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INTRODUCTION
1.1 OVERVIEW
Leaves fall every autumn and then the major clean-up around- the-yard process begins. But
if the leaves you collect could be repurposed and made into fire logs instead of making their
way into the seasonal yard waste collection trucks. It is common knowledge that dry leaves
burn easily, so an economical home heating solution is to make fire logs from them. We took
the concept to action by developing the low-profile, renewable and energy-efficient Leaf Log.
You can save a lot of money by making your own fire logs with leaves from your backyard.
Leaf Logs are environmentally friendly Eco log products, a renewable and sustainable source
of energy in the form of solid fuel which is suitable for homes and industry.
Leaf log products offer a number of benefits, they are:
Easy to use/light :- Simply place any Leaf log product on the grate, light the bag and
sit back and enjoy the warmth of a real fire. Providing immediate ignition from an
open flame, the ecologs require no kindling or firelighters and produce a clean smoke
free flame.
Clean: - Our ecologs are very clean with a low ash residue, the fine dust which is left
(less than 1%) can then be used to fertilize gardens.
Versatile: - The Leaf log ecology range can be used on wood burning /multi fuel
stoves, chimneys and for recreational use such as camp fires.
Easy to handle and store: - Our eco logs are conveniently wrapped in old
newspapers. Each log weighs approx. 200grams and a dozen will last indefinitely if
stored in a dry place.
Value for money: - Independent test results of Leaf Log provided a net calorific value
of 27,840 kJ per kg proving that Leaf Log burns as hot as coal and 3 times longer than
wood (weight for weight).
Cost effective:-The Leaf log ecologs range is competitively priced. When the cost of
the coal plus the periphery requirements such as firelighters and kindling are added
on, our ecologs are much cheaper than other fuels in price comparisons.
Ethical: - There are other natural products on the market, such as soft or hardwood
logs. However, unlike our ecologs, for those products to exist, something has to die.
Even some logs made of sawdust are made directly from trees that have been cut
down in order to produce the logs.
1.3 SURVEY
Why we should not burn leaves:
Because of the moisture that is usually trapped within leaves, they tend to burn slowly
and thus generate large amounts of airborne particulatesfine bits of dust, soot and
other solid materials. These particulates can reach deep into lung tissue and cause:
coughing, wheezing, chest pain, shortness of breath and sometimes long-term
respiratory problems.
Leaf smoke contains hazardous compounds such as:
1. Carbon Monoxide This can bind with haemoglobin in the bloodstream and reduce
the amount of oxygen in the blood and lungs.
2. Benzopyrene - This has been believed to be a major factor in lung cancer caused by
cigarette smoke.
Breathing in leaf smoke can irritate the eyes, nose and throat of healthy adults, it can
really wreak havoc on small children, the elderly and people with asthma or other
lung or heart diseases.
Mulching of Leaves
Soil Enrichment, Water Conservation, Insulation and Mulch prevents compaction and
erosion of soils from wind and rain.
Composting
CHAPTER: 2
INTRODUCTION TO MECHANISMS
2.1 CONCEPT OF DEGREE OF FREEDOM
In the design or analysis of a mechanism, one of the most important concern is
the number of degrees of freedom (also called movability) of the mechanism. It is defined as
the no. of input parameters which must be independently controlled in order to bring the
mechanism into a useful engineering Purpose.
-equation 1
This equation is called Kutzbach criterion for the movability of a mechanism having plane
motion. If there are no two degree of freedom pairs (i.e. higher pairs), then h=0, substituting
h=0 in equation 1, we have
n=3(l-1)-2j
LINK
MATERIAL
DEGREE OF
FREEDOM
CRANK
(crank pedal arm of a
Chromoly Steel
1
(Rotational motion along x
direction)
2
(Translation motion along x
and y direction)
Carbon Steel
Sheet Metal
0
(neither translation motion
nor rotation motion along
any direction)
Wood
Iron
Sheet Metal
1
(Translation motion along x
direction)
bicycle)
COUPLER
(made up of hand pump rod)
FIXED LINK
Bicycle frame
cuboid
SLIDER
Wooden block
Rod
Cuboidal piston
AC MOTOR
An AC motor is an electric motor driven by an alternating current (AC). The AC motor
commonly consists of two basic parts, an outside stationary stator having coils supplied with
alternating current to produce a rotating magnetic field, and an inside rotor attached to the
output shaft producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.
