GOVERNMENT POLYTECHNIC COLLEGE

TUTICORIN-628008

PROJECT REPORT
ON
DESIGN AND FABRICATION OF SOLAR POWERED MOVING MACHINE

Under the guidance of

(Thiru. B.RAMESHKUMAR, B.E., M.BA,)

Submitted by
S.NO REG.NO NAME
1 15248861 MAGESHKUMAR.R
2 15248862 MANIKANDAN.N
3 15248863 MANIKANDAN.R
4 15248864 MANOJ.V
5 15248865 MANOJ.V

Submitted in partial fulfilment for the award of

Diploma in Mechanical Engineering,
of State Board of Technical Education, Tamil Nadu.

DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC YEAR 2016-2017
BONAFIDE
 GOVERNMENT POLYTECHNIC COLLEGE
THOOTHUKUDI -628 008

BONAFIDE CERTIFICATE

This is to certify that the project entitled DESIGN AND

FABRICATION OF SOLAR POWERED MOVING MACHINE is a Bonafide record
work submitted by selvan.________________________________________
RegNo. ________________________ in the sixth semester Diploma in MECHANICAL
ENGINEERING course during the year 2016 2017.

Project Guide Head of the Department

Thiru.B.RAMESH KUMAR, B.E, MBA Thiru.P.Muthurasu, M.E,MIE,Phd

Submitted for Board Practical Examination held on_______ _____________

Internal Examiner External Examiner

OBJECTIVES
 OBJECTIVES

When we study books, are able to know the information

regarding the scientific development of the present mechanical world. When we see the

equipments are working we do something by ourselves. We become familiar with the

equipments and we can ever suggest the information, which may in order to work the

equipments in efficient manner.

The project work induces the activity of students both

physically and mentally.

It also promotes co-operation and initiates group activity

by involving our self with the organization .The capacity of the individual is also increased.

We plan and execute our project and therefore we are learning the things by doing the same

with proper co-relation of various subject studied.

We feel at a sense of achievement by the success of this

Project. It trains us to think and to study in the scientific manner, it teaches us the dignity of

manner.
ACKNOWLEDGEMENT
 ACKNOWLEDGEMENT

We take great pleasure in expressing our

heartfelt thanks to the GOVERNMENT POLYTECHNIC COLLEGE for helping
us to complete our project successfully.

We express our sincere and respected

thanks our beloved principal Thiru.V.Subbaraj ME, B.Tech.Ed is having
permitted to use all the availability facilities in bringing out the project
successful.

We extend our sincere thanks to our Head

of the department of Mechanical Engineering Thiru. P.Muthurasu, ME,
MIE,PhD for his kind support and also providing us with his unhindered
support.

We are greatly indebted thanks and we

also extend deep sense of gratitude to our guide Thiru.
B.Rameshkumar B.E, MBA from the depth of our sole for her able
evidence, valuable suggestions, advises and also who has been a source
of inspiration throughout our project.

We also extend sincere thanks to all the

staff of Mechanical Engineering Department who renders their help
throughout our project.
PREFACE
 PREFACE

We thank our director of technical education who has introduce the

subject the Project work for the final semester in Mechanical Education Project work is the

Way of expression of fresh ideas of the student in the form of design and Fabrication by

utilizing the knowledge acquired by them during the course of Study and is also benefited for

the human society. It has given self-confidence every individual for starting small scale of

our own.

