VOICE CONTROLLED CHAIR USING THEO-JANSEN MECHANISM

A THESIS

Submitted by

___________________________

In partial fulfillment for the award of the degree of

BACHELOR OF
MECHANICAL ENGINEERING

CENTRE FOR ENVIRONMENTAL STUDIES

DEPARTMENT OF MECHANICAL ENGINEERING
ANNA UNIVERSITY COIMBATORE: COIMBATORE 641 004

APRIL 2017
ANNA UNIVERSITY COIMBATORE: COIMBATORE 641 004
 BONAFIDE CERTIFICATE

Certified that this Report titled “VOICE CONTROLLED CHAIR USING

THEO-JANSEN MECHANISM” is the bonafide work of Mr.
__________________ (Roll No. ________________) who carried out the work
under my supervision. Certified further that to the best of my knowledge the work
reported herein does not form part of any other thesis or dissertation on the basis of
which a degree or award was conferred on an earlier occasion on this or any other
candidate.

_________________________ ________________________
Professor and Head Assistant Professor
Department of Mechanical Engineering Centre for Environmental
Studies
Anna University Coimbatore Anna University Coimbatore
Coimbatore – 641 004 Coimbatore – 641 004
 ACKNOWLEDGEMENT

At this pleasing moment of having successfully completed our project, we

wish to convey our sincere thanks and gratitude to the management of our college
and our beloved chairman …………………………………………………, who
provided all the facilities to us.

We would like to express our sincere thanks to our principal

………………………………………, for forwarding us to do our project and
offering adequate duration in completing our project.

We are also grateful to the Head of Department Prof.

…………………………………….., for her constructive suggestions &
encouragement during our project.

With deep sense of gratitude, we extend our earnest & sincere thanks to our
guide …………………………………………………….., Department of MECH
for her kind guidance & encouragement during this project.

We also express our indebt thanks to our TEACHING and NON TEACHING
staffs of MECHANICAL ENGINEERING
DEPARTMENT,……………………….(COLLEGE NAME).
 CONTENTS

CHAPTER NO PARTICULARS PAGE NO.

AKNOWLEDGEMENT

1. ABSTRACT

2. INTRODUCTION

3. LITERATURE REVIEW

4. COMPONENTS AND DESCRIPTION

5. PRODUCT DESCRIPTION

6. MANUFACTURING PROCESS

7. WORKING PRINCIPLE

8. 2D DRAWING

9. ADVANTAGES, APPLICATIONS

10. LIST OF MATERIALS

11. COST ESTIMATION

12. CONCLUSION

REFERENCES

BIBLOGRAPHY

PHOTOGRAPH OF THE MODEL

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CHAPTER 1
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ABSTRACT
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CHAPTER-1
 ABSTRACT

Automatic chair cum bed with voice control mechanism for paraplegic

patients is an innovative idea in the field of rehabilitation. For precise control and

accurate movements, the voice control mechanisms are used by the patients. Voice

controlled movement will be extremely helpful to someone who might lack the

physical ability to move both their legs. The chair can also be customized as a bed

by stretching it. This will help the paraplegic patient to lie down without an auxiliary

support. The main aim of our project is to build an automatic wheel chair cum bed

which acts as both wheel chair and when as stretched it can be used as a bed. The

wheel chair cum bed model is a mechanism which is used for moving the bed up and

down. This is used for handicapped person for in order to lead a normal life as other

persons do. For making the handicapped person’s job easy (i.e., they can move bed

up and down). Switches are used to control the wheel chair.

According to a recently conducted census about 2.13%of total population of

India comprises of physically disabled people. 75% of the disabled live in rural areas,

only 49% are literate and only 34% are employed. While earlier the focus was on

medical rehabilitation of these people now the focus has shifted to the social

rehabilitation of the same and hence independency remains an untold parameter in

this. Another important factor that restricts the modern technology invading and

improvising the lives of these people is the cost involved. The poorer section of the
disabled is found on the streets of India making their living through various sources.

Due to the terrain and the road conditions these people face difficulty in adapting

themselves in any public facility and hence are very often assisted by another

member. This puts underdevelopment stress not only on the differently able but also

on the person assisting him. Hence the idea of making them independent and

adaptable to Indian terrain was thought of in the form of walking chair. The concept

was then thought of to make it cheap and available to all sections of the society.

The Theo Jansen mechanism is gaining widespread popularity among the

legged robotics community due to its scalable design, energy efficiency, low

payload-to-machine-load ratio, bio inspired locomotion, and deterministic foot

trajectory. In this paper, we fabricate the four-legged robot driven by a dc motor and

spur gears composed of Theo Jansen mechanisms.

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CHAPTER 2
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INTRODUCTION
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 CHAPTER-2
INTRODUCTION
In this the first wheel chair which was identified was for moving bed manually

or by the other person. At present, it is need for advanced in this type because

physical disabled person cannot depend on mostly others to help him.

So far they have adapted moving in this. But to find a change in this system

we have introduced our projects the requirements are fulfilled in our project thus the

requirement of the handicapped is solved through this project. That is why we have

chosen the wheel chair cum bed for handicapped as our project. The project which

we have selected is to reduce the human needs for the physical disabled person. For

the person sitting on the chair should have to move bed in the constant speed. By

using the wheel chair cum bed we can move bed the handicapped person easily. The

cost this wheel chair costs a little bit higher than the wheel chair has facility of

moving stretcher.

According to a recently conducted census about 2.13%of total population of

India comprises of physically disabled people. 75% of the disabled live in rural areas,

only 49% are literate and only 34% are employed. While earlier the focus was on

medical rehabilitation of these people now the focus has shifted to the social

rehabilitation of the same and hence independency remains an untold parameter in

this. Another important factor that restricts the modern technology invading and
improvising the lives of these people is the cost involved. The poorer section of the

disabled is found on the streets of India making their living through various sources.

