Advanced Electromechanisms Fabrication PDF

ELECTR
MECHANISM
FABRICATION
Di
Do
C=X-^-^-X-l(Di+D2)
2
2
Electromechanical
Technology Series
TERC EMT STAFF
DELMAR PUBLISHERS, MOUNTAIiSlVIEW AVENUE, ALBANY, NEW YORK
12205
DELMAR PUBLISHERS
Division of Litton Educational Publishing, Inc.
Copyright
1973
By Technical Education Research Centers,
Copyright
all
is
claimed until Feb.
portions of this
will
be
in
1,
1978.
work covered by
Inc.
Thereafter
this copyright
the public donnain.
All rights reserved.
No
the copyright hereon
part of this
may
work covered by
be reproduced or used
any form or by any means
in
graphic, electronic, or
mechanical, including photocopying, recording, taping,

or information storage and retrieval systems
without
written permission of Technical Education Research

Centers.
Library of Congress Catalog Card
Number:
72-75564
PRINTED
IN
THE UNITED STATES OF AMERICA
Published simultaneously In Canada by
Delmar Publishers,
Van
The
a division of
Nostrand Reinhold, Ltd.
project presented or reported herein was per-
formed pursuant to
a grant
from the U.S. Office of
Education, Department of Health, Education, and

Welfare. The opinions expressed herein, however, do
not necessarily reflect the position or policy of the
U.S. Office of Education, and no official endorsement
by the U.S. Office of Education should be
inferred.
Foreword
The marriage of
electronics
and technology
New
technical personnel in today's industries.
with combination
many
devices of
optical
must
Increasingly, technicians
kinds
for
occupations have emerged
who work
many
with systems and
mechanical, hydraulic, pneumatic, thermal, and
be competent also
skills is especially significant
in industrial
new demands
requirements well beyond the capability of
skill
technical specialists.
creating
is
in
electronics. This need for
for the youngster
who
is
combination
preparing for a career
technology.
one of a series of closely related publications designed

for students who want the broadest possible introduction to technical occuThis manual
The most
pations.
is
manuals
effective use of these
is
combination textbook-
as
laboratory guides for a full-time, post-secondary school study program that

provides parallel and concurrent courses
in
electronics, mechanics, physics,
mathematics, technical writing, and electromechanical applications.
unique feature of the manuals
in this series is
the close correlation of
technical laboratory study with mathematics and physics concepts.
topic
is
studied
by use of
practical
Each
examples using modern industrial applica-
The reinforcement obtained from multiple applications of the concepts

has been shown to be extremely effective, especially for students with widely
diverse educational backgrounds. Experience has shown that typical junior
tions.
college or technical school students can
make
satisfactory progress in a well-
coordinated program using these manuals as the primary instructional material.
School administrators
manuals to support
programs
in
such fields
or quality assurance.
will
common
as:
be interested
first-year
in
the potential of these
core of studies for two-year
instrumentation, automation, mechanical design,
This form of technical core program has the advantage
of reducing instructional costs without the corresponding decrease in holding
power so frequently found
in
general core programs.
This manual, along with the others
in
the series,
is
the result of six years
of research and development by the Technical Education Research Centers,

Inc.,
(TERC),
quarters
in
a national nonprofit, public service corporation with head-
Cambridge, Massachusetts.
It
has undergone a
number of
revisions
as a direct result of experience gained with students in technical schools
community
and
colleges throughout the country.
Maurice W. Roney
Hi
The Electromechanical Series
TERC
is
engaged
cal Technology.
in
an on-going educational program
The following
titles
in
Electromechani-
have been developed for this program:
INTRODUCTORY
ELECTROMECHANISMS/MOTOR CONTROLS
ELECTROMECHANISMS/DEVICES
ELECTRONICS/AMPLIFIERS
ELECTRONICS/ELECTRICITY
MECHANISMS/DRIVES
MECHANISMS/LINKAGES
UNIFIED PHYSICS/FLUIDS
UNIFIED PHYSICS/OPTICS
ADVANCED
ELECTROMECHANISMS/AUTOMATIC CONTROLS
ELECTROMECHANISMS/SERVOMECHANISMS
ELECTROMECHANISMS/FABRICATION
ELECTROMECHANISMS/TRANSDUCERS
ELECTRONICS/COMMUNICATIONS
ELECTRONICS/DIGITAL
MECHANISMS/MACHINES
'
>
MECHANISMS/MATERIALS
For further information regarding the

