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ILLUSTRATED S O U R C E B O O K

of

MECHANICAL COMPONENTS

S E C T I O N 27

CREATIVE
10 Ways to Amplify Mechanical Movements 10 Ways to Amplify Mechanical Action
How to Damp Axial and Rotational Motion

27-2 27-4 27-6 27-8 27-10 27-12 27- 14 27- 16 27- 18 27-20 27-21 27-22 27-23

8 Snap-Action Devices
Make Diaphragms Work for You Control-Locks Thwart Vibration and Shock liquid level Mechanisms, Indicators and Controllers Liquid Level Indicators and Controllers Hangers Put Up by Hand Assemble Sheetmetal with Sheetmetal Devices for Indexing or Holding Mechanical Movements Slash Errors with Sensitive Balance Rotary Piston Engine

27-2

10 Ways to Amplify
Mechanical Movements
How levers, membranes, cams, and gears are arranged to measure, weigh, gage, adjust, and govern.
Federico Strasser

HIGH AMPLIFICATION f o r simple measuring instruments is provided b y double lever acfion. Accuracy can be as high
ab

Bridge lever

-Spring

0.0001 in.

PIVOTED LEVERS allow extremely sensitive action in compardtof-type memuring device shown here. The range, however, is sniall.
Corn t o l l o w e r 7

ULTRA-HIGH AMPLIFICATION, w i t h only one lever, is provided in the Hirth-Minimeter shown here. Again, thc range is siiinll.
Aujusftng corn-

A@bsfing

Section through A - A
-Worm

qeur

COR CLOSE ADJUSTMENT,


c l e c t r i c i l nie:isiiring i n s t r n tiicnts e m p l o j eccentric ciini\. l l e r c niovenient i s rcducrtl, nut ;iniplified.

MICROSCOPIC ADJUSTMENT is achieved liere 112 employing ;I large eccentric-c;iiit cotipled ((I :I worni-gear drive. Snioolli, f i i i e udjuslnienl result.

Creative Assemblies

27-3

/ever or beum

CAPSULE UNIT for gaspressure indicators should be provided with a compression spring to preload the membrane for more positive action.

Sfeelyord rod-

LEVER ACTUATED \+eighscale needs no springs to niaiciVain balance. The lever system, mounted on knife edges, is extremely sensitive.

AMPLIFIED MEMBRANE MOVEMENT can be gained by

the arrangement shown here. A


the lever system.

small chain-driven gear links

gear m d p/nfon

QUADRANT-GEAR AND PINION couplctt to an l,-le\cr providc wiiple mot rniriit of indicirttrr needle for snisll chiu~gcs in go\rrnor speed.

GEARED quadrant are I J W ~ herc to give flie coniI)artator

iiiaxiniuni sensitivity coinhitied with ruggedness.

27-4

10 Ways to Amdifv Mechahical Actibn


I

Levers, wires, hair, and metal bands are arranged to give high velocity ratios for adjusting and measuring.
Federico Strasser

Ius

Geared lever

LEVER

AND

GEAR

train amplify the microscope control-knob movement. Knife edges provide frictionless pivots for lever.

DfAL INDICATOR starts with rack and pinion amplified by gear train. The return-spring takes out backlash.

Spring cenfer fines

Moveme

Curved lever

spring

ball

measuring face

Or

CURVED LEVER is so shaped and pivoted that the force exerted on the stylus rod, and thus stylus pressure, remains constant.

ZElSS COMPARATOR is

provided with a special lever to move the stylus clear of the work. A steel ball greatly reduces friction.

HOT-WIRE AMMETER

relies on the thermal expansion of a current-canying wire. A relatively large needle movement occurs.

Creative Assemblies

27-5

Sfeel

HYGROMETER actuated by a hair. When humidity causes expansion of the hair, its movement is amplified by a lever.

STEEL RIBBONS trans-

mit movement without the slightest backlash. The movement is amplified by differences in diameter.

METAL BAND is twisted and supported at each end. Small movement of contact sphere produces large needle movement.