Due to the terrain and the road conditions these people face difficulty in adapting

themselves in any public facility and hence are very often assisted by another

member. This puts underdevelopment stress not only on the differently able but also

on the person assisting him. Hence the idea of making them independent and

adaptable to Indian terrain was thought of in the form of walking chair. The concept

was then thought of to make it cheap and available to all sections of the society.

GENERAL

It is well known that animals can travel over rough terrain at speeds much

greater than those possible with wheeled or tracked vehicles. Even a human being,

by "getting down on all fours" if necessary, can travel or climb over terrain which is

impossible for a wheeled or tracked vehicle. Nature, apparently, has no use for the

wheel. It is therefore of considerable interest to learn what machines for land

locomotion can do if they are designed to imitate nature. With this idea in mind I

started studying linkages and the comparative function of a set of linkages with
certain degrees of freedom arrested. It turned out numerous implementations could

be done so as to bring forth set of linkages so designed as to perform locomotion.

WALKING MECHANISM

As mentioned above nature has always chosen legs as the best mode of

locomotion so using linkages we tried to mimic nature and come up with certain

walking mechanism which will suite all terrain. After reviewing certain mechanisms

we came across two of them which proved to be more efficient.

THEO JANSEN MECHANISM

Using eleven small rods, Dutch kinetic sculptor Theo Jansen has created a

planar mechanism that, when used in tandem with many others identical to it, can

walk in a smooth forward motion. The resulting device has a very organic look,

much like a creeping animal. His “beasts” have been made to be wind powered,

using a combination of wind sails and empty plastic bottles that can be pumped up

to high pressures.
Using inspiration from Jansen’s “Strandbeest” kinetic sculptures, this project aims

to create an alternate for tyres which can be used for rough terrains.
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CHAPTER 3
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LITERATURE REVIEW
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 CHAPTER-3
LITERATURE REVIEW

Researching about mining and excavation industries I came across with these

data. The statistics suggests that about 50% of mining cost is spent on roadway and

rail transports in the vicinity of the mines (haul roads & side rails). Haul roads cause

a great damage to tyres of transporting vehicle requiring frequent and regular

replacement. Maintenance cost of haul roads is also high and it needs a separate

wing. Weight distribution is uneven in haul roads causing higher stress problems in

transport vehicles. On a rough terrain legs have advantage over tyres so I came on

Klann Mechanism. After researching through this mechanism on internet and going

though few reports and watching its motion in the YouTube videos found that Klann

Mechanism has its own demerits which include steering and stability. After crossing

out the Klann Mechanism from the list I stumbled on Theo Jansen Mechanism. This

mechanism gave me the smoothest motion and is able to carry loads without much

high forces applied to it. With the inspiration from Jansen’s walking mechanisms, I

began searching for various applications of the Jansen leg mechanism. I found

several images and videos on the Internet showing different applications of this

design large and small that helped me identify what I wanted my design to look like.

The appropriation of the Jansen mechanism has ranged from tiny motorized robots

to large multi-legged two-seater vehicles. This mechanism is very simple to build

and it requires very less energy to run itself. But the only drawback found about this

mechanism is its speed. How fast can it run? Except for that one point the Jansen

design is incomparable with any other leg mechanism with such simplicity.

Strandbeest Computerized Robot Further research from patents, academic

papers, and articles show that nobody’s yet created such a model that I aim to design.

System Design As mentioned earlier we intend to design a replacement for tyres in

load carrying trucks in mineral excavation belts which face a lot of wear and tear

due to poor haul road construction. To make the design possible I needed reference

data. Using the information power of the internet I came across a report journal on

“Finite Element Stress analysis of a solid tyre”. This issue belongs to (Journal of

achievements in material and manufacturing engineering-Volume 31 Issue 2

December 2008). The report involves the standard Finite element analysis of a solid

tyre and deflections produced in it on application of load. The detail related to the

analysis is given further in the report. With reference to the Journal report I decided

the dimensions of our setup.

Journal papers and patents explored here are related directly or indirectly to

the proposed area of work that is design and development of a chair cum Stretcher.

These papers are to support and enlighten the whole process of design in the specific
area. In this section various wheel chair models that are invented for disabled persons

are studied and this project is fabricated.

Wheelchair and Stretcher

A chair is chair with wheels, designed to help the disabled individuals.

Stretchers are mobility devices used to transport the patients from one place to other.

These both medical mobility aids are used in hospitals and clinics for helping the

patients. Stretchers are simple in construction and the patient needs the support of

an assistant to transport from one place to other. Whereas chair is designed in such

a way that either patient can control the device manually or with

the help of someone’s assistance. The device consists of proper handle with cushion

in hand rest and seating area. The direction movement is a critical part when it comes

to emergency situation. Proper selection of caster wheels facilitates to overcome the

situations.

Selection of Wheelchair

According to Mr. Peter Axelson, Mr. Jean Minkel, and Mr.Denise Chesney,

selection of an appropriate chair will lead a comfortable living to the user.

Performance, safety and dimensions are the three categories which have to be

considered while selecting a manual or powered wheelchair. An excellent approach

to the chair selection is to set priorities based on user’s mobility and seating needs.

It is highly recommended that a novice can consult with the rehabilitation specialists

in order to select the appropriate wheelchair.

Caster Wheel Shimmy

James J. Kauzlarich, says self excited vibration is one of the most interesting

topics in the field of vibrations and is the science prevailing caster wheel shimmy.

Self excited vibration is characterized by vibration that is produced by the motion of

the system like chair speed. It can be observed that in most of the cheapest

wheelchairs, the design of the casters makes use of a sliding frictional damper in the

spindle support to improve the shimmy characteristics. Understanding the theory of

damping for the casters show how shimmy prevention works in ultra-light and

powered wheelchairs.

