System Analysis Report of a Toy Car

Function: A toy car is a basic prototype of a normal car primarily used for playing purposes. Also, it can be used to get acquainted with the basic parts of a car.

Subsystem Analysis: o Outer Body: Protects other components of the car and serves as an abstraction layer. Colour- red Material- plastic Approximate length- 8.1cm Approximate breadth- 5.8cm

Base (holding wheels): Serves as supporting framework for gears, wheels and flywheel. Approximate length- 7.85cm Approximate breadth- 3.6cm Approximate breadth of outer projection- 4.9cm Approximate depth- 2.2cm

Wheels: They rotate in a particular direction to transport the car forward or backward accordingly. Back wheel radius- 1.4cm Front wheel radius- 1.1cm

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Gear Systems: To change speed and power. o o o Gear 1 :- Outer radius = 0.6cm Inner Radius = 0.4cm Gear 2 :- Outer radius = 0.7cm Inner Radius = 0.6cm

Gear 3 :- Radius = 0.6cm

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Flywheel:- 1.2cm Function: Flywheel stores rotational energy which is used to move the car forward after the applied force is removed.

Calculated speed of the car for a known acceleration : 0.52m/s(after taking the am of two trials) Manufacture: o Popular Manufacturers: o Hotwheels. DieCast Toys. MatchBox.

Gear materials: Numerous nonferrous alloys, cast irons, powder metallurgy and plastics are used in the manufacture of gears. However steels are most commonly used because of their high strength to weight ratio and low cost. Plastic is commonly used where cost or weight is a concern. A properly designed plastic gear can replace steel in many cases because it has many desirable properties, including dirt tolerance, low speed meshing, and the ability to "skip" quite well. Manufacturers have employed plastic gears to make consumer items affordable in items like copy machines, optical storage devices, VCRs, cheap dynamos, consumer audio equipment, servomotors, and printers.Gears are most commonly produced

via hobbing, but they are also shaped, broached, cast, and in the case of plastic gears, injection moulded. For metal gears the teeth are usually heat treated to make them hard and more wear resistant while leaving the core soft and tough. For large gears that are prone to warp a quench press is used. o o Inspection: Gear geometry can be inspected and verified using various methods such as industrial CT scanning, coordinate-measuring machines, white light scanner or laser scanning. Particularly useful for plastic gears, industrial CT scanning can inspect internal geometry and imperfections such as porosity. Maintenance: The toy car will remain functional for a good period of time if protected from physical damage. The wheels and gears of the car may wear out from prolonged use. Abuse and overuse of the product should be avoided. Failure analysis: o *The gears if not assembled properly can cause the contact points to shift, and may not transfer the energy from one gear to another effectively. o *The fly wheel contact if broken can make the car; sustain the momentum its attained only for a short finite span of time. o *The wheels will become ineffective due to prolonged effects of friction over a period of usage. o *The wheel and axle should be fitted properly for the car to work effectively as a system.

Gears and Type of Gears:

o A gear is a modification of the wheel and axle. It just has teeth around it. Like all simple machines, gears may change the direction in which a force is applied; or increase or reduce a force or the distance over which a force is applied.

The toy car given to us had two types of gears namely spur and crown(face) gears:

Spur Gears:

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Spur gears are the most common type used. Tooth contact is primarily rolling, with sliding occurring during engagement and disengagement. Some noise is normal, but it may become objectionable at high speeds. Spur gears have their teeth parallel to the axis and are used for transmitting power between two parallel shafts. They are simple in construction, easy to manufacture and cost less. They have highest efficiency and excellent precision rating. They are used in high speed and high load application in all types of trains and a wide range of velocity ratios. Hence, they find wide applications right from clocks, household gadgets, motor cycles, automobiles, and railways to aircrafts.

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Face Gear: Face gears are a circular disc with a ring of teeth cut on one side. The gear teeth are tapered toward the center of the tooth. These gears typically mate with a spur gear.

