ABSTRACT

This system or method for precisely controlling lubricant supply to one

or more rotating mechanical gear parts in machines. The pump draws lubricant
form a lubricant source and supplies it to a rotating machine. This system is
automated by means of a timer device. The sequential time is controlled by
using microcontroller, which is fed by a programming language. The time
interval can be varied by a controller. Self lubricating system is used to reduce
the noise produced inside the machine and to achieve the efficient work.

This system reduces manual errors and prevent from major accidents
while lubricating on the complicated machines. It typically delivers a
controlled amount of lubricant (oil) to multiple, specific locations on a
machine while the machine is operating, at specific times from a central
location. Self lubrication systems offer superior features than manual
lubrication. The benefits of self lubrication include less downtime due to
bearing failure, reduced man-hours required for the lubrication task, and
increased worker safety, as well as reduced lubricant and cleanup costs.
 CHAPTER1
INTRODUCTION
Machines produce more heat and noise due to the motion of rotating and
reciprocating parts. Lubrication will minimize the noise produced by the
machine components. Lubrication systems and equipment are essential
components of manufacturing and industrial machinery and technology. To
ensure reliable and efficient operation of such equipment, these moving parts
often need a constant supply of lubricating fluids, and the lubrication system is
able to provide this at the proper temperature, viscosity, flow rate and pressure.
Lubrication allows smooth continuous operation of equipment, with only mild
wear, and without excessive stresses or seizures at bearings. When lubrication
breaks down, metal or other components can rub destructively over each other,
causing destructive damage, heat, and failure. The most important components
of a lubricating system are the reservoir, pump and filter. The reservoir is the
area in which the lubricant is stored after coming back from the area it
lubricates. The pump is used to move the lubricant through the system and into
areas that need to be lubricated.

OBJECTIVES
 To fabricate the self lubricating setup with timer circuit

To lubricate the complicated machine components

CHAPTER2
LITERATURE REVIEW
Nathan E. McIntire and Zelma M. Porter proposed on automatic
lubrication system. An automatic lubrication system for conveyors and the like,
said system comprising means for initiating a lubrication cycle whereby a
lubricant agitator and pump are sequentially actuated to deliver lubricant to a
dispensing passageway, a timer and relay arrangement effective to open a
lubrication solenoid valve to permit a quantity of lubricant to flow into the
dispensing passageway and subsequently open a gas solenoid valve to blow gas
through the passageway and expel substantially all of the lubricant there from
onto the member being lubricated, in such a manner that dripping of the excess
lubricant or clogging of the passageway is eliminated.

Richard W.dochterman and Fort Wayne were invented the lubrication

system for electric machine. A lubrication system which serves both to lubricate
bearings and to occlude the primary airflow path through a machine. The
system includes a capillary seal (spaced apart plates with or without wick
material there between) serving both as a capillary air seal and as portion of
lubricant transfer path. This system is especially effective to support a pressure
differential across an electric motor. This invention relates generally to
lubrication systems for bearing supported shaft members , and more particularly
to improved air sealing lubrication systems for supplying lubricant to the
bearing journaling surfaces in electric machines while also preventing air flow
there –through .

In current refrigeration systems having at least one refrigerated

compartment and a compartment open to the ambient area and housing such
systems components as a condenser and compressor, a motor driven fan is
usually mounted in each compartment for purposes of circulating air. In such
systems, it has been the practice to mount a separate motor and fan within each
compartment.

In order to reduce cost and yet retain the air circulation benefits, it is quit
desirable to use only one motor to drive a number of fans since this obviously
will cost less than a separate motor for each fan. It is also desirable in order to
accomplish this end that this one motor be

mounted exteriorly of the refrigerated compartment so that motor heat will not
be introduced in to the refrigerated compartment during operation of the motor.

However, this approach introduces certain difficulties since there is a

pressure differential between the interior of a refrigerated compartment and the
ambient area about the compartment. Thus, when a refrigerated compartment is
cooled, the pressure and the temperature in the compartment are lowered, and a
pressure differential is created between the compartment and the surrounding
area such an s the room or the condenser compartment. It is well known that in
commercial refrigerator units for example, pressure differentials ranging
between three and six inches of water occur during at least the first portion of
the each cooling cycle. Normal leakage through the door seal, electrical conduit
openings etc, equalizes the pressure within and without the refrigerated
compartment after some period of time.

It would be desirable to place externally mounted fan motor in sealed

engagement within an opening in the wall of a refrigerated compartment with
the motor shaft extending through the opening into the compartment for
mounting the fan with the shaft also being accessible in order to drive a second
fan in another compartment.

However, if there is an air flow path through the motor, relatively warm,
moist ambient air will be drawn through the motor into the refrigerated
compartment due to the initial pressure differential across the motor. this air
flowing through the motor into the compartment deposits it’s moisture on to the
first cold object it conducts, which is the motor shaft, fan blades, fan enclosure
is will results in ice forming on the shaft and blades and the motor may then
over load and eventually burn out, damage to the motors used in this application
is especially undesirable as this motors are normally mounted in relatively
inaccessible locations and thus are difficult to repair and replace.
 I have found that the usual fan motor is unacceptable for the discussed
application as it will not support a pressure differential without at least some air
leakage. The primary path of air flowing through the usual totally enclosed fan
motor when it is mounted across a pressure differential occurs in the bearing
lubrication system.
Accordingly it would be highly desirable to provide a fan motor which
may be mounted externally of a refrigerated compartment in communication
both with the interior of the compartment and with the surrounding locations
such as the room in which the refrigeration apparatus is present or the
compressor compartment. In this regard, it would be advantageous to provide
an inexpensive fan motor having a highly dependable air sealing lubrication
system which prevents air flow through the motor and especially through the
primary air flow path of the motor.