For our turn, be have taken the task of designing preparing details and

Assembly drawing and manufacturing of the DESIGN AND FABRICATION OF

SOLAR POWERED MOVIN MACHINE

For every each fabrication project work, sequence of operation Involves four important

factors

They are:
1. Design of the project

2. Preparation of details and assembly drawings

3. Collecting necessary materials and proper layout

4. Manufacturing and marketing

SYNOPSIS
CONTENTS
 CONTENTS

TABLE OF CONTENT

CHAPTER NO. CHAPTER

1. ABSTRACT
2. INTRODUCTION
3. LIST OF PARTS
4. PARTS DESCRIPTION
5. PARTS SPECIFICATION
6. DETAILED DRAWING
7. WORKING PRINCIPLE
8. COST ESTIMATION
9. APPLICATIONS
10. ADVANTAGES
11. CONCLUSION
12. PHOTOGRAPHS
13. BIBLIOGRAPHY
 ABSTRACT

ABSTRACT

This project presents the kinematics of the movement for a

six- legged mobile robot, inspired from the living world, as well as the command and control
system, which allow the robot to move on different surfaces with different speeds. For

generating the movement, through a command and control system, stepping motors and bars

are used. A frame, connecting rod, crank and a lever constitute to obtain the required motion.

In this project, the application of simple four bar mechanism is used. The most important

benefit of this mechanism is that, it does not require microprocessor, controller and other

actuator mechanisms. The military, law enforcement, Explosive Ordinance Disposal units,

and private security firms could also benefit from applications of this mechanism. It would

perform very well as a platform with the ability to handle stairs and other obstacles better

than wheeled or tracked vehicles. In this mechanism links are connected by pivot joints and

convert the rotating motion of the crank into the movement of foot similar to that of animal

walking.
INTRODUCTION

INTRODUCTION
 Generally the walking mechanisms are developed by
imitating natures like insects movement. The nature inspired the researchers and new
innovative ideas come in mind but sometimes they are simple and effective, sometimes
cumbersome and critical.. This walking machine had four legs arranged into pairs. Legged
machine have been used for at least a hundred years and are superior to wheels. Legged
locomotion should be mechanically superior to wheeled or to tracked locomotion over a
variety of soil conditions and certainly superior for crossing obstacles. US army investigation
reports that about half the earth surface is inaccessible to wheeled tracked vehicles, whereas
this terrain is mostly exploited by legged animals. Wheeled machine are the simplest and
cheapest also tracked machines are very good for moving, but not over almost all kinds of
terrain. There are different types of legged walking machines. They are roughly divided into
groups according to the number of legs they possess. Bipeds have two legs, quadrupeds four,
hexapods six and octopods have eight legs. Bipeds machines are dynamically stable, but
statically unstable, such machines are harder to balance, and dynamic balance can only be
achieved during walking. Hexapods are six legged machines, on the other hand, have
advantages of being statically stable. During walking they can move three legs at a time, thus
leaving three other legs always on the ground forming a triangle.

This project presents the kinematics of the movement for a six- legged Moving
machine , inspired from the living world, as well as the command and control system, which
allow the robot to move on different surfaces with different speeds. For generating the
movement, through a command and control system, stepping motors and bars are used. A
frame, connecting rod, crank and a lever constitute to obtain the required motion. In this
project, the application of simple four bar mechanism is used. The most important benefit of
this mechanism is that, it does not require microprocessor, controller and other actuator
mechanisms.
 LIST OF PARTS

LIST OF PARTS

The vehicle consists of many parts. They are

 SOLAR PANEL

ELECTRIC MOTOR

BATTERY

CRANK LINK BAR

FREE WHEEL SPROCKET

SPROCKET CHAIN

THREADED ROD
 PART DESCRIPTION

PARTS DESCRIPTION
The parts and there construction details are briefly given below
SOLAR PANEL
 The solar panel refers to a panel design to absorb the sun

rays as a source of energy for generating electricity or heating. A solar cell is an electronic

device that catches sunlight and turns it directly into electricity. Its about the size of an

adults palm, octagonal in shape, and coloured bluish black. Solar cells are often bundled

together to make larger units called solar modules. The cells in a solar panel are designed to

generate electricity but where a batterys cells make electricity from chemicals, a solar

panels cells generated power by capturing sunlight instead.