Engineering and mathematical foundations: o *The toy car given to us was modeled on a manual gear car.

*The car employed the rear wheel drive mechanism and had three gears of equal number of teeth(24 each). *The crown gear was attached to the fly wheel which acts as a reserve of kinetic energy. *The toy car didnt have a clutch as the fly wheel didnt derive its energy from the engine rather the force that we applied on the car in the form of a push transferred momentum and energy from the wheels to the gears and then to the fly wheel.

1). Inertia o Inertia is a property of all matter: a resistance to changes in motion. To be clear, a change in motion is not just beginning to move from a stop. Slowing down, speeding up, and changing direction are all changes in motion. The only way to change a object's motion is to apply a force to that object. A book slid across a table only comes to a stop because of the frictional forces acting on it. Inertia is proportional to mass, so a more massive object is more difficult to move or stop than a lighter one (even on a frictionless surface).

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Rotational Inertia Just as a book slides until a force opposes its motion, a disc will spin until its rotation is opposed by some force. This property is aptly named rotational inertia.

A flywheel is an inertial energy-storage device. It absorbs mechanical energy and serves as a reservoir, storing energy during the period when the supply of energy is more than the requirement and releases it during the period when the requirement of energy is more than the supply

Many children's toys use rotational inertia. In friction-drive cars, the child pushes the car forward several times to set an internal flywheel in motion. When the car is put down, the flywheel is still spinning and the car moves. This is an interesting way to store energy -- in kinetic, rather than potential format. Rotational inertia is also used to avoid changes in motion for such objects as record players, where it is important to rotate at a constant speed. A flywheel could conceivably be used to store energy to keep an ELEC 201 robot operating after its motors were required to be shut off.

Flywheels-Function need and Operation The main function of a fly wheel is to smoothen out variations in the speed of a shaft caused by torque fluctuations. If the source of the driving torque or load torque is fluctuating in nature, then a flywheel is usually called for. Many machines have load patterns that cause the torque time function to vary over the cycle. Flywheel absorbs mechanical energy by increasing its angular velocity and delivers the stored energy by decreasing its velocity.

Parameters that define the fly wheel design: There are two stages to the design of a flywheel. First, the amount of energy required for the desired degree of smoothening must be found and the (mass) moment of inertia needed to absorb that energy determined. Then flywheel geometry must be defined that caters the required moment of inertia in a reasonably sized package and is safe against failure at the designed speeds of operation.

Gear Functioning: Gear Design:

Number of teeth, N : How many teeth a gear has, an integer. In the case of worms, it is the number of thread starts that the worm has. Gear, wheel : The larger of two interacting gears or a gear on its own. Pinion : The smaller of two interacting gears. Path of contact : Path followed by the point of contact between two meshing gear teeth. Line of action, pressure line : Line along which the force between two meshing gear teeth is directed. It has the same direction as the force vector. In general, the line of action changes from moment to moment during the period of engagement of a pair of teeth. For involute gears, however, the tooth-to-tooth force is always directed along the same linethat is, the line of action is constant. This implies that for involute gears the path of contact is also a straight line, coincident with the line of actionas is indeed the case. Pitch Line: Axis of revolution of the gear; center line of the shaft. Pitch point, p : Point where the line of action crosses a line joining the two gear axes. Pitch circle, pitch line : Circle centered on and perpendicular to the axis, and passing through the pitch point. A predefined diametral position on the gear where the circular tooth thickness, pressure angle and helix angles are defined. Pitch diameter, d : A predefined diametral position on the gear where the circular tooth thickness, pressure angle and helix angles are defined. The standard pitch diameter is a basic dimension and cannot be measured, but is a location where other measurements are made. Its value is based on the number of teeth, the normal module (or normal diametral pitch), and the helix angle. It is calculated as: in imperial units.[17]