It is therefore, a general object of this invention to provide an electric

machine having a lubrication system which alleviates the problems and
incorporates the desired result mentioned above. It is a more specific object of
the present invention to provide an improved lubrication system for an electric
machine having a bearing supported rotatable shaft which incorporates an air
flow sealing arrangement for occluding the primary air flow path through the
machine.

A further object of the present invention is the provision of a capillary

sealed lubrication arrangement for an electric machine which is inexpensive to
produce and highly dependable in operation, and which nonetheless provides
adequately controlled lubricant feed to the motor bearing shaft area.
 Hermann Werner, Erich Lessol and Burkard Mueller were invented the
bicycle dynamo having a rotary-current generator. Bicycle dynamo having a
rotary-current generator having stator and a rotator which can be rotated relative
to the stator. The stator or the rotor has radially extending pole fingers which
are wound individually with one surrounding magnetic coil winding
respectively. The ratio of the number of poles of the rotor to the number of
poles of the stator is a non-integer value, this permits the implementation of a
bicycle dynamo of a high efficiency event at a relatively low riding speed,
which may be used, for an example, to power bicycle lighting systems.

Cheng-Hsien Wu and Yu-Tai Kung proposed journal of a parametric

study on oil/air lubrication of a high-speed spindle. The ball-bearing is widely
used on many high-speed spindles due to its low starting friction and high load
capacity. However, heat generation and dynamic loading caused by high-speed
rotation have been obstacles for increasing the speed

limit in many high-speed ball-bearing applications. Applying an appropriate

lubrication and preload cannot be overemphasized. Recently, oil/air lubrication
has been used on high-speed spindles because of its accuracy in oil quantity
control and high cooling efficiency. However, an oil/air supply with inadequate
parameters is undesirable. In this study, the performance of a high-speed
spindle under different lubrication parameters and preloads was investigated.
The Taguchi method was applied to study the effects of design parameters on
the lubrication efficiency. This method can also be used to obtain the optimum
lubrication conditions. The optimum operating conditions that create the
smallest temperature increase were established. The effects of preload on the
temperature increase, the thermal deformation and the static stiffness of an
oil/air lubricated spindle were studied. The results provide a useful tool in
designing a high-speed spindle with a small increase in temperature and
sufficient static stiffness.

James C. Gwynn proposed paper on programmable electronic timer

circuit. A programmable timer circuit includes a counter that contains a
plurality of sequentially arranged counter stages. A toggle logic gate is disposed
between each sequential pair of counter stage to accept the output signal from
the preceding stage and to the input signal from the preceding stage and to issue
an input signal to the succeeding counter stage. The logic state of the input
signal is determined by the logic state of the program signal is determined by
the state of a fuse associated with the program stage. The logic state of the
program signal is determined by the state of a fuse associated with the program
stage. Selected fuses can be blown by a programming routine to adjust the time
delay between the initiation signal and issuance of the output signal. This sets
the counter stages at power-up to a predetermined logic state in which the
output signal will be produced with a predetermined time delay when the
initiation signal is applied to the integrated circuit. The program routine
includes activating the counter stages that will be active at the desired count and
issuing a programming signal to burn the fuse associated with the active counter
stage.
 CHAPTER 3
PROBLEM DESCRIPTION
In some major industries, machine runs continuously for their production.
Due to continuously running process of machines leads to more tear and wear.
For this problem, some industries employed labours to lubricate the machine.
Manual lubrication typically produces inconsistent lubrication. The uneven
lubrication cycle leads to wasted lubricant and allows contaminants to enter the
bearing – producing premature wear. Even though labours are equipped with
safety features, during manual lubrication many accidents are happened in
industries. Many machines are dangerous to lubricate while running. Under
lubrication will cause bearing damage and premature failure.

This project describes a fabrication of self lubrication system which

automated by timer that works by dynamo. Dynamo gets power by rotational
motional for ac motor which is coupled with belt.

Benefits of an Automatic Lubrication System

All critical components are lubricated, regardless of location or ease of access

Lubrication occurs while the machinery is in operation causing the lubricant to

be

equally distributed within the bearing and increasing the machine’s availability

Less wear on the components means extended component life, fewer

breakdowns, reduced downtime, reduced replacement costs and reduced
maintenance costs
Safety - no climbing around machinery or inaccessible areas
 CHAPTER 4

FABRICATION OF EXPERIMENTAL SETUP

The experimental apparatus of our project consists of major parts like ac

motor, dynamo, pump, sump, timer circuit and rechargeable battery. First of all
the materials were brought to fabricate the ac motor and dynamo, and then the
major parts of the system that is pump, timer circuit and rechargeable battery.
The whole experimental setup made into rectangular steel frame with supported
bars.

AC motor is mounted on the steel frame and in other end dynamo is

mounted. The top surface of the steel frame is covered by sheet metal where
other components like timer circuit and pump are placed on it. Sump contains
lubricating oil, which placed in bottom of steel frame.