ELECTRIC MOTOR

An electric motor is an electrical machine that converts electrical

energy into mechanical energy. A fractional horsepower motor (FHP) is an electric motor

with a rated output power of 746 Watts or less. There is no defined minimum output,

however, it is generally accepted that a motor with a frame size of less than 35mm square

can be referred to as a 'micro-motor'. Servo motors and stepper motors are specialist types of

fractional horsepower electric motors usually intended for high-precision or robotics

applications. Electric motors are used to produce linear or rotary force (torque), and should
be distinguished from devices such as magnetic solenoids and loudspeakers that convert

electricity into motion but do not generate usable mechanical powers. A motor is selected

with respect to the mass of the entire setup. In normal motoring mode, most electric motors

operate through the interaction between an electric motor's magnetic field and winding

currents to generate force within the motor. In certain applications, such as in the

transportation industry with traction motors, electric motors can operate in both motoring

and generating or braking modes to also produce electrical energy from mechanical energy.

BATTERY

A battery is an electro chemical cell that can be charged electrical

to provide a static potential for power or released electrical charge when needed.Battery

convert chemical energy directly to electrical energy.A battery consists of some number of

voltaic cells.

CRANCK LINK BAR

The mechanism usually

consists of a four supporting rods of suitable gaps. They determine the overall width of the

mechanism. They act as a support for the entire arrangement comprising of connecting rod,

legs and motor. Drills are made at suitable areas in coherence with the position of the holes
in the connecting rod and the legs. The thickness of these bars is usually less to increase the

ease of drilling and to reduce the weight.

SUPPORTING BARS

The supporting bars are usually aluminium bars of length 25cm

and width 2cm.The mechanism usually consists of a four supporting rods of suitable gaps.

They determine the overall width of the mechanism. They act as a support for the entire

arrangement comprising of connecting rod, legs and motor. Drills are made at suitable areas

in coherence with the position of the holes in the connecting rod and the legs. The thickness

of these bars is usually less to increase the ease of drilling and to reduce the weight

LEG LINKAGE

In a reciprocating piston engine, the connecting rod connects the

piston to the crank or crankshaft. Together with the crank, they form a simple mechanism

that converts reciprocating motion into rotating motion. In the same way it transfers the

motion or power from the threaded stud to the legs. Connecting rods are used to convert

rotating motion into reciprocating motion. The entire mechanism consists of six connecting

rods connected between the stud and the leg. The length of the connecting rod is varied with

respect to the dimensions of the leg. The ends need not be well polished like the legs since it

does not involve any contact with the ground. Here the stud acts as the crank which receives

power from the motor. Holes are made at both the ends of the connecting rod.

FREE WHEEL SPROCKET

 A Freewheel (also known as

a block) consists of either a single sprocket or a set of sprockets mounted on a body which

contains an internal ratcheting mechanism and mounts on a threaded hub. Threaded rear hubs

were available in different thread patterns, The condition of a driven shaft spinning faster

than its driveshaft exists in most bicycles when the rider holds his or her feet still, no longer

pushing the pedals. In a fixed-gear bicycle, without a free wheel, the rear wheel would drive

the pedals around. A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain, track or other perforated or indented material. The name

'sprocket' applies generally to any wheel upon which radial projections engage a chain

passing over it. It is distinguished from a gear in that sprockets are never meshed together

directly, and differs from a pulley in that sprockets have teeth and pulleys are smooth.

Sprockets are of various designs, a maximum of efficiency being claimed for each by its

originator. Sprockets typically do not have a flange. Some sprockets used with timing belts

have flanges to keep the timing belt centered. Sprockets and chains are also used for power

transmission from one shaft to another where slippage is not admissible, sprocket chains

being used instead of belts or ropes and sprocket-wheels instead of pulleys. They can be run

at high speed and some forms of chain are so constructed as to be noiseless even at high

speed.

SPROCKET CHAIN
 Roller chain or bush roller chain

is the type of chain drive most commonly used for transmission of mechanical power. It is

driven by a toothed wheel called a sprocket. It is a simple, reliable, and efficient means of

power transmission. There are actually two types of links alternating in the bush roller chain.