its
EMT
program or for assistance
in
implementation, contact:
Technical Education Research Centers, Inc.
44
Brattle Street
Cambridge, Massachusetts 02138
iv
Preface
Technology, by
its
very nature,
such, the laboratory portion of
is
any technology program
These materials are intended to provide

tion techniques for students of
a laboratory-oriented activity.
is
As
vitally important.
meaningful experience
in fabrica-
modern technology.
The sequence of presentation chosen
is
by no means
may choose
expected that individual instructors
inflexible.
to use the materials
It
is
other
in
than the given sequence.
The
particular topics chosen for inclusion in this
volume were selected
to provide experience as near as possible to the industrial situation.

instructors
them to
better
The
many
may
meet
their local needs.
materials are presented
an action oriented format combining
in
of the features normally found
ciated with a laboratory manual.
1.
textbook with those usually assoEach experiment contains:

in a
An INTRODUCTION which
and often includes
2.
A DISCUSSION
3.
A MATERIALS
identifies the topic to be
a rationale for
examined
doing the exercise.
which presents the background, theory, or techniques needed to carry out the exercise.
list
which
laboratory experiment.
identifies all of the items
A PROCEDURE
needed
in
in
the
lists.)
which presents step-by-step instructions for
forming the experiment.
the
(Items usually supplied by the student
such as pencil and paper are normally not included
4.
Some
wish to omit one of the exercises or to supplement some of
In
per-
most instances the measurements are
done before calculations so that all of the students can at least

finish making the measurements before the laboratory period ends.
5.
PROBLEMS
are included for the purpose of reviewing and rein-
forcing the points covered
in
the exercise.
The problems may be
of the numerical solution type or simply questions about the

exercise.
Students should be encouraged to study the textual material, perfornn

the experiment,
work the review problems, and submit
a technical report
on
each topic. Following this pattern, the student can acquire an understanding
of,
and
skill
with, basic fabrication techniques that will be extremely valu-
able on the job.
The
material
on fabrication comprises one of
pared for technical students by the
TERC EMT
a series of
staff at
volumes
pre-
Oklahoma State
The prin-
University, under the direction of D.S. Phillips and R.W. Tinnell.
author of these materials
cipal
An
Robert
Instructor's
L.
Krishan Paul.
is
Data Book
is
available for use with this volume.
the instructor's data book for them.
made
Mr.
Gourley was responsible for testing the materials and compiling
valuable contributions
in
Other members of the
TERC
staff
the form of criticisms, corrections, and
suggestions.
It
is
sincerely
hoped that
this
volume as well as the other volumes in

and the other supplementary mate-
this series, the instructor's data books,

rials will
make the study
of technology interesting and rewarding for both
students and teachers.
Contents
NUMERICAL CONTROL OF MACHINE TOOLS
experiment 2
SIGNAL INJECTOR
experiment 3
PREPROGRAMMED PLAYER ORGAN
experiment
19
experiment
INTRODUCTION.
DISCUSSION. Numerical
is
This project should give the student an understanding of and experience
programming and operating
tools
NUMERICAL CONTROL OF
MACHINE TOOLS
numerical control
drill press.
control of machine
The
an area of automation which has been
making steady progress for the
last
axes
decade or
are
Numerically-controlled machines are be-
so.
ing used
in
available
tors used for
Wherever used,
numerically-controlled machines increase ac-
addition to
the
all
which
its
are synchro-
movement along the X