For our convenience, we have used AC motor of 1440 rpm converted to

dynamo by means of belt. Dynamo produces 5V ac voltage which is used for
timer circuit. With programmed microcontroller, which performs further
operations based upon the preset value. Thus relay gets activated by the signal
instructed from the timer. Based the relay function, pump gets power supply
from rechargeable battery. Whereas pump draws lubricating oil from sump to
supply on gear parts which needs to be lubricate.
 11

LAYOUT DESCRIPTION

Dynamo produces electric energy by rotation motion of AC motor.

Power produced by dynamo used to run the timer circuit. Relay switch is
activated by timer circuit which incorporates microcontroller. Relay switch is
placed between the rechargeable battery and pump. Lubricating oil can be
pumped from sump and distributed to varies complicated components of
machines.

To lubricating
parts

MAIN DYNAMO
TIMER
MOTOR CIRCUIT

RECHARGABLE
RELAY PUMP
BATTERY

SUMP
(Lubricating Oil)
 12

AC MOTOR
AC Motor’s Principle and Working
The standard definition for an AC Motor is an electric motor that is
driven by alternating current. The AC Motor is used in the conversion of
electrical energy into mechanical energy. This mechanical energy is made from
utilizing the force that is exerted by the rotating magnetic fields produced by the
alternating current that flows through its coils. The AC Motor is made up of two
major components: the stationary stator that is on the outside and has coils
supplied with AC current, and the inside rotor that is attached to the output
shaft.

The fundamental operation of an AC Motor relies on the principles of

magnetism. The simple AC Motor contains a coil of wire and two fixed
magnets surrounding a shaft. When an electric (AC) charge is applied to the
coil of wire, it becomes an electromagnet, generating a magnetic field. Simply
described, when the magnets interact, the shaft and the coil of wires begin to
rotate, operating the motor.

Figure 4.2 Rotor Magnets interaction with Stator

 13

AC Motor Feedback

AC Motor products have two options for feedback controls. These

options are either an AC Motor resolver or an AC Motor encoder. Both the AC
Motor resolver and the AC Motor encoder can sense direction, speed, and the
position of the output shaft. While both the AC Motor resolver and AC Motor
encoder offer the same solution in multiple applications, they are greatly
different.

AC Motor resolvers use a second set of stator coils called the transformer
to provoke rotor voltages across an air gap. Since the resolver lacks electronic
components, it is very rugged and operates over a large temperature range. The
AC Motor resolver is also naturally shock resistant, due to how it is designed.
The resolver is often used in harsh environments.

The type of application will establish whether a resolver or an encoder is

desired. AC Motor encoders are easier to implement and more precise, so they
should be the primary preference for any application. A resolver should only be
chosen if the environment in which it will be used requires it.

Basic types of an AC Motor

The AC Motor comes in three different types known as Induction,

Synchronous, and Industrial. These AC Motor types are determined by the rotor
design used in the construction. Anaheim Automation carries all three types in
its product line.

Induction AC Motor

Induction AC Motor is referred to as asynchronous motors or rotating

transformers. This type of AC Motor uses electromagnetic induction to power
the rotating device which is usually the shaft. The rotor in Induction AC Motor
 14
products typically turns slower than the frequency that is supplied to it. Induced
current is what causes the magnetic field that envelops the rotor of these
motors. This Induction AC Motor is designed in one or three phases.

Synchronous AC Motor

The Synchronous Motor is typically an AC Motor that has its rotor

spinning at the same rate as the alternating current that is being supplied to it.
The rotor can also turn at a sub multiple of the current it is supplied. Slip rings
or a permanent magnet supplied with current is what generates the magnetic
field around the rotor.

Industrial AC Motor

Industrial AC Motors are designed for applications requiring a three-

phase, high- power induction motor. The power ratings of an industrial motor
exceed those of a standard single-phase AC induction motor. Anaheim
Automation offers Industrial AC Motors from 220W to 2200W, in 3-Phase
operation at 220VAC or 380VAC.

Applications

AC Motors are primarily used in domestic applications due to their

relatively low manufacturing costs, and durability, but are also widely used in
industrial applications.
 15
They can also be found in industrial applications:

 Pumps

 Blowers

 Conveyors

 Compressors

Advantages of an AC Motor

 Low Cost

 Long Lifespan

 High-Efficiency and Reliability

 Simple Construction

 High Starting Torque (Induction)

 No Slip (Synchronous)

Disadvantages of an AC Motor

 Frequency Causes Rotation Slips (Induction)

 Starting Switch Needed (Induction)

 16

Grinder Motor

Figure 4.3 AC Motor

Capacity: 0.5 HP

Speed: 1440 RPM

Phase: Single Phase

 17

Features

Stampings: Stator consists of thin lamination of high quality low core

loss silicon steel
Copper Wire: Super enamel insulated high conductivity copper wire
of an ISO 9002 company
Rotor: Dynamically balanced pressure die cast rotor for complete
vibration free operation
Shaft: High graded mild steel machined and centrelex grinding to close
tolerance.