Suppoff bushing

+b --+

,hticromefer meosures movement of b i n response fo movement

ACCURACY of YU'squares

TORSIONAL deflection of

can be checked with a device shown here. The rod makes the error much more apparent.

the short arm is transmitted with low friction to the longer arm for micrometer measurement.

27-6

How to Damp Axial and Rotational Motion


Fluid-friction devices include two hydraulic and two pneumatic actions; swinging-vane arrangements dissipate energy and govern speed.
Frederico Strasser

CI

ADJUSTABLE BYPASS between the

two sides of the piston controls speed at which fluid can flow when piston is moved.

CHECK VALVE in piston lets speed be controlled so that the piston moves faster in one direction than in the other.

Sori& grip a ftachmenf

ROTATING VANES are resisted by the air a9 they revolve. Make allowance for sudden stops by providing a spring.

SWlNGlNG VANES create increased wind drag as centrifugal force opens them to a larger radius.

Creative Assemblies

27-7

screw

A
PNEUMATIC CHECK VALVE acts i n manner similar to that of previous device. Vertical position, of course, is necessary. FLEXIBLE DIAPHRAGM controls short movements. Speed is fast in one direction, but greatly slowed in return direction.

-.

Sfafionory position Copper or aluminum disk

Closed- circuit currenfs esfoblkh their own magnetic field

'I LJ

Magnet

UI

VANE AREA INCREASES when the spring-loaded vanes swing out. Forces differ for niotion into or against the wind.

EDDY CURRENTS are induced in disk when it is moved through a magnetic field. Braking is directly proportiona1 to speed.

27-8

8 Snap-Action Devices
A further selection of basic arrangements for obtaining
sudden motion after gradual buildup of force.
Peter

C.Noy

Acfuofing force

Preload force

1
Torsion ribbon

bent as shown will turn "inside out" at A with a snap action when twisted at 6. Design factors are ribbon width and thickness, and bend ongle.

...

Resef

2
Collapsing cylinder

has elastic walls that may be deformed gradually until their stress changes from compressive to bending with the resultant collapse of the cylinder

...

3
Bowed spring

...

Y
4
Flap vane

Adjus fment

will collapse into new shape when loaded as shown. "Push-pull" type of steel measuring tape illustrates this action; the curved material stiffens the tape so that it can be held out as a cantilever until excessive weight causes it to collapse suddenly.

...

is for air or liquid flow cutoff at a limiting velocity. With a regulating valve, vane will snap shut (because of increased velocity) when pressure is ieduced below a certain value.

Creative Assemblies

27-9

Fusible link

Closed container,

6
Gravity-tips

...

5
Sacrificing link
IS

used generally where high heat or chemically corrosivc conditions would be hazardous -if temperature becomes too high, or atmosphere too corrosive, link will yield at whatever conditions it is designed for. Usually the device is required to act only once, although a device like the lower one is quickly reset but restricted to temperature control.

...

aithough slower acting than most snap mechanisms, can t.r called snap mechanisms because they require an accumulation of energy to trigger an automatic release. Tippingtroughs used to spread sewage exemplify arrangement shown in A, once overbalanced, action is fast.

re

8
W

Overcentering leaf-spring

...

7
Overcentering tension

...

spring combined with pivoted contact-strip is one arrangement among many similar ones used in switches. Arrangement shown here i s somewhat unusual, since the actuating force bears on the spring itself.

action i s also the basis for many ingenious snap-action switches used for electrical control. Sometimes spring action is combined with the thermostatic action of a bimetal strip to make the switch respond to heat or cold either for control purposes or as a safety feature.

27- 1 0

Make Diaphragms Work for You


Diaphragms have more uses than you think. Heres a display of applications that simple fabric-elastomer diaphragms can handle economically and with a minimum of design problems
John F. Taplin

A /nospheric

pressure
connecfi

Oil

lnlef

Pressure

possoge

Expansion compensator for liquid-filled systems handles thermal expansion of the liquid as well as any system losses.

A balanced valve uses a fabric-elastomer diaphragm to hydrostatically balance the valve poppet as well as the valve head.