Smart Power Assisted Wheelchair

Mr. Richard Simpson, says almost 10% of all individual who are legally blind

also have a mobility impairment and majority of these individuals are dependent on

others mobility. A smart power assistance module (SPAM) for manual chair is being

developed to provide independent mobility for this population. The power assist
chair that provides for obstacle detection and avoidance for those with visual

impairments. The control of the chair will be carried out by the microprocessor and

also allow the SPAM to provide a smoother and nuanced control.

Wheelchair Configuration

According to Mr. Rory A. Cooper, rehabilitation is a humanistic profession.

Measurement of the user and chair are critical to achieving maximum functional

mobility. He says Biomechanics and ergonomics provide the information necessary

to understand many aspects of chair use. These factors affect seating comfort and

posture, propulsion, efficiency and pain. Proper seating is an important aspect of

chair selection, and chair cushions provide pressure relief and some postural support.

Electric powered mobility may be the best choice for driving long distance and may

be beneficial for people with upper and lower extremity impairments.

Patients Transfer System

Dr. Daniel E. Jolly, says proper preparation should be taken before

transferring the patient from chair to bed or vice versa. Use of sliding boards will be

helpful for paraplegic patients. The best sliding board is made of hard wood, smooth,

tapered on ends. Support of two assistance, support straps, belts etc will facilitate
easy transfer. The patient should not be slide into chair, lift from the chair and

transfer is the optional and safety method for patient transfer.

Mechanical Principles for chair Design

Mr. Amos Winter, says following the mechanical principles will be helpful

for a better design. Understanding the centre of gravity location is important in chair

design. Weight should be the other important factor for chair design. Reducing

weight will results the comfortable use for the user and also lowers material cost.

The best strategy is to maximize the strength and minimize the weight of the frame

tubing. Calculating the moment of inertia and weight results the best strength and

can be used to make the strongest frame at the least weight.

Anthropometric Consideration

Mr. Debkumar Chakrabarti says primary consideration should be given for

comfort, so that people can sit for long time without feeling any physical discomfort.

Considering the suitable materials for seat surface, frame and can make a

comfortable seating for the design. Without considering the ergonomics and

application can make a diverse effect to the user. Seat cushions are so important in

the design of wheelchair. A chair or stretcher design without cushion is not

recommended for the hospital purposes. A stretcher or chair design without cushion

may create spinal cord injuries to the patients

Structure of Common Wheelchair

Chair is a wheeled chair consists of various parts and each part with different

functions. This is an ergonomically designed medical equipment consists of a

foldable frame type mechanism for easy carry. Seating and hand resting position are

well designed for a comfortable sitting. Adjustable foot rest with a heel loop on the

harper bracket is provided so that user won’t get problems while transportation.

Handles are placed in the back rest of chair with suitable grip on that. Push rims are

the other features of the chair when into comes to the indoor purpose for the user.

The user can be independent by the help of push rim, which may help the user to

move from one place to other. Brakes are provided for stopping the chair on both the

push rim wheels. Caster wheels are another major part which directs the way and for

easy transportation.
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CHAPTER 4
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COMPONENTS AND DESCRIPTION
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 CHAPTER-4

COMPONENTS AND DESCRIPTION

The components that are used in the project VOICE CONTROLLED CHAIR

USING THEO-JANSEN MECHANISM are as follows,

 Frame

 Dc motor

 Battery

 Spur gear

 Bearing

 Control unit

FRAME

This is made of mild steel material. The whole parts are mounted on this frame

structure with the suitable arrangement. Boring of bearing sizes and open bores done

in one setting so as to align the bearings properly while assembling. Provisions are

made to cover the bearings with grease.

DC MOTOR

An electric motor is a machine which converts electrical energy to mechanical

energy. Its action is based on the principle that when a current-carrying conductor is
placed in a magnetic field, it experiences a magnetic force whose direction is given

by Fleming’s left hand rule.When a motor is in operation, it develops torque. This

torque can produce mechanical rotation. DC motors are also like generators

classified into shunt wound or series wound or compound wound motors.

FLEMING’S LEFT HAND RULE

Keep the force finger, middle finger and thumb of the left hand mutually

perpendicular to one another. If the fore finger indicates the direction of magnetic

field and middle finger indicates direction of current in the conductor, then the thumb

indicates the direction of the motion of conductor.

PRINCIPLE OF OPERATION OF DC MOTOR

Figure I show a uniform magnetic field in which a straight conductor carrying

no current is placed. The conductor is perpendicular to the direction of the magnetic

field.In figure II the conductor is shown as carrying a current away from the viewer,

but the field due to the N and S poles has been removed. There is no movement of

the conductor during the above two conditions. In figure III the current carrying

conductor is placed in the magnetic field. The field due to the current in the

conductor supports the main field above the conductor, but opposes the main field

below the conductor.

 The result is to increase the flux density in to the region directly above the

conductor and to reduce the flux density in the region directly below the conductor.

It is found that a force acts on the conductor, trying to push the conductor downwards

as shown by the arrow. If the current in the conductor is reversed, the strengthening

of flux lines occurs below the conductor, and the conductor will be pushed upwards.

Now consider a single turn coil carrying a current as shown in the above figure. In

view of the reasons given above, the coil side A will be forced to move downwards,

whereas the coil side B will be forced to move upwards. The forces acting on the

coil sides A and B will be of same magnitude. But their direction is opposite to one

another. As the coil is wound on the armature core which is supported by the
bearings, the armature will now rotate. The commutator periodically reverses the

direction of current flow through the armature. Therefore the armature will have a

continuous rotation. A simplified model of such a motor is shown in figure VI. The

conductors are wound over a soft iron core. DC supply is given to the field poles for

producing flux. The conductors are connected to the DC supply through brushes.

Let's start by looking at the overall plan of a simple 2-pole DC electric motor. A

simple motor has 6 parts, as shown in the diagram below.

 An armature or rotor,

 A commutator,

 Brushes,

 An axle,

 A field magnet,

 A DC power supply of some sort.