Insulation: Class B insulation specially treated to withstand a

maximum temperature of 120°C.
Bearings: Sealed ball bearings are used at both ends to ensure smooth running.
 18

DYNAMO

A dynamo is an electrical generator that produces direct current with use

of commutator. It converts mechanical power to electrical power. It converts the
mechanical motion of the driven wheel into electrical energy, with the aid of a
magnet. A dynamo is an electrical generator that produces direct current with
the use of a commutator. Dynamos were the first electrical generators capable
of delivering power for industry, and the foundation upon which many other
later electric-power conversion devices were based, including the electric
motor, the alternating-current alternator, and the rotary converter. Today, the
simpler alternator dominates large scale power generation, for efficiency,
reliability and cost reasons. A dynamo has the disadvantages of a mechanical
commutator. Also, converting alternating to direct current using power
rectification devices (vacuum tube or more recently solid state) is effective and
usually economic.

In electricity generation, an electric generator is a device that converts

mechanical energy to electrical energy. A generator forces electric charge
(usually carried by electrons) to flow through an external electrical circuit. The
source of mechanical energy may be a reciprocating or turbine steam engine,
water falling through a turbine or waterwheel, an internal combustion engine, a
wind turbine, a hand crank, compressed air, or any other source of mechanical
energy.
 19

The reverse conversion of electrical energy into mechanical energy is

done by an electric motor, and motors and generators have many similarities.
Many motors can be mechanically driven to generate electricity and frequently
make acceptable generators.

Working

It converts the mechanical motion of the driven wheel into electrical

motion, with the aid of a magnet. Many scientists say that the full circle of
energy that keeps the world spinning, grows crops, and paints the sky with the
Aurora Borealis, begins and ends with magnetism that the sun’s rays are
magnetic rays. Magnetism is the force that keeps the compass needle pointing
north and south. Take a steel rod and hold it along the north and south line,
slightly inclined towards the earth, and strike it a sharp blow with a hammer,
and it becomes a magnet feeble, it is true, but still a magnet.
Armatures

This experiment gives the theory of the dynamo. Instead of passing only
one wire through the field of force of a magnet, we have hundreds bound
lengthwise on a revolving drum called an armature. Instead of one magnetic
pole in a dynamo we have two, or four, or twenty according to the work the
machine is designed for always in pairs, a North pole next to a South pole, so
that the lines of force may flow out of one and into another, instead of escaping
in the surrounding air.
 20

Figure 4.4 Armature winding in Dynamo

If we could see these lines of force, they would appear in countless

numbers issuing from each pole face of the field magnets, pressing against the
revolving drum like hair brush bristles trying to hold it back. This drum, in
practice, is built up of discs of annealed steel, and the wires extending
lengthwise on its face are held in place by slots to prevent them from flying off
when the drum is whirled at high speed. The drum does not touch the face of
the magnets, but revolves in an air space.

If we give the electric impulses generated in these wires a chance to flow

in a circuit flow out of one end of the wires, and in at the other, the drum will
require more and more power to turn it, in proportion to the amount of
electricity we permit to flow. Thus, if one electric light is turned on, the drum
will press back with certain strength on the water wheel; if one hundred lights
are turned on it will press back one hundred times as much. Providing
 21

there is enough power in the water wheel to continue turning the drum at its
predetermined speed, the dynamo will keep on giving more and more electricity
if asked to, until it finally destroys itself by fire.

We cannot take more power, in terms of electricity, out of a dynamo that

we put into it, in terms of mechanical motion. In fact, to insure flexibility and
constant speed at all loads, it is customary to provide twice as much water
wheel, or engine, power as the electrical rating of the dynamo.

Bicycle Dynamo Specification

The max diameter of the dynamo body is: 40.5mm, the longest length of
the main body is: 94.5mm. Maximum Output: 12V

Figure 4.5 Dynamo

 22

Components of Dynamo

1. Friction roller 6. Coil

2. The dynamo body 7. Wrench

3. Magnetic steel 8. Lug plate

4. Winding support 9. Rear Cover

5. Spring housing
 23

12V DC PUMP

This is a brushless DC motor-driven centrifugal pumps, use special

design closed impeller. Main features: High water head, moderate flow rate,
long life (use fine ceramic bearing), continues work, low noise, stable
performance.

Figure 4.6 12V DC Pump

Pump chamber and the motor is absolutely isolated, magnetic drive

technology can be guaranteed no leak forever, completely avoid the
presence of traditional DC motor pumps' liquid leakage. If the mining
epoxy resin package, you can completely and totally waterproof
diving use.
Brushless motor circuit design optimization using a large movement
of low- temperature, stable performance, long life. Closed impeller
simple structure, with less water loss, pump output high efficiency,
can effectively enhance higher water head.
Impeller/rotor shaft with ceramic materials, enhance the wear
resistance, high accuracy, precision with resistance to shock, to extend
the life of the pump. Bearing sleeve with graphite self-lubricating
 24
properties, reduce noise at work. Low noise down to 35dB, smaller
consumption pump even down to 30 decibels, almost silent operation.
Pump chamber seal can withstand 5 bar pressure without leakage.
Each pump in the production line has to go through stress tests, which
can effectively prevent the leakage of product defects.

Pump uses high-strength engineering plastics, PPS PPE, PA66, etc.,

can be used for hot water circulation, strong endurable capacity,
resistance to weak acid corrosion. Can be recycled with a small
impurity of the liquid; do not plug the pump chamber.