The first type is inner links, having two inner plates held together by two sleeves or bushings

upon which rotate two rollers. Inner links alternate with the second type, the outer links,

consisting of two outer plates held together by pins passing through the bushings of the inner

links. The "bushing less" roller chain is similar in operation though not in construction;

instead of separate bushings or sleeves holding the inner plates together, the plate has a tube

stamped into it protruding from the hole which serves the same purpose. This has the

advantage of removing one step in assembly of the chain. Some sprockets used with timing

belts have flanges to keep the timing belt centered. Sprockets and chains are also used for

power transmission from one shaft to another where slippage is not admissible, sprocket

chains being used instead of belts or ropes and sprocket-wheels instead of pulleys. They can

be run at high speed and some forms of chain are so constructed as to be noiseless even at

high speed
THREADED ROD

A threaded rod, also known as a stud, is a relatively long rod

that is threaded on both ends; the thread may extend along the complete length of the rod.

They are designed to be used in tension. Threaded rod in bar stock form is often called all-

thread. For studs that are not completely threaded, there are two types of studs: full-bodied

studs, and undercut studs. Full-bodied studs have a shank equal to the major diameter of the

thread. Undercut studs have a shank equal to the pitch diameter of the screw thread.

Undercut studs are designed to better distribute axial stresses. In a full-bodied stud the

stresses are greater in the threads than in the shank. Undercut studs (rolled thread) are also

stronger because the metal is "rolled" up to the major diameter, not removed. This preserves

the grain of the steel and in some cases even enhances it. Full bodied studs (cut thread) are

weaker because metal is removed to create the thread, disturbing the grain of the steel.

Undercut studs are only required in applications where the stud is exposed to fatigue. Cut

threads are entirely suitable for many applications, even when rolled threads might be

slightly stronger. Mass-produced fasteners (standard bolts and studs) are usually rolled, but

jobbed parts with custom features and small lot sizes are likely to be cut
SPECIFICATION
 PARTS SPECIFICATION

SOLAR PANEL
Power 13.5 w
Dimensions 350 mmx 1310mm

ELECTRIC MOTOR
Voltage 12 V
Amphere 20 amps

BATTERY
Voltage 12 V
Amphere 20 amps

SPROCKET
No of teeth - 18
Inner Diameter 35mm

CHAIN
Pin pitch 12.7mm
Roller Diameter 7.9MM
DRAWINGS
 DRAWING
2D DESIGN VIEW OF OUR PROJECT

3D DESIGN
WORKING PRINCIPLE
 WORKING PRINCIPLE

It consists of motor or engine mounted at the top.

Out of three gear one is connected to motor or engine shaft called Driving gear and

remaining two are meshes with driving gear with the help of chain.
The crank is connected to the shaft on which two driven gears are mounted.
As the motor made to ON the driving gear drives another two gear , one is clockwise

while other is anticlockwise as the gears are rotate in opposite direction.

Due to this rotation resulting in the crank rotation
Crank moves the forcing link gives the momentum in a particular line of action with

help of supporting link.

The work of supporting link is to move the arm in a particular profile which made by

the end point of arm and move back to its normal position i.e. initial position.

All these give the walking motion to the arm like a spider.

WORKING OF LEGGED MECHANISM

The operation of the mechanism can be by temporarily

installing a wired control box. The box consists of two DPDT switches wired to control the

forward and backward motion of the two legs. But before you test the mechanism, you need

to align its legs. The legs on each side should be positioned so that either the center leg

touches the ground or the front and back leg touch the ground. The leg is the same as an

insects and provides a great deal of stability. To reverse, one set of legs stops (or reverses)

while the other set continues. During this time, arrangement of the legs will be lost, but the

robot will still be supported by at least three legs. An easy way to align the legs is to loosen
the chain sprockets (so you can move the legs independently) and position the middle leg all

the way forward and the front and back legs all the way back. Retighten the sprockets, and