Fig 5: AC Motor
An industrial type of AC motor with electrical terminal box at the top and output rotating
shaft on the left. Such motors are widely used for pumps, blowers, conveyors and other
industrial machinery. Less commonly, linear AC motors operate on similar principles as
rotating motors but have their stationary and moving parts arranged in a straight line
configuration, producing linear motion instead of rotation.
OPERATING PRINCIPLE
AC motors operate with two rotating (or moving) magnetic fields on the rotor and stator
respectively. Pulling or pushing the poles of the two magnetic fields along, the speed of the
stator rotating magnetic field (Ws) and the speed of the rotor rotating magnetic field (Wr),
which is relative to the speed of the mechanical shaft (Wm), must maintain synchronism for
average torque production by satisfying the synchronous speed relation (i.e., Ws Wr =
Wm). Otherwise, asynchronously rotating magnetic fields would produce pulsating or nonaverage torque.
The two main types of AC motors are classified as:1) Induction Motor
2) Synchronous Motor
1) Induction Motor
The induction motor (or asynchronous motor) always relies on a small difference in speed
between the stator rotating magnetic field and the rotor shaft speed called slip to
induce rotor current in the rotor AC winding. As a result, the induction motor cannot
produce torque about synchronous speed where induction (or slip) is irrelevant or ceases
to exist. In contrast, the synchronous motor does not rely on slip-induction for operation
and uses either permanent magnets, salient poles (having projecting magnetic poles), or
an independently excited rotor winding.
2) Synchronous Motor
The synchronous motor produces its rated torque at exactly synchronous speed. The
brushless wound-rotor doubly-fed synchronous motor system has an independently
excited rotor winding that does not rely on the principles of slip-induction of current. The
brushless wound-rotor doubly-fed motor is a synchronous motor that can function exactly
at the supply frequency or sub to super multiple of the supply frequency.
Other types of motors include eddy current motors, and also AC/DC mechanically
commutated machines in which speed is dependent on voltage and winding connection.
The rpm of an AC motor can be calculated with the help of tachometer
The tip of tachometer can be connected to the shaft of an AC motor to determine the rpm.
Hence,
The rpm of ac motor = 1480
The rotor of an AC motor is directly connected to the rear tires of the cycle with the help of a
pulley.
The rear tyre of the cycle is rotating with an rpm of 138 when the pulley is made in direct
contact with the rear tyre. The rpm of tyre can be noted down with the help of tachometer.
Now, to calculate the rpm of crank, it is compulsory to calculate the gear ratio.
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GEAR RATIO
The gear ratio of a gear train, also known as its speed ratio, is the ratio of the angular velocity
of the input gear to the angular velocity of the output gear. The gear ratio can be calculated
directly from the numbers of teeth on the gears in the gear train. The torque ratio of the gear
train, also known as its mechanical advantage, is determined by the gear ratio. The speed
ratio and mechanical advantage are defined so they yield the same number in an ideal
linkage.
Formula
The teeth on gears are designed so that the gears can roll on each other smoothly (without
slipping or jamming). In order for two gears to roll on each other smoothly, they must be
designed so that the velocity at the point of contact of the two pitch circles (represented by v)
is the same for each gear.
Mathematically, if the input gear GA has the radius rA and angular velocity
with output gear GB of radius rB and angular velocity
, then,
, and meshes
The number of teeth on a gear is proportional to the radius of its pitch circle, which means
that the ratios of the gears' angular velocities, radii, and number of teeth are equal.
Where NA is the number of teeth on the input gear and NB is the number of teeth on the output
gear, the following equation is formed:
This shows that a simple gear train with two gears has the gear ratio R given by
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This equation shows that if the number of teeth on the output gear GB is larger than the
number of teeth on the input gear GA, then the input gear GA must rotate faster than the output
gear GB.
This gear ratio can be determined by calculating the number of teeth in the front sprocket and
the rear sprocket.
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Now, to calculate force on each member of the link, first we will draw the layout of the
mechanism,
Here, Link 1 represents the fixed frame which includes the frame of bicycle and the support
on which the cuboidal cylinder is mounted.
Link 2 represents the crank of the mechanism which is the crank pedal arm of the bicycle.
Link 3 represents the connecting rod.
Link 4 represents the slider which compromises a wooden block, an iron rod and the cuboidal
piston of wood.
Let be the angle between the crank and the fixed link and be the angle between the
connecting rod and the slider.