Table 4.1 12V DC Pumps Specification

No Items Specifications
.
1 Sizes and weight 83x63x48; 250g
2 Dimension of inlet 5mm
3 Dimension of outlet 6mm
4 Driving method Brushless, Magnetic , 2 phase or 3 phase
5 Pump material PA66+GF30% (optional)
6 Condition of use Continuously
7 Fluids Water, oil, gasoline, acid and alkali solution etc
8 Max working temp 60 degree (2 phase)or 100 degree (3 phase)
9 Power consumption 2.5W~26.4W
10 Rated voltage 12Vdc
11 Voltage used 5Vdc ~ 12Vdc
12 Max rated current 1.2A
13 Power supply Solar panel; DC electric source; battery

Features
 25

1. Durable magnetic rotor and ceramic /stainless steel shaft

2. Long life brushless pump, ideal life for 30000 hours

3. Low noise: ≤ 42dB far from 1m distance

4. Low or no maintenance

5. Low power consumption

Applications

1. Circulation system

2. Solar energy panel

3. Aquarium

4. Cooling system

5. Water heater and so on

 26

Limitations

1. Power to DC Power Supply, reverse polarity is strictly prohibited,

generally red positive power supply, black to negative.
2. Pumps in addition to immersible work can be identified, the rest cannot
be immersed in water, or they will cause a short circuit burned.
3. Pumps is prohibited by the strong shock, fall from a height on the ground
and other external damage.
4. Pumps cannot take strong acid and other corrosive liquids and granular
solids with a tiny hard.
5. Pumps were not long-time stall, causing the motor burned.

6. Pumps cannot withstand high voltage shock.

RECHARGEBLE BATTERY

The rechargeable batteries are lead-lead dioxide systems. The dilute

sulfuric acid electrolyte is absorbed by separators and plates and thus
immobilized. Should the battery be accidentally overcharged producing
hydrogen and oxygen, special one-way valves allow the gases to escape thus
avoiding excessive pressure build-up. Otherwise, the battery is completely
sealed and is, therefore, maintenance-free, leak proof and usable in any
position.
 27

Figure 4.7 Rechargeable Battery

Specification

Voltage: 6V

Capacity: 4ah

Dimensions (mm): 70(L)*45(W)*99(H)*104(TH)

Approx Weight (Kgs): 0.7

 28

Application

Power: Electric tools, toys, portable suction fans, Robots, electric bicycle

Speakers: Insert earphones, cassette decks, portable CD players

Video: Cameras, portable TV sets, lap-tops

Correspondence: Car telephone, mobile system, portable radio transmitter

Survey: Measuring instruments

Medical treatment: Blood-pressure meters, electric wheelchairs

 29

SUMP

The oil is used to lubricate the machine's moving parts and it pools in a
reservoir, known as a sump. Use of a sump requires the engine to be mounted
slightly higher to make space for it. Often though, oil in the sump can surge
during hard cornering starving the oil pump.

LUBRICATING OIL
Motor Oil
Motor oil or engine oil is an oil used for lubrication of various internal
combustion engines. The main function is to lubricate moving parts; it also
cleans, inhibits corrosion, improves sealing, and cools the engine by carrying
heat away from moving parts. Motor oils are derived from petroleum-based and
non-petroleum-synthesized chemical compounds.

Figure 4.8 Motor Oil

 30

Motor oils today are mainly blended by using base oils composed of
hydrocarbons, polyalphaolefins (PAO), and polyinternal olefins (PIO), thus
organic compounds consisting

entirely of carbon and hydrogen. The base oils of some high-performance motor
oils however contain up to 20% by weight of esters.

Uses

Motor oil is a lubricant used in internal combustion engines. These

include motor or road vehicles such as cars and motorcycles, heavier vehicles
such as buses and commercial vehicles, non-road vehicles such as go-karts,
snowmobiles, boats (fixed engine installations and outboards), lawn mowers,
large agricultural and construction equipment, locomotives and aircraft and
static engines such as electrical generators. In engines, there are parts which
move against each other causing friction which wastes otherwise useful power
by converting the energy to heat. Contact between moving surfaces also wears
away those parts, which could lead to lower efficiency and degradation of the
engine. This increases fuel consumption, decreases power output and can lead
to engine failure.

Lubricating oil creates a separating film between surfaces of adjacent

moving parts to minimize direct contact between them, decreasing heat caused
by friction and reducing wear, thus protecting the engine. In use, motor oil
transfers heat through convection as it flows through the engine by means of air
flow over the surface of the oil pan,
 31

oil cooler and through the buildup of oil gases evacuated by the Positive
Crankcase Ventilation (PCV) system. In petrol (gasoline) engines, the top
piston ring can expose the motor oil to temperatures of 160 °C (320 °F). In
diesel engines the top ring can expose the oil to temperatures over 315 °C (600
°F). Motor oils with higher viscosity indices thin less at these higher
temperatures.

Coating metal parts with oil also keeps them from being exposed to
oxygen, inhibiting oxidation at elevated operating temperatures preventing rust
or corrosion. Corrosion inhibitors may also be added to the motor oil. Many
motor oils also have detergents and dispersants added to help keep the engine
clean and minimize oil sludge build-up. The oil is able to trap soot from
combustion in itself, rather than leaving it deposited on the internal surfaces. It
is a combination of this, and some singeing that turns used oil black after some
running.
 32

Rubbing of metal engine parts inevitably produces some microscopic

metallic particles from the wearing of the surfaces. Such particles could
circulate in the oil and grind against moving parts, causing wear. Because
particles accumulate in the oil, it is typically circulated through an oil filter to
remove harmful particles. An oil pump, a vane or gear pump powered by the
engine, pumps the oil throughout the engine, including the oil filter. Oil filters
can be a full flow or bypass type.