-Diaphragm
Rubber dust
SOl

Spring

A force-balance load cell converts the


weight or force of any object into an accurate reading at a remote point.

Linear actuator converts gas or fluid pressure into a linear stroke without leakage or break-out friction effects.

Creative Assemblies

27- 11

,Diuphragms

. Piston

Double-acting actuator provides for thrust in either direction by placing two diaphragm assemblies back to back.

Diap n raynm

Regulating valve controls the value ot air pressure by means of a diaphragm-balanced valve and two control diaphragms.

Double-acting pump has two diaphragms to give smooth and continuous flow of fluid to equipment at a safe working pressure.

Diaphragm

'

u+I

Shaft

Shaft seal uses lubricant pressure to force the sidewall of the diaphragm to roll against the shaft and housing.

Damping mechanism prevents abrupt or sudden motion in a machine. Damping amount is controlled by orifice size.

27- 12

Vibration and Shock


Frank William

Control-Locked Thwart

Critical adjustments stay put-safe against accidental turning or deliberate fiddling with them.
Wood JR.

a..SPLIT YOKE clamps on shaft when eccentric squeezes ends of yoke together. Knurled knob is handy for constant use, and eliminates need for tool. Another advantage is high torque capacity. But this design needs considerable space on panel.

w
Clamp knob

FINGER springs into place between gear te h at turn of cam. Although gear lock is ideally suited for right-angle drives, size of teeth limits positioning accuracy.

Knurled

Split

3,.SPLIT

'

BUSHING tightens on control shaft, because knurled knob has tapered thread. Bushing also mounts control to panel, so requires just one hole. Lever, like knob, does away with tools, but locks tighter and faster. For controls adjusted infrequently, hex nut turns a fault into an advantage. Although it takes a wrench to turn the nut, added difficulty guards against knobtwisters.

Control shaft

Hex nut-'

Creative Assemblies

27-13

4 . . CONSTANT D R A G of tapered collar on shaft makes control stiff, so it doesnt need locking and unlocking. Compressed lip both seals out dust and keeps molded locking nut from rotating.

5 . T O N G U E slides in groove, clamps down on edge of dial. If clamp is not tight, it can scratch the face.

6 , . SPOT-BRAKE clamp is self-locking, which means it takes two hands to make an adjustment, one to hold the clamp open and one to turn the dial.

27- 14

Li uid level Mechanisms

In icators and Controllers


Means o f determining liquid level, detection of changes in liquid level, transmission of indicated levels. o r warnings of changes heyond set limits; and means of using level changes for level control, or control of other conditions such a5 temperature and pressure, have been accomplished by numerous mechanisms. The most pcpular devices employ floats or pressure measurement with instruments such as the U-tube manameter, bourdon tube, and bellows. The methods shown here are largely indicating methods or simple devices for automatic control of liquid level although they can conceivably be applied to control other conditions such as tem-

perature a n d pressure. Methods using electric resistance of a column of liquid and measurement of pressure changes by means of piezo-electric crystals are not shown. Patent No. 2,162,180 describes a method involving determination of change in air pressure when a measured volume nf air is introduced into a tank.

&

Sfof for f i o a t
-Ffoaf chamber

counterweighf ann
1

Sfop for f/oaf movemen f--'--

fed or dece/erated movements ofplunger for any floaf movemen

Fig. 1-Float and Lever- Operated Pilot Valve

U Fig.2-Float and CamOperated Pilot Valve

flfi

Bourdon tube sqpporfs magnefic core in resista7ce coils i Y (Magnefic core _.- : i t m a v b e ~ u d ~

pokted C;i;-'o by float in

I/ tube)

mercury

I M II
/ndicafor or recorder--- -

<i----r

4 i r e connecfion fo gafvanometer in receiver

F/ouf---,

Fig.4-Float and Pulley Indicator

Fig.5-Pressure Dome Indicator-

.
I
_-__---------.-.-.-.-

Fig.7-U-Tube Manometer with Water Columns


Sec+/ona/ view excepf for weigbfs and ffoaf

Fig. 6-Float Control o f Discharge


Tape visible through window Vapor-fighf covers -/

Creative Assemblies
:---F/oafing
frigerunf sdmpling reservoir

27-15

Double bdancing mechanism fUfs mercury swifcbes for u/arms when refri eranf i s be/ow eifher operufing or idle &e/s