An electric motor is all about magnets and magnetism: a motor uses magnets

to create motion. If you have ever played with magnets you know about the

fundamental law of all magnets: Opposites attract and likes repel. So if you have 2

bar magnets with their ends marked north and south, then the North end of one

magnet will attract the South end of the other. On the other hand, the North end of

one magnet will repel the North end of the other (and similarly south will repel
south). Inside an electric motor these attracting and repelling forces create rotational

motion.

In the diagram above and below you can see two magnets in the motor, the

armature (or rotor) is an electromagnet, while the field magnet is a permanent

magnet (the field magnet could be an electromagnet as well, but in most small motors

it is not to save power).

ELECTROMAGNETS AND MOTORS

To understand how an electric motor works, the key is to understand how the

electromagnet works. An electromagnet is the basis of an electric motor. You can

understand how things work in the motor by imagining the following scenario. Say

that you created a simple electromagnet by wrapping 100 loops of wire around a nail

and connecting it to a battery. The nail would become a magnet and have a North

and South pole while the battery is connectedNow say that you take your nail

electromagnet, run an axle through the middle of it, and you suspended it in the

middle of a horseshoe magnet as shown in the figure below. If you were to attach a

battery to the electromagnet so that the North end of the nail appeared as shown, the

basic law of magnetism tells you what would happen: The North end of the

electromagnet would be repelled from the north end of the horseshoe magnet and

attracted to the south end of the horseshoe magnet.The South end of the
electromagnet would be repelled in a similar way. The nail would move about half

a turn and then stop in the position shown.

You can see that this half-turn of motion is simple and obvious because of the

way magnets naturally attract and repel one another. The key to an electric motor is

to then go one step further so that, at the moment that this half-turn of motion

completes, the field of the electromagnet flips. The flip causes the electromagnet to

complete another half-turn of motion.You flip the magnetic field simply by changing

the direction of the electrons flowing in the wire (you do that by flipping the battery

over). If the field of the electromagnet flipped at just the right moment at the end of

each half-turn of motion, the electric motor would spin freely.

THE ARMATURE

The armature takes the place of the nail in an electric motor. The armature is

an electromagnet made by coiling thin wire around two or more poles of a metal

core. The armature has an axle, and the commutator is attached to the axle. In the

diagram above you can see three different views of the same armature: front, side

and end-on. In the end-on view the winding is eliminated to make the commutator

more obvious. You can see that the commutator is simply a pair of plates attached
to the axle. These plates provide the two connections for the coil of the

electromagnet.

THE COMMUTATOR AND BRUSHES

The "flipping the electric field" part of an electric motor is accomplished by

two parts: the commutator and the brushes. The diagram at the right shows how

the commutator and brushes work together to let current flow to the electromagnet,

and also to flip the direction that the electrons are flowing at just the right moment.

The contacts of the commutator are attached to the axle of the electromagnet, so they

spin with the magnet. The brushes are just two pieces of springy metal or carbon that

make contact with the contacts of the commutator.

PUTTING IT ALL TOGETHER

When you put all of these parts together, what you have is a complete electric

motor,In this figure, the armature winding has been left out so that it is easier to see

the commutator in action. The key thing to notice is that as the armature passes
through the horizontal position, the poles of the electromagnet flip. Because of the

flip, the North pole of the electromagnet is always above the axle so it can repel the

field magnet's North pole and attract the field magnet's South pole.

If you ever take apart an electric motor you will find that it contains the same

pieces described above: two small permanent magnets, a commutator, two brushes

and an electromagnet made by winding wire around a piece of metal. Almost always,

however, the rotor will have three poles rather than the two poles as shown in this

article. There are two good reasons for a motor to have three poles:

 It causes the motor to have better dynamics. In a two-pole motor, if the

electromagnet is at the balance point, perfectly horizontal between the two

poles of the field magnet when the motor starts; you can imagine the armature

getting "stuck" there. That never happens in a three-pole motor.

 Each time the commutator hits the point where it flips the field in a two-pole

motor, the commutator shorts out the battery (directly connects the positive

and negative terminals) for a moment. This shorting wastes energy and drains

the battery needlessly. A three-pole motor solves this problem as well.

 It is possible to have any number of poles, depending on the size of the motor

and the specific application it is being used in.

BATTERY
 In isolated systems away from the grid, batteries are used for storage of excess

solar energy converted into electrical energy. The only exceptions are isolated

sunshine load such as irrigation pumps or drinking water supplies for storage. In

fact for small units with output less than one kilowatt.

Batteries seem to be the only technically and economically available storage

means. Since both the photo-voltaic system and batteries are high in capital costs.

It is necessary that the overall system be optimized with respect to available energy

and local demand pattern. To be economically attractive the storage of solar

electricity requires a battery with a particular combination of properties:

(1) Low cost

(2) Long life

(3) High reliability

(4) High overall efficiency

(5) Low discharge

(6) Minimum maintenance

(A) Ampere hour efficiency

(B) Watt hour efficiency

We use lead acid battery for storing the electrical energy from the solar panel

for lighting the street and so about the lead acid cells are explained below.
LEAD-ACID WET CELL

Where high values of load current are necessary, the lead-acid cell is the type

most commonly used. The electrolyte is a dilute solution of sulfuric acid (H 2SO4).

In the application of battery power to start the engine in an auto mobile, for example,

the load current to the starter motor is typically 200 to 400A. One cell has a nominal

output of 2.1V, but lead-acid cells are often used in a series combination of three for

a 6-V battery and six for a 12-V battery.

The lead acid cell type is a secondary cell or storage cell, which can be

recharged. The charge and discharge cycle can be repeated many times to restore

the output voltage, as long as the cell is in good physical condition. However, heat

with excessive charge and discharge currents shortens the useful life to about 3 to 5

years for an automobile battery. Of the different types of secondary cells, the lead-

acid type has the highest output voltage, which allows fewer cells for a specified

battery voltage

BEARING WITH BEARING CAP:-

The bearings are pressed smoothly to fit into the shafts because if hammered

the bearing may develop cracks. Bearing is made upon steel material and bearing

cap is mild steel.