However, in modern designs, there are also passageways through the rods
which carry oil from the rod bearings to the rod-piston connections and
lubricate the contacting surfaces between the piston rings and interior surfaces
of the cylinders. This oil film also serves as a seal between the piston rings and
cylinder walls to separate the combustion chamber in the cylinder head from the
crankcase. The oil then drips back down into the oil pan. Motor oil may also
serve as a cooling agent. In some constructions oil is sprayed through a nozzle
inside the crankcase on the piston to provide cooling of specific parts that
underly high temperature strain. On the other hand the thermal capacity of the
oil pool has to be filled up, i.e. the oil has to reach its designed temperature
range until it can protect the engine under high load. This typically takes longer
than heating the main cooling agent - water or mixtures thereof - up to its
operating temperature.
 33

Non-Vehicle Motor Oils

An example is lubricating oil for four-stroke or four-cycle internal

combustion engines such as those used in portable electricity generators and
"walk behind" lawn mowers. Another example is two-stroke oil for lubrication
of two-stroke or two-cycle internal combustion engines found in snow blowers,
chain saws, model airplanes, gasoline powered gardening equipment like hedge
trimmers, leaf blowers and soil cultivators. Often, these motors are not exposed
to as wide service temperature ranges as in vehicles, so these oils may be single
viscosity oils.

In small two-stroke engines, the oil may be pre-mixed with the gasoline
or fuel, often in a rich gasoline: oil ratio of 25:1, 40:1 or 50:1, and burned in use
along with the gasoline. Larger two-stroke engines used in boats and
motorcycles will have a more economical oil injection system rather than oil
pre-mixed into the gasoline. The oil injection system is not used on small
engines used in applications like snowblowers and trolling motors as the oil
injection system is too expensive for small engines and would take up too much
room on the equipment. The oil properties will vary according to the individual
needs of these devices. Non-smoking two-stroke oils are composed of esters or
polyglycols. Environmental legislation for leisure marine applications,
especially in Europe, encouraged the use of ester- based two cycle oil.
 34

Properties

Most motor oils are made from a heavier, thicker petroleum hydrocarbon
base stock derived from crude oil, with additives to improve certain properties.
The bulk of typical motor oil consists of hydrocarbons with between 18 and 34
carbon atoms per molecule.[6] One of the most important properties of motor
oil in maintaining a lubricating film between moving parts is its viscosity. The
viscosity of a liquid can be thought of as its "thickness" or a measure of its
resistance to flow. The viscosity must be high enough to maintain a lubricating
film, but low enough that the oil can flow around the engine parts under all
conditions. The viscosity index is a measure of how much the oil's viscosity
changes as temperature changes. A higher viscosity index indicates the
viscosity changes less with temperature than a lower viscosity index.
 35

Oil is largely composed of hydrocarbons which can burn if ignited. Still

another important property of motor oil is its flash point, the lowest temperature
at which the oil gives off vapors which can ignite. It is dangerous for the oil in a
motor to ignite and burn, so a high flash point is desirable. At a petroleum
refinery, fractional distillation separates a motor oil fraction from other crude
oil fractions, removing the more volatile components, and therefore increasing
the oil's flash point (reducing its tendency to burn).

Another manipulated property of motor oil is its Total Base Number

(TBN), which is a measurement of the reserve alkalinity of an oil, meaning its
ability to neutralize acids. The resulting quantity is determined as mg KOH/
(gram of lubricant). Analogously, Total Acid Number (TAN) is the measure of
a lubricant's acidity. Other tests include zinc, phosphorus, or sulfur content, and
testing for excessive foaming.

The NOACK volatility (ASTM D-5800) Test determines the physical

evaporation loss of lubricants in high temperature service. A maximum of 15%
evaporation loss is allowable to meet API SL and ILSAC GF-3 specifications.
Some automotive OEM oil specifications require lower than 10%.
 36

Grades

The Society of Automotive Engineers (SAE) has established a numerical

code system for grading motor oils according to their viscosity characteristics.
SAE viscosity grading includes the following, from low to high viscosity: 0, 5,
10, 15, 20, 25, 30, 40, 50 or
60. The numbers 0, 5, 10, 15 and 25 are suffixed with the letter W, designating
their “winter” (not "weight") or cold-start viscosity, at lower temperature. The
number 20 comes with or without a W, depending on whether it is being used to
denote a cold or hot viscosity grade. The document SAE J300 defines the
viscometrics related to these grades.