- -Groo ves

Fig.10 -Refrigerant Balance

indicufed b y /tghf reflecffon from menrsrus

liquid >eve/ 5.50

Fig.11 -Automatic
Battery Filler
Back
Front

Tank floor, At-Pu//ey frome supporf

Fig. 8-Tank Roof Indicator

Fig.9-Dip Stick Indica tor

27- 16

Liquid Level Indicators and Controllers


Thirteen different systems of operation are shown. Each one represents at least one commercial instrument. Some of them are available in several modified forms.

I m l
Bubbler fixture
&Air
supply

Either method can

The Bristol Co.

DXAPHRAQM ACTUATED INDICATOR. Can be used with a n y kind of liquid, whether it be flowing, turbulent, or

carrying solid matter. Recorder can be mounted above or belnw the level of the tank or reservoir.

BUBBLER TYPE RECORDER measures height E. can be used with a 1 1 kinds of liquids, including those carrying solids. Small amount of air is bled into submerged pipe. Gage measures pressure of air that displaces fluid.

I I i L/,51

Use terminol5 forpumpdown, terminal 3 for ourno-uo control

BELLOWS ACTUATED

INDICATOR.

Two bellows and

connecting tubing are fllled with incompressible fluid. Change in liquid level 'displaces transmitting bellows and pointer.

ELECTRICAL T Y P E LEVEL CONTROLLER. Positions of probes determine duration of pump operation. When liquid touches upper probe, relay operates and puinp stops. Through auxiliary contacts, lower pmbe Provides relay holding cdrrent until liquid drops below It.

op-ociing switch

/--

-- - -

To float in
Minneapolis- Honeywell

ion&

___-Indicator and tank U n i t are connected by a single wire. As liquid level in tank increases, brush contact on tank rheostat moves to the rlght, introducing an increasing amount of resistance into circuit that grounds the "F" coil. Displacement o f needle from empty mark Is proportional to the amount of resistance introduced into this circuit.
AUTOMOTIVE TYPE LIQUID LEVEL INDICATOR.

FLOAT-SWITCH T Y P E CONTROLLEX. When liquid reaches predeter-

mined level, float actuates switch through horseshoe-shape arm. Switch can operate valve or pump, as required.

Creative Assemblies

27-17

Recorder

Counterweighf

'rope

yoot

float chamber

Minmaplis Mneywell

Pointer can be a t t w h e d to a calibrated float tape to give a n approximate hstantaneous indication of fluld level.

FLOAT TYPE RECORDER.

MAGNETIC LIQUID LEVEL CONTROLLER.

DIFFERENTIAL P R E S S U R E SYSTEM.

When liquid level is normal, common-to-right leg circuit of mercury switch is closed. When level drops to predetermined level. magnetic Piston is drawn below the magnetic field.

Applicable to liquids under pressure. Measuring element is mercury manometer. Mechanical or electric meter body can be used. Seal pots protect meter body.

r-7

t of ocfuofing,
element

-_PA

Pressure gouge

Seof required fw corrosive or viscous fluiUs

Mimqoofis-HmRywrll

Inexpensive, direct-reading gage has dial calibruted to tank volume. Comparable type as far as simplicity I s concerned h a s needle connected through a right-angle a r m to float. As liquid level drops, float rotates the a r m and the needle.
DIRECT READING FLOAT TYPE GAGE.

PRESSURE UAUE INDICATOR for open vessels. Pressure

of liquid head is imposed directly upon actuating element of pressure gage. Center line of the actuating element must conincide wlth the minimum level line if the gage i s to read zero when the liquid reaches the minlhum level.