INTRODUCTION
 Ball and roller bearings are used widely in instruments and machines in order

This technology was brought to its p resent state o f perfection only after a

long period of research and development. The benefits of such specialized research

can be obtained when it is possible to use a standardized bearing of the proper size

and type. However, such bearings cannot be used indiscriminately without a careful

study of the loads and operating conditions. In addition, the bearing must be

provided with adequate mounting, lubrication and sealing. Design engineers have

usually two possible sources for obtaining information which they can use to select

a bearing for their particular application:

a) Textbooks

b) Manufacturers’

Catalogs Textbooks are excellent sources; however, they tend to be overly

detailed and aimed at the student of the subject matter rather than the practicing

designer. They, in most cases, contain information on how to design rather than how

to select a bearing for a particular application. Manufacturers’ catalogs, in turn, are

also excellent and contain a wealth of information which relates to the products of

the particular manufacturer. These catalogs, however, fail to provide alternatives

which may divert the designer’s interest to products not manufactured by them. Our

Company, however, provides the broadest selection of many types of bearings made

by different manufacturers.
 For this reason, we are interested in providing a condensed overview of the

subject matter in an objective manner, using data obtained from different texts,

handbooks and manufacturers’ literature. This information will enable the reader to

select the proper bearing in an expeditious manner. If the designer’s interest exceeds

the scope of the presented material, a list of references is provided at the end of the

Technical Section. At the same time, we are expressing our thanks and are providing

credit to the sources which supplied the material presented here.

Construction and Types of Ball Bearings

A ball bearing usually consists of four parts: an inner ring, an outer ring, the

balls and the cage or separator.

To increase the contact area and permit larger loads to be carried, the balls

run in curvilinear grooves in the rings. The radius of the groove is slightly larger

than the radius of the ball, and a very slight amount of radial play must be provided.

The bearing is thus permitted to adjust itself to small amounts of angular

misalignment between the assembled shaft and mounting. The separator keeps the

balls evenly spaced and prevents them from touching each other on the sides where

their relative velocities are the greatest. Ball bearings are made in a wide variety of

types and sizes. Single-row radial bearings are made in four series, extra light, light,

medium, and heavy, for each bore, as illustrated in Fig. 1-3(a), (b), and (c).
 The heavy series of bearings is designated by 400. Most, but not all,

manufacturers use a numbering system so devised that if the last two digits are

multiplied by 5, the result will be the bore in millimeters. The digit in the third place

from the right indicates the series number. Thus, bearing 307 signifies a medium-

series bearing of 35-mm bore. For additional digits, which may be present in the

catalog number of a bearing, refer to manufacturer’s details.

Some makers list deep groove bearings and

bearings with two rows of balls. For bearing

designations of Quality Bearings & Components

(QBC), see special pages devoted to this purpose. The

radial bearing is able to carry a considerable amount of axial thrust.

However, when the load is directed entirely along the axis, the thrust type of

bearing should be used. The angular contact bearing will take care of both radial and

axial loads. The self-aligning ball bearing will take care of large

amounts of angular misalignment. An increase in radial capacity may be secured

by using rings with deep grooves, or by employing a double-row radial bearing.

Radial bearings are divided into two general classes, depending on the method of

assembly. These are the Conrad, or no filling-notch type, and the maximum or

filling-notch type. In the Conrad bearing, the balls are placed between the rings as

shown in .
 Then they are evenly spaced and the separator is riveted in

place. In the maximum-type bearing, the balls are a (a) (b) (c) (d) (e) (f) 100

Series Extra Light 200 Series Light 300 Series Medium Axial Thrust Bearing

Angular Contact Bearing Self-aligning Bearing Fig. 1-3 Types of Ball Bearings Fig.

1-4 Methods of Assembly for Ball Bearings (a) Conrad or non-filling notch type (b)

Maximum or filling notch type

SPUR GEAR

The spur gears, which are designed to transmit motion and power between

parallel shafts, are the most economical gears in the power transmission industry.

Spur gears or straight-cut gears are the simplest type of gear. They consist of

a cylinder or disk with teeth projecting radially. Though the teeth are not straight-

sided (but usually of special form to achieve a constant drive ratio,

mainly involute but less commonly cycloidal), the edge of each tooth is straight and

aligned parallel to the axis of rotation. These gears mesh together correctly only if

fitted to parallel shafts.

INTERNAL SPUR GEAR

The internal gears are spur gears turned "inside out." In other words, the teeth

are cut into the inside diameter while the outside diameter is kept smooth. This

design allows for the driving pinion to rotate internal to the gear, which, in turn,

allows for clean operation. Intended for light duty applications, these gears are

available only in brass. When choosing a mating spur gear, always remember that

the difference in the number of teeth between the internal gear and pinion should not

be less than 15 or 12.

EXTERNAL SPUR GEAR

Perhaps the most often used and simplest gear system, external spur gears are

cylindrical gears with straight teeth parallel to the axis. They are used to transmit

rotary motion between parallel shafts and the shafts rotate in opposite directions.

They tend to be noisy at high speed as the two gear surfaces come into contact

at once. Internal spur gears: The internal spur gear works similarly to the external

spur gears except that the pinion is inside the spur gear. They are used to transmit
rotary motion between parallel shafts but the shafts rotate in the same direction with

this arrangement.

CONTROL UNIT

In automotive electronics, Electronic Control Unit (ECU) is a generic term

for any embedded system that controls one or more of the electrical system or

subsystems in a motor vehicle. Types of ECU include Electronic/engine Control

Module (ECM), Power train Control Module (PCM), Transmission Control Module

(TCM), Brake Control Module (BCM or EBCM), Central Control Module (CCM),

Central Timing Module (CTM), General Electronic Module (GEM), Body Control

Module (BCM), Suspension Control Module (SCM), control unit, or control

module. Taken together, these systems are sometimes referred to as the car's

computer. Technically there is no single computer but multiple ones. Sometimes one

assembly incorporates several of the individual control modules. Some

modern motor vehicles have up to 80 ECUs. Embedded software in ECUs continues

to increase in line count, complexity, and sophistication. Managing the increasing

complexity and number of ECUs in a vehicle has become a key challenge

for original equipment manufacturers (OEMs).