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Here, force F12 and F32 form a couple which is equal to the applied torque and the
perpendicular distance between these two forces is h.
Force F12 is the force applied by the link 1 on links 2 and the force F32 is the force applied
by the link 3 on link 2.
The forces F23 and F43 are of same magnitude which is acting along the same line and are in
opposite direction
Force F23 is applied by the link 2 on link 3 and is equal to the force F32, force F43 is applied
by the link 4 on link 3.
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Here, F34 is the force applied by link 3 on link 4 which is equal to the F43 and the force F14
is applied by the fixed link 1 on slider 4, normal force and F is the force which is applied on
the piston i.e., piston effort.
Calculation part
Now, the rpm of an AC motor=1480
Power of an ac motor= 373 W
Therefore, torque produced by the motor is given by the following formula
P = T
i.e.
P= (2NT60)
373 = (21480T) 60
Therefore, T = 2.41Nm
The rpm of rear tyre having diameter of 0.72m is made in direct contact with a pulley of
diameter of 0.08m.
Since, according to speed ratio,
The rpm of tyre should be (R2 R1) 1480
i.e., (0.040.36) 1480
Rpm of tyre= 164
But, when, it is calculated with the help of the tachometer it is found to be 138 because some
of its energy is lost in friction, heat etc.
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16
Now, to calculate the horizontal force on the piston considering the free body diagram of
piston.
Therefore, the driving force of the piston which compresses the leaf log up to 70%
reduction in its volume is of 15N.
CHAPTER: 3
17
CONCEPT 1
CONCEPT 2
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This concept uses hydraulic force from right side to compress piston inside the cylinder and
compress the leaves entered from above through hopper in multiple stages.
CONCEPT 3
This concept uses a slider crank mechanism to compress a piston inside cuboid and slits are
introduced in between to compress leaves introduced through hopper in stages and avail easy
access to output.
CRITERIA
CONCEPT
1
CONCEPT
2
CONCEPT
3
BEST
CONCEPT
Portable
Light weight
Good looking
Easy to
manufacture
Reliable
Easy to use
Material cost
Safety
Strength
Easy to maintain
Product stability
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*
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****
*
**
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**
1
1
3
2
**
**
***
*
*
**
*
***
***
*
***
****
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****
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3
3
3
3
3
3
2
Three concepts were developed and are evaluated under twelve criteria of importance. Study
of concept selection reveals that CONCEPT 3 scores highest value.
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DESIGN SPECIFICATION
Concept 3 is the best design that can be evaluated. Table below is the detail product design
specification of concept 3.
S.NO MATERIAL
TYPE
SIZE(cm)
QUANTITY
IRON STRIPES
SHEET METAL
MILD STEEL
SHEET METAL
Height-53.5
Base -41.5
11.5*11.5*64
3
4
WOOD
PLASTIC
CARDBOARD
THIN PLASTIC BOX
2
1
WOOD
CARDBOARD
10.5*15*0.5
Dia.-15
Height-18
10.5*10.5*10.5
IRON ROD
IRON
WOOD
WOODEN BLOCK
Length-44
Dia.-0.5
14.5*5*8
8
9
WOOD
STEEL ROD
117.5*41.5*2
Length-24
Dia.-0.6
1
1
10
STEEL ROD
CARDBOARD
MILD STEEL
ELECTRO
GALVANISED
CHROMOLY STEEL
11
STEEL PLATE
CHROMOLY STEEL
Length-12.5
Dia.-0.4
Dia.-20
12
STEEL ROD
CHROMOLY STEEL
13
STEEL FRAME
CARBON STEEL
Length-18.5
Dia.-0.6
Multiple dim.
14
RUBBER TYRE
RUBBER
Dia.-67
15
STEEL
SPROCKET
CHROMOLY STEEL
Dia.-9
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3.4 FABRICATION
After design phase fabrication processes takes place. These processes are about using
material selection and make product based on design by following design dimensions. Many
methods can be used to fabricate a product like Welding, Drilling, Cutting, Bending,
Grinding, Finishing and many more. This process includes part by part fabrication and
assembling of components.
Processes involved:
In order to transform our design into reality, fabrication needs to be done first. The fabrication
starts from dimensioning the raw materials until it finishes as a desired product. The
processes that involves are:
1. Getting material
Our project includes various material like Sheet Metal (Mild Steel), Wood, Iron rod, Plastic
for hopper, Cardboard, Rubber tyre etc.