in metric units or

Angle of action : Angle with vertex at the gear center, one leg on the point where mating teeth first make contact, the other leg on the point where they disengage. Arc of action: Segment of a pitch circle subtended by the angle of action. Pressure angle, ; The complement of the angle between the direction that the teeth exert force on each other, and the line joining the centers of the two gears. For involute gears, the teeth always exert force along the line of action, which, for involute gears, is a straight line; and thus, for involute gears, the pressure angle is constant. Addendum, a :Radial distance from the pitch surface to the outermost point of the tooth. a = (Do D) / 2 Dedendum, b : Radial distance from the depth of the tooth trough to the pitch surface. b = (D rootdiameter) / 2 Whole depth, ht : The distance from the top of the tooth to the root; it is equal to addendum plus dedendum or to working depth plus clearance. Clearance : Distance between the root circle of a gear and the addendum circle of its mate. Working depth : Depth of engagement of two gears, that is, the sum of their operating addendums. Circular pitch, p : Distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the pitch circle. Diametral pitch, pd : Ratio of the number of teeth to the pitch diameter. Could be measured in teeth per inch or teeth per centimeter. Base circle : In involute gears, where the tooth profile is the involute of the base circle. The radius of the base circle is somewhat smaller than that of the pitch circle. Base pitch, normal pitch, pb : In involute gears, distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the base circle. Types of gears commonly used: A wheel and axle assembly becomes especially useful when gears and belts are brought into the picture. Gears can be used to change the direction or speed of movement, but changing the speed of rotation inversely affects the force transmitted. A small gear meshed with a larger gear will turn faster, but with less force. There are four basic types of gears: spur gears, rack and pinion gears, bevel gears, and worm gears. Spur gears are probably the type of gear that most people picture when they hear the word. The two wheels are in the same plane (the axles are parallel). With rack and pinion gears there is one wheel and one rack, a flat

toothed bar that converts the rotary motion into linear motion. Bevel gears are also known as pinion and crown or pinion and ring gears. In bevel gears, two wheels intermesh at an angle changing the direction of rotation (the axles are not parallel); the speed and force may also be modified, if desired. Worm gears involve one wheel gear (a pinion) and one shaft with a screw thread wrapped around it. Worm gears change the direction of motion as well as the speed and force. Belts work in the same manner as spur gears except that they do not change the direction of motion. o Gear Transmission: In both gears and belts, the way to alter speed and force is through the size of the two interacting wheels. In any pair, the bigger wheel always rotates more slowly, but with more force. This "tradeoff" between force and speed comes from the difference in the distance between the point of rotation and the axle between the two wheels. o How is Relative velocity between two gears nullified to get maximum efficiency? On both the big and the small gear, the linear velocity at the point of contact for the wheels is equal. If it was unequal and one gear were spinning faster than the other at the point of contact then it would rip the teeth right off of the other gear. As the circumference of the larger gear is greater, a point on the outside of the larger gear must cover a greater distance than a point on the smaller gear to complete a revolution. Therefore the smaller gear must complete more revolutions than the larger gear in the same time span. (It's rotating more quickly.) The force applied to the outer surface of each wheel must also be equal otherwise one of them would be accelerating more rapidly than the other and again the teeth of the other wheel would break. The forces of interest however are not the forces being applied to the outer surfaces of the wheels, but rather the forces on the axles. o Velocity and power multiplication needs: Returning to the concept of levers, we know that the distance at which the force is applied affects the force yielded, and a wheel and axle works like a lever. Equal forces are being applied to each wheel, but on the larger wheel that force is being applied over a