Kinematic viscosity is graded by measuring the time it takes for a

standard amount of oil to flow through a standard orifice, at standard
temperatures. The longer it takes, the higher the viscosity and thus higher SAE
code. The SAE has a separate viscosity rating system for gear, axle, and manual
transmission oils, SAE J306, which should not be confused with engine oil
viscosity. The higher numbers of a gear oil (e.g., 75W-140) do not mean that it
has higher viscosity than an engine oil.
 37

TIMER CIRCUIT

Timer circuit will create and maintain the on and off time delay to do the
specific job or task. The sequential time is controlled by using microcontroller,
which is fed by a programming language. The time interval can be varied by
push type switches in circuit. Timer circuit consists of general circuit elements
like capacitors, diode, resistor, voltage regulator, LCD display, microcontroller
and relay.
Initially the power produced from dynamo is rectified using a rectifier
and output supplied to microcontroller. Microcontroller is then control the
signal to actuate the pump using relay switch. LCD displays OFF and ON time,
and changes can be performed by push type switches. LCD displayed by
additional power. By setting the value, OFF TIME tends to work the pump and
ON TIME tends to delay interval for further operations. While off timing
condition, power supplies from rechargeable battery to pump by means of relay
circuit.
 38

Microcontroller

A micro controller is an integrated circuit or a chip with a processor and

other support devices like program memory, data memory, I/O ports, serial
communication interface etc integrated together. Unlike a microprocessor (ex:
Intel 8085), a microcontroller does not require any external interfacing of
support devices. Microcontrollers are usually dedicated devices embedded
within an application. Since microcontrollers are powerful digital processors,
the degree of control and programmability they provide significantly enhances
the effectiveness of the application. The 8051 is the first microcontroller of the
MCS-51 family introduced by Intel Corporation at the end of the 1970s. The
timer function is one of the basic features of a microcontroller. Although some
compilers provide simple macros that implement delay routines, in order to
determine time elapsed and to maximize use of the timer, understanding the
timer functionality is necessary.

Figure 4.10 8051 Microcontroller

 39
Applications

Microcontrollers are used in products that are controlled automatically. The

various products that make use of microcontrollers in our everyday life are
given below:
Home: Television, DVD player, Telephone, Fax machine, Cellular
phones, Security systems, Camera, Sewing machine, Musical Instrument,
Exercising machine, Video games, Computer, Microwave oven.
Office: Computers, Printers, Telephones, Fax machine, Security systems.
 40

Capacitors

The capability of a capacitor to store electricity is known as capacitance

of that capacitor. It is denoted by C. The measuring unit of capacitance is Farad,
but Farad is very large unit. Its smaller units are Kilo Micro Farad (KMFD),
Micro Farad (MFD), Kilo Pico Farad (KPF) or Nano Farad (NF) and Pico Farad
(PF).

Applications

Its function is to store the electrical energy and give this energy again to
the circuit when necessary. In other words, it charges and discharges the electric
charge stored in it. Besides this, the functions of a capacitor are as follows:

It blocks the flow of DC and permits the flow of AC.

It is used for coupling of the two sections.

It bypasses (grounds) the unwanted frequencies.

It feeds the desired signal to any section.

It is used for phase shifting.

It is also used for creating a delay in time.

It is used as motor starter.

 41

Resistor

A resistor is a two-terminal electrical or electronic component that resists

the flow of current, producing a voltage drop between its terminals in
accordance with Ohm's law. The electrical resistance is equal to the voltage
drop across the resistor divided by the current that is flowing through the
resistor.

Working of Resistor

The working of a resistor can be explained with the similarity of water

flowing through a pipe. Consider a pipe through which water is allowed to
flow. If the diameter of the pipe is reduced, the water flow will be reduced. If
the force of the water is increased by increasing the pressure, then the energy
will be dissipated as heat. There will also be an enormous difference in pressure
in the head and tail ends of the pipe. In this example, the force applied to the
water is similar to the current flowing through the resistance. The pressure
applied can be resembled to the voltage.
 42

Applications

Resistors are used as part of electrical networks and electronic circuits.

All resistors dissipate heat. This is the principle behind electric heaters.

In general, a resistor is used to create a known voltage-to-current ratio in

an electric circuit. If the current in a circuit is known, then a resistor can
be used to create a known potential difference proportional to that
current. Conversely, if the potential difference between two points in a
circuit is known, a resistor can be used to create a known current
proportional to that difference.
 43

4.8.4 Diode

A diode is the simplest two-terminal unilateral semiconductor device. It

allows current to flow only in one direction and blocks the current that flows in
the opposite direction. The two terminals of the diode are called as anode and
cathode.

4.8.4.1 Working of Diode

The diode operates when a voltage signal is applied across its terminals.
The application of a DC voltage to make the diode operate in a circuit is called
as ‘Biasing’. As already mentioned above the diode resembles to that of a one
way switch so it can either be in a state of conduction or in a state of non
conduction. The ‘ON’ state of a diode is achieved by ‘Forward biasing’ which
means that positive or higher potential is applied to the anode and negative or
lower potential is applied at the cathode of the diode
 44

8.4.2 Applications

Rectification – The rectification means converting AC voltage into DC voltage.

