigger load (F2) the distance to the fulcrum
has to increase (D1) or the distance D2 has to decrease.
Exercises:

1st You need to lift a load of 200 kg (F1). The distance from the load to the pivot(D1) is
6 metres and the distance from the pivot to where the force is applied (D2) is 20 metres.
Calculate the value of F1.

2nd On the lever shown in the image D1 = 20, D2 = 400 and F1 = 300 Kg. Calculate
the value of F2

3rd On the same image, calculate the value of D1 if D2 = 70m, F1 = 300Kg and F2 =
60kg

4th Write the lever class of every object shown in the next image:
Pulley

A pulley is a wheel with a groove along its edge, for holding a rope or cable.

Pulleys are usually used to reduce the amount of force needed to lift a load

Types of pulleys

1st Fixed: A fixed pulley has a fixed axle. That is, the axle is "fixed" or anchored in a
place ( maybe the roof). A fixed pulley is used to redirect the force in a rope. A fixed

pulley has a mechanical advantage of 1 2nd Movable: A

movable pulley has a free axle. That is, the axle is "free" to move in space. A movable
pulley is used to transform forces. A movable pulley has a mechanical advantage of 2.

3rd Compound A compound pulley is a combination of fixed and movable pulley

systems. The simplest theory of operation for a pulley system assumes that the pulleys
and ropes are weightless, and that there is no energy loss due to friction. It is also
assumed that the ropes do not stretch.
Dictionary:

Groove : Long narrow channel

Mechanical advantage: It is the factor by which a mechanism multiplies the force put
into it

Stretch: To extend in length

Pulley systems
Pulleys are used to change the speed, direction of rotation or turning force.

A pulley system consists of two pulley wheels each on a shaft, connected by a belt.
This transmits rotary motion and force from the input, or driver shaft, to the output, or
driven shaft.

Image shows a pulley system consisting of two pulley wheels and a belt. The smaller,
driver, pulley is 40mm wide and the larger, driven pulley is 120mm wide. The speed of
the smaller wheel is 100rpm.

If the pulley wheels are different sizes, the smaller one will spin faster than the larger
one. The difference in speed is called the velocity ratio. This is calculated using the
formula:

Velocity ratio = diameter of the driven pulley ÷ diameter of the driver pulley

If you know the velocity ratio and the input speed of a pulley system, you can calculate
the output speed using the formula:

Output speed = input speed ÷ velocity ratio

Another formula that is the combination of the previous two formulas

Input speed* diameter of the driver pulley=output speed* diameter of the driven pulley
Worked example
• Work out the velocity ratio and the output speed of the pulley shown in the
diagram above.
• Velocity ratio = 120mm ÷ 40mm = 3
• Output speed = 100rpm ÷ 3 = 33.3 rpm

Pulley drive belts

Drive belts are usually made of synthetic fibres such as neoprene and polyurethane,
with a V-shaped cross section. It is possible to reverse the direction of the driven pulley
by twisting the belt as it crosses from input to output. Pulley belts have the advantage
over chains that they do not need lubrication (though unlike a chain, a belt can slip).

Exercises
• A fixed pulley is used to;
A. Change the direction of the force and for comfort
B. Increase the force and improve comfort
C. Decrease the force that we have to make
• In a movable pulley, the force that we have to make to lift the load is;
A. Effort=Load
B. Effort=Load/4
C. Effort=Load/2
• In a compound pulley, the formula that allows us to calculatethe force that we
have to make is; (n is the number of movable pulleys)
A. Effort=Load/n
B. Effort=Load
C. Effort=Load/(2*n)
• What force is needed to be applied to lift a load of 50 kg with a fixed pulley?

• What force is needed to be applied to lift a load of 50 kg with a movable pulley?

Gears

Gears consist of toothed wheels fixed to shafts. The teeth interlock with each other, and
as the first shaft (the driver shaft) rotates, the motion is transmitted to the second or
driven shaft. The motion output at the driven shaft will be different from the motion
input at the driver shaft - in place, speed, direction and other ways.
A number of gears connected together are called a gear train. The input (eg a motor) is
connected to the driver gear. The output, is connected to the driven gear.