look out for misalignment of the roller chain and sprockets. If a chain bends to mesh with a

sprocket, it is likely to pop off when the robot is in motion. During testing, be on the lookout

for things that rub, squeak, and work loose. Keep your wrench handy and adjust gaps and

tighten bolts as necessary. Add a dab of oil to those parts that seem to be binding. You may

find that a sprocket or gear doesnt stay tightened on a shaft. Look for ways to better secure

the component to the shaft, such as by using a set screw or another split lock washer. It may

take several hours of tuning up to get the robot working at top efficiency. Though the

balanced positions achieved by the previous level are adequate when the robot lies on a

horizontal surface without disturbing obstacles, in more complex situations they can be non-

optimal. The purpose of the adaptation level is to change the targets aimed at by the different

balances in order to better the environmental conditions detected

BILL OF MATERIALS
 BILL OF MATERIALS

Sl.No COMPONENTS MATERIAL QUANTITY

1 Free Wheel Sprocket Cast Iron 5

2 Bearing Steel 5

3 Chain Steel 1

4 Wheel Mild Steel 4

5 Steering Wheel Mild Steel 1

COST ANALYSIS
 COST ANALYSIS

MATERIAL COST

SL.
MATERIAL QUANTITY COST
NO

1 SPROCKET 05 1000

2 BEARING 05 1000

3 CHAIN 01 250

4 WHEEL 05 400

5 STEERING WHEEL 01 450

6 PEDAL 01 150

7 CHASIS FRAME 01 350

8 BOLT&NUT 04 100

TOTAL 3700
Material Cost = 3700
Overhead cost = 500
Prime Cost = (Material cost + Overhead cost)
= 3700 + 500 = Rs. 4200 /-
Labor Cost = Rs. 750/-
Total Cost = Prime Cost + Labor Cost
= 4200 + 750
= 4950/-
APPLICATIONS
 APPLICATION

Useful on uneven surfaces.

Useful in army for bomb detection and carry weapons.

Useful in industries in place of different conveyors.

Useful in carrying heavy weights.

ADVANTAGES
 ADVANTAGES

Construction expense is low.

Heavy load can be carried.

It can be run in rough surfaces

Easy to control & operate.

Require less maintenance.

CONCLUSION
 CONCLUSION

In this project, a six legged robot is developed. It is

used to step over curbs, climb stairs, or travel into areas that are currently not accessible with

wheels without microprocessor control and other actuator mechanisms. It would be difficult

to compete with the efficiency of a wheel on a smooth hard surface but as the roughness of

the path increases this linkage becomes more viable and wheels of similar size cannot handle

obstacles that this linkage is capable of. Further, pivoting arms could be used to optimize

The height of the legs for the waterline.

Increase the platform height.

 Reduce the vehicle width.

It allows the legs to fold up compactly for storage

This mechanism can be made more flexible by using different link lengths for front, middle

and hind legs. Intelligence can be induced by introducing Sensors and vision to improve the

effectiveness of this robot in future. Range of motion and moments available at each joint are

the greatest concern as it is important for achieving stance and insect like walking.

We are sure that this Project work will be very useful to industries. We

have satisfaction that we have complete Our project work in a best manner with good co-

operation of our hatch and effective Guidance by our department staff member.

PHOTOGRAPHY
BIBILIOGRAPHY
 BIBLIOGRAPHY

TEXT BOOK:
A text book of Manufacturing Technology, author R.K.Rajput

Dr. Kirpal Singh Automobile Engineering Standard Publishers

Distributors, vol. 1, 12th Edition, 2011.

N. G. Lokhande, V.B. Emche, Mechanical Spider by Using Klann

Mechanism Shri Datta Meghe Polytechnic,Hingna Nagpur
WEBSITE:
http://www.google.com
http://www.wikipedia.com
http://www.mechanicalspider.com/index.html.
http://www.mekanizmalar.com/mechanicalspider.html.