Heoter wirerank

Bimetal strip

- ---

-Float

7 ,
BIMETALLIC TYPE INDICATOR. When tank is empty, contacts in tank unit just touch. With switch closed, heaters cause both bimetallic strips to bend. This opens contacts in tank and bimetals cool, closing circuit again. Cycle repeats about once per s e a As Hqutd level increases. float forces cam to bend tank bimetal. Action is simllar to previous case, but current and needle displacement are increased.
SWITCH ACTUATED LEVEL CONTROLLER. Pump is actuated by switch. Float pivots magnet 40 that

upper pole attracts switch contact. Tank wall serves as other contact.

27-18

Hangers Put Up by Hand


No tools needed to install these hangers made of wire, rod or bar-stock.
L. Kasper

CLIP is most secure when tubing of right size helps keep it spread. To install, hook one side over edge of slot and spring in other side.

EDGE HANGER doesnt have to be sprung, but requires enough clearance above holes so that ends can be pushed down through.

RAMPS cam split end together as hanger is pushed into slot. Ends spread again when notches engage sheet.

Small end enters large slot first, then tilts over into smaller, close-fitting slot.

Creative Assemblies

27- 19

LOOP hooks over bar and is held secure by

short tail which snaps into hole drilled through the side.

DOUBLE HANGER supports two tubes 8s they pass through divider. While tubes are in place hanger cant come out.

COIL grips edges of T- or I-section or flat bar. Spreading the ends wraps wire tightly around tubing to prevent vibration.

END PIECE supports pipe between waUs of any thickness. First spring it over pipe, then slide it along pipe into holes.

27-20

Assemble Sheetmetal with

Sheetmetal

These sheetmetal parts join sheetmetal quickly with the simplest of tools.
L. Kasper

SQUEEZE CLIP holds two overlapping sheets together. The ends of the clip are pushed through parallel slots, then bent over much like a staple.

ALIGNING PIECE slides up out of the way in long slot while butting sheets are being positioned. Afterwards it slips down over lower sheet.

ESS supports shelf between uprights, By mating with notched edge it acts as a key to keep shelf from sliding back and forth. and provides positive location,

CUP carries a bar on both sides of divider. Here bars stick up above the top, but deeper cutout will lower them until they are flush or sunk.

Creative Assemblies

27-21

Devices for Indexing or Holding Mechanical Movements


Louis Dodger

detent

ROLLER DETENT POSITIONS IN A NOTCH: Ntana 1-cos RISE, S z= 2 COS a ROLLER RADIUS, R =

( -ivy,

.)( 1

COSa

-cOSa

AXIAL POSITIONING (INDEXINS) BY MEANS OF SPACED HOLES IN INDEX BASE

Re foihihg
Din

Puf/ h o b to release

RADIALLY ARRANGED DETENT HOLDS SLOTTED INDEX BASE

IN

27-22

Slashes Errors with Sensitive Balance

SENSITIVITY OF BALANCE is independent of temperature fluctuations. To keep the center of gravity constant, two temperature-sensitive elements are riveted to aluminumalloy balance beam, bridging a slot which is directly over the balance point. Their coefficient of expansion compensates for beam deflection caused by variations in temperature.

Enclosed in a cylindrical canister at the rear of the balance beam is a vane that damps its movement, preventing oscillation. The hanger at the front of the scale carries sets of ring weights which are lifted by camoperated levers. The shafts on which the cams are mounted are connected to the mechanical readout. The scale in effect weighs by sub-

traction since it is balanced, when empty, by all the ring weights resting on the hanger. To weigh an unknown, the ring weights are lifted from the hanger. The sum o f the raised weights is shown on the mechanical counter, which displays the first three digits. The complete total is displayed by the mechanical plus the optical system that projects through the reticle.

Creative Assemblies

27-23

Rotary Piston Engine


Warren Ogren, Inventor Robert Parrnley, Draftsman

Exploded drawing of engine illustrates the many standard mechanical components that are arranged to preform a function in a new way.

27-24

End View of Rotary Piston Engi

25

\ i

1
.

1
I

FIG. 3

Figure 2
7

c ut-Away View of Rotary Piston Engine

>

Figure 3
41

42

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