The smaller gear makes more revolutions in a given period of time; it turns faster. We
always have:

(Speed gear A * Number of teeth Gear A) = (Speed gear B * Number of teeth gear B)

The ratio of the rotational speeds of two engaged gears is called the Gear ratio.or
velocity ratio, and can be calculated using the number of teeth or using those two
speeds. The formula is:

Gear ratio = number or teeth on driver gear ÷ number of teeth on the driven gear
Or
Gear ratio= driven gear´s velocity ÷driver gear ´s velocity

Gears exercises

Exercise 1. What is the output in Exercise 2: Gear A revolves at 90revs/min.

revolutions per minute at Gear C? . What is the output and direction at Gear C.
Exercise 3: Calculate the output speed (the speed at which the biggest gear moves) if:
V1= 3000 (smallest gear) and t1=20 teeth, T2 = 50 teeth and T3 = 200 teeth

Compounds Gears
Where very large speed reductions are required, several pairs of gears can be used in a
compound gear train. A small gear drives a large gear. The large gear has a smaller gear
on the same shaft. This smaller gear drives a large gear. With each transfer, the speed is
significantly reduced.

In a compound gear, all gears are fixed on the same axel moving at the same speed. This
is an example of a “compound gear train”. Gear A rotates in a clockwise direction at 30
revs/min. What is the output in revs/min at D and what is the direction of rotation ?

Worm Gear

If you want to create a high gear ratio, nothing beats the worm gear. In a worm gear, a
threaded shaft engages the teeth on a gear. Each time the shaft spins one revolution, the
gear moves one tooth forward. If the gear has 60 teeth, you have a 60:1 gear ratio in a
very small package. Below these words, a worm gear representation.
Gear and belt

The advantages of chains and belts are their light weight, their ability to separate the
two gears by some distance, and their ability to connect many gears together on the
same chain or belt. Above, you can see some toothed belt connecting the axel motor to
other components of the car engine

Gear wheels and chains

Everyone has used a bicycle and noticed that it is driven by a large driver gear wheel
(pedal gear) with pedals attached. Smaller gears at the back are driven round, in turn
driving round the back wheel. As the back wheel turns the bicycle moves forwards.
Gears driven by chains are used in motorcycles, in car engines, etc
Rack and pinion

The rack and pinion gear system allows rotary motion of the steering wheel to be
converted to linear motion.
Cams
A cam is a shaped piece of metal or plastic fixed to a rotating shaft. A cam
mechanism has three parts: cam, slide and follower.

The cam shaft rotates continually, turning the cam. The follower is a bar that rests on
the edge of the turning cam. The follower is free to move up and down, but is
prevented from moving from side to side by a slide or guide, so the follower can only do
three things:

1. Rise (move up)

2. Fall (move down) or
3. Dwell (remain stationary)

The follower's pattern of movement depends on the profile or outside edge of the cam
that it follows. If the cam is perfectly round and the fixed shaft is in the centre of the
cam, the follower will dwell. But if the cam is a different shape, and/or the shaft is not
central, the follower will rise or fall. How often and how quickly the follower moves is
determined by the shape of the cam and the position of the shaft.

• Cams come in many different shapes - for example pear-shaped,

triangular or square.
• The cam may have a portion or portions removed, so that the follower
falls into a gap and is then is pushed out again.
• Whatever the shape of the cam, positioning the shaft off-centre will alter
the behavior of the follower.

Pear-shaped cam
The pear shape of this cam means that for half the cycle, the follower will dwell. Then,
as the pointed part of the cam advances, the follower is pushed up (rises), then, as the
point passes, falls and dwells - and the cycle starts again.
Eccentric cam
The eccentric cam is perfectly circular, but the rotating shaft is off-centre, which affects
how it turns. This type of cam produces a smooth, symmetrical rise and fall motion in
the follower, which never pauses to dwell.

Drop cam
With a drop cam the shaft is central in a perfectly round cam, which has a portion
removed. The follower will dwell for most of the cycle, until it suddenly falls into the
removed section, then rises again as the cam regains its circular shape.

Note that if the size of the cut-out portion was larger or the incline smoother, the
follower would behave differently.