CRANK SHAFT
The crank shaft after the linkages is the most important part of this project. The

factor that was considered while making the crank shaft was it had to be made

removable so that the assembly of other components on this crank becomes simpler.

Hence for the sake of simplicity the crank shaft can be divided into two main

components:

Main Shaft

The main shaft is the part of the crank shaft that receives the power from the driving

component and in turn drives the crank and hence the linkages. The main shaft is

made of seamless drawn circular cross section hollow mild steel pipe. This thick

gauge was a necessity because the shaft has to drive the heavy linkage system and

also the mass moment of inertia would help in carrying the momentum like a fly

wheel. The main shaft rotates about its own axis unlike the crank. This shaft is split

in to three different pieces that can be separated from rest of the components. The

splitting of the shaft was done in order to accommodate the linkages in between the

shaft along with the crank. Making it continuous would hinder the movement of

links or rather let the set up not work at all. The main shaft is mounted on the frame

by using bearing blocks. Four bearing blocks are used to hold the main shaft in

position and aligned in one straight line.

2) The Crank
The meaning of the crank is it rotates about an axis of the shaft at a distance. This

distance is called the crank length.

One of the major factors that are to be considered while making a shaft is it should

have balanced forces acting on it, or in other words the angular velocity of the shaft

should be constant. Hence for this purpose the phase between the two cranks on one

side of the set up was chosen to be 180°. This helps in balancing of the shaft

completely. As stated earlier the crank shaft was made removable and could be

disassembled into smallest of the component, the crank was split into the crank plates

and the crank pins.

The crank plates offset the axis of rotation and hence transfer the rotary motion from

the main shaft to the linkages at a distance of 71mm. These plates are made of mild

steel and the width of the plate is 50mm while its thickness is 12mm. These plates

support the crank pins and hence the entire linkages.

There are three crank plates on either side of the driver. The first inside plate is

attached to the main shaft on one side and the crank pin on the other side. The second

plate is the intermediate plate that is double the length of crank. This is because

there is a phase shift of 180° as mentioned earlier. This plate supports crank pins on

both its sides. The third plate is on the outer side and hence on one side it is supported

by the last split of main shaft and the other side it supports the crank pin. These
plates function synchronously in order to vary the position of the foot and perform

the four phases of the Jansen’s mechanism.

The crank plate supports the crank pin. The crank pin in turn drives the linkage

system. While making the crank pin following factors were considered:

• The pin should be strong enough to counter the bending moments developed

• It should be fastened to the crank plates tightly

• It should have a smooth finish to aid easy relative motion between the pin

and the links.

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CHAPTER 5
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 PRODUCT DESCRIPTION
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CHAPTER 5
PRODUCT DESCRIPTION

SPECIFICATIONS

WHY?? Mild steel???

The term ‘mild steel’ is also applied commercially to carbon steels not covered

by standard specifications. Carbon content of this steel may vary from quite low

levels up to approximately 0.3%. Generally, commercial ‘mild steer’ can be

expected to be readily weldable and have reasonable cold bending properties but to

specify ‘mild steel’ is technically inappropriate and should not be used as a term in

engineering. Mild steel is the most widely used steel which is not brittle and cheap

in price. Mild steel is not readily tempered or hardened but possesses enough

strength.

Mild steel Composition

 Mild steel contains –C45

 Carbon 0.35 to 0.45 % (maximum 0.5% is allowable)

 Manganese 0.60 to 0.90 %

 Silicon maximum 0.40%

 Sulfur maximum 0.04%

 Phosphorous maximum 0.04%

 Mildest grade of carbon steel or mild steel contains a very low amount of

carbon - 0.05 to 0.26%


Tensile strength – 63-71 kgf/mm2

 Yield stress -36 kgf/mm2

 Izod impact valve min -4.1 kgf m

 Brinell hardness (HB) - 229

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CHAPTER 6
--------------------------------------------------------------------------------------
 --------------------------------------------------------------------------------------
MANUFACTURING PROCESS
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CHAPTER-6
MANUFACTUING PROCESSES

Introduction:
 Manufacturing involves turning raw material to finished products, to be used

for various purposes. There are a large number of processes available. These

processes can be broadly classified into four categories.

1 Casting processes

2 Forming processes

3 Fabrication processes

4 Material removal processes

Casting Processes:

These processes only processes where the liquid metal is used. Casting is also

the oldest known manufacturing process.

Basically it consists of inducing the molten metal into a cavity of mould of

the required form and allowing the metal to solidify. The object after solidification

removed from the mould. Casting processes are universally used to manufacture a

wide variety of products. Casting is the most flexible and cheapest method and given

high strength of rigidity to the parts which are difficult to produce by other

manufacturing processes. The principle process among these sand casting where

sand is used as the raw material. The process is equally suitable for the production
of a small batch as well as on a large scale. Some of the other classified casting

processes for specialized need are

· Shell mould casting

· Precision mould casting

· Plaster mould casting

· Permanent mould casting

· Die casting

· Centrifugal casting

Forming Processes:

These are solid state manufacturing processes involve minimum amount of

material wastage. In forming process metal may be heated to temperature which is

slightly below. This solidify temperature and large force is applied such the material

flows and act in desired shape. The desire shape is controlled by means of a set of

tool ties and dies, which may be closed during manufacturing.

These processes are normally used for large scale production rates. These are

generally economical and in many cases improve the mechanical properties. These

are some of the metal forming processes.