Clipper- Diode can be used to clip off some portion of pulse without
distorting theremaining part of the waveform.
Clamper – A clamping circuit restricts the voltage levels to exceed a limit
by shifting the DC level. The peak to peak is not affected by clamping.
Diodes with resistors and capacitors are used to make clamping circuits.
Sometimes independent DC sources can be used to provide additional
shift.
 30

4.8.5 Relay

Relay is an electromagnetic device which is used to isolate two circuits

electrically and connect them magnetically. They are very useful devices and
allow one circuit to switch another one while they are completely separate.
They are often used to interface an electronic circuit (working at a low voltage)
to an electrical circuit which works at very high voltage. For example, a relay
can make a 5V DC battery circuit to switch a 230V AC mains circuit. Thus a
small sensor circuit can drive, say, a fan or an electric bulb. A relay switch can
be divided into two parts: input and output. The input section has a coil which
generates magnetic field when a small voltage from an electronic circuit is
applied to it.
This voltage is called the operating voltage. Commonly used relays are
available in different configuration of operating voltages like 6V, 9V, 12V, 24V
etc. The output section consists of contactors which connect or disconnect
mechanically. In a basic relay there are three contactors: normally open (NO),
normally closed (NC) and common (COM). At no input state, the COM is
connected to NC. When the operating voltage is applied the relay coil gets
energized and the COM changes contact to NO. Different relay configurations
are available like SPST, SPDT, DPDT etc, which have different number of
changeover contacts. By using proper combination of contactors, the electrical
circuit can be switched on and off.
 31

Figure 4.11 Relay

 32

CHAPTER 5

ROLE OF MIRCOCONTROLLER IN TIMER CIRCUIT

MICROCONTROLLER

Microcontrollers are usually dedicated devices embedded within an

application. For example, microcontrollers are used as engine controllers in
automobiles and as exposure and focus controllers in cameras. In order to serve
these applications, they have a high concentration of on-chip facilities such as
serial ports, parallel input/output ports, timers, counters, interrupt control,
analog-to-digital converters, random access memory, read only memory, etc.
The I/O, memory, and on-chip peripherals of a microcontroller are selected
depending on the specifics of the target application. Since microcontrollers are
powerful digital processors, the degree of control and programmability they
provide significantly enhances the effectiveness of the application.
 33

The microcontroller incorporates all the features that are found in

microprocessor. The microcontroller has built in ROM, RAM, Input Output
ports, Serial Port, timers, interrupts and clock circuit. A microcontroller is an
entire computer manufactured on a single chip. Microcontrollers are usually
dedicated devices embedded within an application. For example,
microcontrollers are used as engine controllers in automobiles and as exposure
and focus controllers in cameras. In order to serve these applications, they have
a high concentration of on-chip facilities such as serial ports, parallel input
output ports, timers, counters, interrupt control, analog-to-digital converters,
random access memory, read only memory, etc. The I/O, memory, and on-chip
peripherals of a microcontroller are selected depending on the specifics of the
target application.
The 8051 family with its many enhanced members enjoys the largest
market share, estimated to be about 40%, among the various microcontroller
architectures. The microcontroller has on chip peripheral devices. In this unit
firstly we differentiate microcontroller from microprocessor then we will
discuss about Hardware details of 8051 and then introduce the Assembly level
language in brief.
 34

Microcontrollers

Microcontroller (MC) may be called computer on chip since it

has basic features of microprocessor with internal ROM, RAM,
Parallel and serial ports within single chip. Or we can say
microprocessor with memory and ports is called as
microcontroller. This is widely used in washing machines, vcd
player, microwave oven, and robotics or in industries.
Microcontroller can be classified on the basis of their bits
processed like 8bit MC, 16bit MC.
8 bit microcontroller means it can read, write and process 8 bit
data. Ex. 8051 microcontroller. Basically 8 bit specifies the size
of data bus. 8 bit microcontroller means 8 bit data can travel on
the data bus or we can read, write process 8 bit data.

Advantages of an Automatic Lubrication System

Lubrication occurs while the machinery is in operation causing

the lubricant to be equally distributed within the bearing and
increasing the machine’s availability. All critical components are
lubricated, regardless of location or ease of access. Proper lubrication
of critical components ensures safe operation of the machinery. Less
wear on the components means extended component life, fewer
breakdowns, reduced downtime, reduced replacement costs and
reduced maintenance costs. There is no climbing around machinery
or inaccessible areas by the use of this system.
 35

CHAPTER 7
CONLUSION

This self lubrication systems offer superior features than

manual lubrication. This system eliminates productions loss where as
manual lubrication requires machine shut down. It provides effective
and clean lubrication. Self lubrication system will improve safety
features and prevents accidents that occur during manual lubrication.
It provides consistent lubrication that extends bearing life and
prevents unplanned downtime. This system can be used complicated
machines in small scale industries.
 36

REFERENCES

1. C. James Erickson, Charles D. Potts, Byron M. Jones

“Electrical and Electronics Engineering”

2. Muhammad Ali Mazidi, Janice Gillispie Mazidi and Rolin D.

McKinlay “The 8051 Microcontroller and Embedded Systems

Using Assembly and C” Second EditionNathan E. McIntire and
Zelma M. Porter (1972) “Automatic Lubrication System”
3. Hermann Werner, Erich Lessol and Burkard Mueller (1996)

“Bicycle Dynamo having a rotary-current generator” – US

patent
4. Richard W. Dochterman and Fort Wayne (1967) “Lubrication

System for Electric Machines”

5. Cheng-Hsien Wu, Yu-Tai Kung “A parametric study on oil/air

lubrication of a high- speed spindle” Precision Engineering,

Volume 29, Issue 2, April 2005, pp 162-167

6. James C. Gwynn (1995) “Programmable Electronic Timer Circuit” - US

patent

7. Willam Bolton “Mechatronics” (2011) Fourth Edition - Microprocessor

pp 336-372

8. www.wikipedia.org
 37

9. www.wikitronics.com

10. www.interlubesystem.co.uk

11. www.electronicsforu.com

12. www.engineergarage.com

photography