2. Measuring and marking
After getting the material, the next step is measuring and marking. The Equipment used are
measuring Tape, Engineers Square, Spirit Level and ruler.
Measuring tape
A tape measure or measuring tape is a flexible ruler. It consists of a ribbon of cloth,
plastic, fiber glass, or metal strip with linear-measurement markings. It is a common
measuring tool.
Fig 17:
Measuring
tape
Engineers Square
A machinist square or engineer's square is the metalworkers' equivalent of a try
square. It consists of a steel blade inserted and either welded or pinned into a heavier
body at an angle of 90
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Spirit Level
A spirit level, bubble level or simply a level is an instrument designed to indicate
whether a surface is horizontal (level) or vertical (plumb)
Ruler
A ruler, sometimes called a rule or line gauge, is an instrument used in geometry,
technical drawing, printing as well as engineering and building to measure distances
or to rule straight lines.
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3. Cutting material
After measurement and Marking various tools are used like Metal and Wood Saw, Metal
Sheer Cutter, Plier and Shearing machine for cutting material.
Wood saw
A saw is a tool consisting of a hard blade, wire, or chain with a toothed edge. It is
used to cut through relatively hard material, most often wood. The cut is made by
placing the toothed edge against the material and moving it forcefully back and forth.
This force may be applied by hand, or powered by steam, water, electricity or
other power source.
Shearing Machine
Shearing machines (sheet metal) use a shearing or scissor-like action to cut metal into
sheets or strips.
Pliers
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Pliers are a hand tool used to hold objects firmly. They are also useful for bending and
compressing a wide range of materials.
4. Drilling
Vertical drilling machine was used with various bits of varying sizes for Drilling holes in
Wood, Mild Steel etc.
A upright drilling machine, called a drill press, is used to cut holes into or through
metal, wood, or other materials. Drilling machines may be used to perform other
operations. They can perform countersinking, boring, counterboring, spot facing,
reaming, and tapping.
5. Bending
After marking sheet metal, iron rods etc. was beaten on Anvil to bend along the marked lines
by using Mallet and hammer.
6. FINISHING TOOLS
Various pieces after cutting are finished to remove sharp edges by using tools like Jack
planar, Wood & Metal files and Grinding Machine.
Jack Plane
A jack plane is the general-purpose bench plane, used for general smoothing of the
edges, sizing of timber but only making it smaller to correct size.
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Grinding Machine
A grinding machine, often shortened to grinder, is any of various power tools or
machine tools used for grinding, which is a type of machining using an abrasive
wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small
chip from the work piece via shear deformation.
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CHAPTER: 4
APPLICATIONS AND SCOPE
4.1 APPLICATIONS
1) Industrial Application
Cement and steel industries uses coal and its ash in furnaces which can be
substituted by renewable source of energy leag log.
2)Cook Food
Traditional chulha in rural areas uses wood that promotes deforestation which can
easily be substituted by cleaner energy resource.
3)Thermal Power Generation
Thermal Power Stations uses high calorific value pulverised coal which is nonrenewable and air polluting fuel and this makes it easier to replace it with
environment friendly leaf logs.
4)Warm our homes
Fireplaces are used in winter to warm our homes, offices, hotels, etc which uses
conventional wood or gelled isopropyl alcohol. These are either expensive or nonrenewable which makes leaf logs perfect fireplace fuel.
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It will be efficient practice to introduce a shredder with the feeding mechanism through
hopper, to reduce time required to shred the leaves.
CONCLUSION
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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 feel that the project work is a
good solution to bridge the gates between institution, industries and rural areas.
We are proud that we have completed the work with the limited time successfully. The Leaf
Log Maker 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, let us add a few more lines about our impression
project work. Thus we have developed a Leaf Log Maker which helps to know how to
achieve low cost alternative fuel source with simple products which can easily available at
any place so that many people can utilises our project. The application of reciprocating
mechanism produces smooth operation. By using more techniques, this project can be
modified and developed according to the applications.
REFERENCES
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1. http://www.leaflog.com/
2. http://www.logmaker.org.uk/
3. http://www.ehow.com/how_6969367_make-firelogs-out-leaves.html
4. http://inventionsusa.blogspot.in/2013/07/leaf-pacleaf-log.html
5. http://www.dailymail.co.uk/sciencetech/article1226943/British-inventors-green-idea-using-leavesmake-logs.html
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