 · Rolling forging

· Drop forging

· Press forging

· Upset forging

· Extrusion forging

· Wire forging

· Sheet metal operation

Fabrication Processes:

These are secondary manufacturing processes where the starting raw materials

are produced by any one of the previous manufacturing processes desired. Its

assembly involve joining pieces either temporary or permanent. So that they would

be perform the necessary function. The joining can be achieved by either or both of

heat and pressure joining materials. Many of the steel structure construction, we see

are first rolled and then joined together by a fabrication process are

· Gas welding

· Electric arc welding

· Electrical resistance welding

 · Thermo welding

· Brazing welding

· Soldering welding

· Cold welding

Material removal processes:

These are also a secondary removal manufacturing process, where the

additional unwanted material is removed in the form of chips from the blank material

by a hard tools so as to obtain the final desired shape.

Material removal is normally a most expensive manufacturing process.

Because more energy is consumed and also a lot of waste material is generated in

this process. Still this process is widely used because it deliver very good

dimensional accuracy and good surface finished. Material removal process are also

called machining processes. Various processes in this category are

 Turning

 Drilling

 Shaping and planning

 Milling

 Grinding
  Broaching

 Sawing

 Trimming

WELDING:

Welding is a process of joining two metal pieces by the application of heat.

Welding is the least expensive process and widely used now a days in fabrication.

Welding joints different metals with the help of a number of processes in which heat

is supplied either electrically or by mean of a gas torch. Different welding processes

are used in the manufacturing of Auto mobiles bodies, structural work, tanks, and

general machine repair work. In the industries, welding is used in refineries and pipe

line fabrication. It may be called a secondary manufacturing process.

Classification of welding processes:

There are about 35 different welding and brazing process and several

soldering methods, in use by the industry today. There are various ways of

classifying the welding for example, they may be classified on the basis of source of

heat (flames, arc etc.)

In general various welding processes are classified as follows.

1: Gas Welding

(a): Air Acetylene

(b): Oxy Acetylene

(c): Oxy Hydrogen Welding

2: Arc Welding

(a): Carbon Arc welding

(b); Plasma Arc welding

(c): Shield Metal Arc Welding

(d): T.I.G. (Tungsten Inert Gas Welding)

3: Resistance Welding:

(a): Spot welding

(b): Seam welding

(c): Projection welding

(d): Resistance Butt welding

4: Solid State Welding:

(a): Cold welding

(b): Diffusion welding

(c): Forge welding

(d): Fabrication welding

(e): Hot pressure welding

(f): Roll welding

5: Thermo Chemical Welding

(a): Thermite welding

(b): Atomic welding

6: Radiant Energy Welding

(a): Electric Beam Welding

(b): Laser Beam Welding

Welding Joints:
DRILLING:

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-

section in solid materials. The drill bit is usually a rotary cutting tool, often

multipoint. The bit is pressed against the workpiece and rotated at rates from

hundreds to thousands of revolutions per minute. This forces the cutting edge

against the workpiece, cutting off chips (swarf) from the hole as it is drilled.

In rock drilling, the hole is usually not made through a circular cutting motion,

though the bit is usually rotated. Instead, the hole is usually made by hammering

a drill bit into the hole with quickly repeated short movements. The hammering

action can be performed from outside of the hole (top-hammer drill) or within the

hole (down-the-hole drill, DTH). Drills used for horizontal drilling are called

drifter drills.
 DRILLING PROCESS:

 Center drilling

 Deep hole drilling

 Gun drilling

 Trepanning

 Micro drilling

 Vibration Drilling

Types of Drilling Jigs:

1. Template jig

2. Plate type jig

3. Open type jig

4. Channel jig

5. Leaf Jig

6. Box type jig

1: Template Jig:

This is the simplest type of jig; It is simply a plate made to the shape and size

of the work piece; with the require number of holes made it. It is placed on the work

piece and the hole will be made by the drill; which will be guided through the holes
in the template plate should be hardened to avoid its frequent replacement this type

of jig is suitable if only a few part are to be made.

2. Plate Type Jig:

This is an improvement of the template type of jig. In place of simple holes,

drill bushes are provided in the plate to guide the drill. The work piece can be

clamped to the plate and holes can be drilled. The plate jig are employed to drill

holes in large parts, maintaining accurate spacing with each other.

3. Open Type Jig:

In this jig the top of the jig is open; the work piece is placed on the top.

4. Channel jig:

The channel jig is a simple type of jig having channel like cross section. The

component is fitted within the channel is located and clamped by locating the knob.

The tool is guided through the drill bush.

5. Leaf Jig:

It is also a sort of open type jig , in which the top plate is arrange to swing

about a fulcrum point , so that it is completely clears the jig for easy loading and

unloading of the work piece.

6. Box Type Jig:

When the holes are to drill more than one plane of the work piece, the jig has

to be provided with equalant number of bush plates. For positioning jig on the
machine table feet have to be provided opposite each drilling bush plate. One side

of the jig will be provided with a swinging leaf for loading and unloading the work

piece, such a jig would take the form of a box.

METAL CUTTING OPERATIONS:

1. Blanking:

Blanking is the operation of cutting a flat shape from sheet metal. The product

punched out is called the “blank” and the required product of the operation the hole

and the metal left behind is discarded as waste.

2. Punching or Piercing:
 It is a cutting operation by which various shaped holes are made in sheet

metal. Punching is similar to blanking except that in punching, the hole is the desired

product. The material punched out from the hole being waste.

3. Notching:

This is cutting operation by which metal pieces are cut from the edge of the

sheet, strip or blank.

4. Perforating:

This is a process by which multiple holes are very small and close together

are cut in a flat sheet metal.

5. Trimming:

This operation consists of cutting unwanted excess of material from the

periphery of a previously formed component.

6. Shaving:

The edge of a blanked part are generally rough, uneven and un-square.

Accurate dimensions of the part are obtained by removing a thin strip of metal along

the edges.

7. Slitting:
 It refers to the operation of making incomplete holes in a work piece.

8. Lancing:

This is a cutting operation in which a hole is partially cut and then one side is

bent down to form a sort of tab. Since no metal is actually removed and there will

be no scrap.