greater distance. Thus for the larger wheel the force on the axle is greater than the force on the axle for the smaller wheel. o o o o o o The gear basics and the principle of gears can be seen in the following video: http://www.youtube.com/watch?v=D_i3PJIYtuY&feature=related. Why do we change gears while driving in a car? Although this function cannot be realised in the toy car provided to us can be understood by watching this video. http://www.youtube.com/watch?v=bgGgH0j0KQE. Gear ratios: Gears are toothed members which transmit power / motion between two shafts by meshing without any slip. Hence, gear drives are also called positive drives. In any pair of gears, the smaller one is called pinion and the larger one is called gear immaterial of which is driving the other. When pinion is the driver, it results in step down drive in which the output speed decreases and the torque increases. On the other hand, when the gear is the driver, it results in step up drive in which the output speed increases and the torque decreases. o Law of Gearing: The fundamental law of gearing states that the angular velocity ratio between the gears of a gear set must remain constant throughout the mesh. This amounts to the following relationship: 1/2=d2/d1=z2/z1. Where; Number of teeth(z) Diameter(d) Angular speed(w) Pinion z1 d1 w1 Gear z2 d2 w2

In order to maintain constant angular velocity ratio between two meshing gears, the common normal of the tooth profiles, at all contact points with in mesh, must always pass through a fixed point on the line of centers, called pitch point.

Involute:

 Involute is the path generated by the end of a thread as it unwinds from a reel. In involute gear design contact between a pair of gear teeth occurs at a single instantaneous point (see figure at right). Rotation of the gears causes the location of this contact point to move across the respective tooth surfaces. The path traced by this contact point is known as the Line of Action (also called Pressure Line or Line of Contact). A property of the involute tooth form is that if the gears are meshed properly, the line of action is straight and passes through the Pitch Point of the gears. When this is true, the gears obey the Fundamental Law of Gearing:[1]

The angular velocity ratio between two gears of a gearset must remain constant throughout the mesh.
This property results in smooth transmission of power without speed or torque variations as pairs of teeth go into or come out of mesh.

The involute has some properties that makes it extremely important to the gear industry: If two intermeshed gears have teeth with the profile-shape of involutes (rather than, for example, a "classic" triangular shape), they form an involute gear system. Their relative rates of rotation are constant while the teeth are engaged, and also, the gears always make contact along a single steady line of force. With teeth of other shapes, the relative speeds and forces rise and fall as successive teeth engage, resulting in vibration, noise, and excessive wear. For this reason, nearly all modern gear teeth bear the involute shape.

The need for involutes can be understood from the video,ie need for maintaining constant velocities : http://www.youtube.com/watch?v=Dh83mGUCiws. Variation in centre distance does not affect the velocity ratio. Pressure angle remains constant throughout the engagements which results in smooth running. Straight teeth of basic rack for involute admit simple tools. Hence, manufacturing becomes simple and cheap.

Advantages of Involute Gears

Alternative designs: Increased durability of the plastics used in the manufacture of toy cars can greatly improve its quality. Also, products which undergo minimal chemical treatment and yield mminimum waste can be used. Intellectual property: o New toy car base design diagrams

 Toy car base patents: Origin Patent Number US44597 76 Filing date Issue date al Assign ee Oct 25, 1982 Jul 17, 1984 Marvin Glass & Associ ates Motor driven wheele d toy with floating driven axle US48139 06 Nov 25, 1987 Mar 21, 1989 Tomy Kogyo Co., Inc. USD2743 44 Dec 16, 1981 Jun 19, 1984 CPG Produc ts Corp. USD3698 39 May 18, 1992 May 14, 1996 Tyco Invest ment Corp. Referenced by Patent Number US775375 5 Original Filing date Jul 11, 2005 Issue date Jul 13, 2010 Assigne d Wall racer toy vehi cles US798091 Feb 23, Jul 19, 2011 Wall Title Toy vehicle Pivotabl e running toy Toy vehicle Title

2009

racer toy vehi cles

USD59089 5 USD59089 6 References: o o o

Mar 12, 2008 Oct 21, 2008

Apr 21, 2009 Apr 21, 2009

Toy car base Toy car base

http://www.schsm.org/html/gear_ratio_calculations.html http://www.engineersedge.com/gears/gear_types.htm http://science.howstuffworks.com/transport/enginesequipment/gear2.htm/printable http://nptel.iitm.ac.in/courses/IITMADRAS/Machine_Design_II/pdf/2_1.pdf www.wikipedia.org.