9. Nibbling:

The nibbling operation, which is used for only small quantities of components,

is designed for cutting out flat parts from sheet metal. The flat parts from simple to

complex contours. This operation is generally substituted for blanking. The part is

usually moved and guided by hand as the continuously operating punch cutting away

at the edge of the desired contour.

Forming Operations:
1. Bending:

In this operation; the material in the form of flat sheet or strip is uniformly

strained around a linear axis which lies in the neutral plane and perpendicular it’s

the length wise direction of the sheet or metal.

1. Drawing:

This is a process of forming a flat work piece into a hollow shape by means

of a punch which cause the blank into a die cavity.

3. Squeezing:
 Under the operation, the metal is caused to flow to all portions of a die cavity

under the action of compressive forces.

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CHAPTER 7
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WORKING PRINCIPLE
---------------------------------------------------------------------------------------
 CHAPTER-7

WORKING PRINCIPLE

A. Introduction To Walking Mechanism

The Jansen’s linkage is basically a crank based mechanism wherein the rotary

motion of one link of the mechanism is converted into the walking motion of the

entire mechanism. The foot of the linkage is the contact with the ground which has

the four phases of lifting, returning, supporting and lowering which in combination

propels the system forward. The locus of the foot represents the way the linkage

actions. Figure 1: Crank based Jansen linkage mechanism also called the leg system

B. Walking Mechanism

The Jansen Linkage in its raw form cannot be utilized for the purpose of making

a walking chair as it was designed for a single leg on huge Strandbeest. Hence there

should be a proportionate reduction in the linkage lengths without losing the

desirable traits mentioned in the previous section.

If we consider the above shown pair of limbs to be a set of limbs that act together

in the entire project, then four of such sets were utilized for the complete locomotion

of the project. Two sets were fixed on the right side of the seat and the other two on

the left side.

C. Drive Mechanism
 For the driving of the chair, amongst the options available like electric motor

drive was chosen. It was chosen simply because use of Electric motor would reduce

the manual work and leg pedaling was impractical since it the objective was to

develop this project for the movement disabled people.

--------------------------------------------------------------------------------------
CHAPTER 8
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2D DRAWING
-------------------------------------------------------------------------------------
2D DRAWING
--------------------------------------------------------------------------------------
CHAPTER 9
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
ADVANTAGES, DISADVANTAGES AND APPLICATIONS
--------------------------------------------------------------------------------------
 CHAPTER-9
ADVANTAGES, DISADVANTAGES AND APPLICATIONS

ADVANTAGES

The benefits of walking over rolling on rough terrain are summed up in the following:

1. Higher energy efficiency, better fuel economy

2. Increased speed

3. Greater mobility

4. improved isolation from terrain inconsistencies

DISADVANTAGES

1. This is for prototype model only

APPLICATIONS

1. It’s very useful for all Handicapped

--------------------------------------------------------------------------------------
CHAPTER 10
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
LIST OF MATERIALS
--------------------------------------------------------------------------------------
 CHAPTER-10
LIST OF MATERIALS

SL. NO. NAME OF THE PARTS MATERIAL

1 dc motor 12v

2 spur gear ci

3 battery 12v

4 bearing steel

5 disc MS

6 leg links MS

7 Control unit -

8 Frame MS
--------------------------------------------------------------------------------------
CHAPTER 11
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
COST ESTIMATION
--------------------------------------------------------------------------------------
 CHAPTER-11
COST ESTIMATION

1. MATERIAL COST:

S.NO PART NAME QUANTITY AMOUNT

1. Dc motor 2 4000

2. Spur gear 2 1000

3. Battery 1 2000

4. Bearing 4 500

5. Disc 1 500

6. Leg links - 1000

7. Control unit 1 2000

8. Frame 1 4000

TOTAL=15000
2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS

CUTTING:
Cost = 3400

3. OVERHEAD CHARGES
The overhead charges are arrived by “Manufacturing cost”
 Manufacturing Cost = Material Cost + Labour cost
= 15000+3400
= 18400
Overhead Charges = 20% of the manufacturing cost
= 3680
TOTAL COST

Total cost = Material Cost + Labour cost + Overhead

Charges
= 15000+3400+3680
= 22080
Total cost for this project = 22080 rs
 ---------------------------------------------------------------------------------------
CHAPTER 12
---------------------------------------------------------------------------------------

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CONCLUSION
---------------------------------------------------------------------------------------
 CHAPTER-12
CONCLUSION
A strong multidiscipline team with a good engineering base is necessary for

the Development and refinement of advanced computer programming, editing

techniques, diagnostic Software, algorithms for the dynamic exchange of

informational different levels of hierarchy.

This project work has provided us an excellent opportunity and experience,

to use our limited knowledge. We gained a lot of practical knowledge regarding,

planning, purchasing, assembling and machining while doing this project work.

We are proud that we have completed the work with the limited time

successfully. The “VOICE CONTROLLED CHAIR USING THEO-JANSEN

MECHANISM” is working with satisfactory conditions. We are able to understand

the difficulties in maintaining the tolerances and also quality.

We have done to our ability and skill making maximum use of available

facilities. In conclusion remarks of our project work. Thus we have developed a

“VOICE CONTROLLED CHAIR USING THEO-JANSEN MECHANISM”.

By using more techniques, they can be modified and developed according to the

applications.
---------------------------------------------------------------------------------------

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 REFERENCE
---------------------------------------------------------------------------------------

REFERENCE

 Manufacturing technology (Machine Processes & Types),

-G.K.Vijayaraghavan.

 Engineering economics & cost analysis (Cost of Material),

-S.Senthil, L.Madan, N.Rabindro Singh.

 Design data book

- PSG College of technology

 Strength of materials

- R.S Kurmi
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PHOTOGRAPH OF THE MODEL
---------------------------------------------------------------------------------------

PHOTOGRAPH OF THE MODEL