movement
continuous
numerical control machines
two
though holes can be
the
(Other machines
movement along
planes.)
The two mo-
have
moving the table
along
parts:
only along two
computer
axis
and
This limits the range and direction
axis.
of continuous
Basically,
is
nized so that the table moves at a 45 angle in
curacy, precision, and speed of operation.
are comprised of
movement
table
the horizontal plane.
other than horizontal
phases of engineering effort,
in all
from design to production.
in
of the table.
curve
is
not
Milling
possible
drilled along the circum-
The
which reads the coded instructions, interprets,

and communicates them, and the machine
ference of a circle or any other curvature.
tool which executes the instructions. The
centers of holes along the circumference of a
punched on
structions are generally
inch-wide
code.
common
type
The
study
first
in
plot the
circle.
a one-
used
is
is
in
some
Suppose we are required to
appli-
by far the most
a circle
step in using any machine
is
nine
three inches
in
diameter.
Figure 1-1
shows the circle with the points. To determine the angular position of hole centers, we
divide 360 by the number of holes, which
to
Most machines currently
being used for numerical
drill
equidistant holes along the circumference of
use today.
features.
its
in-
method should be used to
tape using some standard
paper
magnetic tape
though the former
cations,
following
case gives
in this
tape control are
point-to-point machines, though continuous-
path features are also available.
The
instruc-
on punched tape and fed to

The
controller interprets the instructions and directs the machine through the intended opertions are stored
the controller through a tape reader.
ations.
Remember
machine
will
do, and
it
rectly only
if
If
that a numerical control
do whatever
will
It
perform
all
it is
programmed
can be seen that
the holes will be
all
at an angular distance of 40
one hole
is
located at
from each
in
position of the other eight holes
to
C, D, E, F, G, H,
the operations cor-
bered that hole
the instructions are correct.
and
I.
(It
other.
Figure 1-1, the

is
given by B,
should be remem-
can be located anywhere
along the circumference and the positions of

the rest of the holes will be located at an an-
Feed control and the capability for

ing holes as well as milling are
gular
drill-
two other
im-
point.)
portant features of this machine.
increments
of 40
beginning at this
Also, for the sake of convenience,
consider the center of the circle as the center
EXPERIMENT
MACHINE TOOLS
\^100
40
MS^'l
Fig. 1-1
of the
the point
(0, 0).
0) with
Position of Nine Holes
Y axis; or in other words,

Now point A is -1.5 in. from
the center 0 so that
it
and XX' and YY'
is
20
in
Similarly, the
in.
is
sin 20, or 1.5
Point E
is
then represented by (1.41, 0.513).
Similarly, point
sin
60),
point
is
and
lines
plotted
and
1.
machining to be done, dimensions and
hold the work on the
the points are plotted and speci-
fications are studied
we
program which can
later
and the
positions of the fasteners required to
drilling
2.
all
Prepare a detailed drawing showing the
position of holes, the tool path,
holes by choosing a suitable center.
After
only and thus any shape of curves can-
Before the machine can be programmed
(1.5 cos 100, 1.5 sin
programmed for
As already explained, numerical con-
machines allow movement along straight
the following steps are important to note.
in.
100), and so on. All nine points can be similarly
end of the milling operation need to be
not be milled.
given by (1.5 cos 60, 1.5
C by
Circle
this purpose, the points at the beginning
axis dis-
X 0.342 or 0.513
20)
For
trol
(CCW) direction. The distance of point E from the X axis,

therefore, is given by R cos 20, or 1.5 X
0.940 or 1.41
R SIN
charted along which the tool will move.
plotted.
angular distance from the
horizontal axis in the positive
tance
Along A
at the
as
the horizontal and vertical axis respectively.
Point E
For milling, a continuous path has to be
can be plotted as (-1.5,
as the origin
COS 20
20
and
axis
(R
\^
table.
Determine the set-up point and the

sequence of operations.
are ready to write the

3.
be punched on tape
and used by the machine to
drill
Determine the
size
and speed of the
cutting tools.
holes of the
required size.
4.
Prepare a program sheet.
EXPERIMENT
MACHINE TOOLS
MATERIALS
1
Numerical control machine
1/16
Program punching machine with tape
Brass plate, 5.6
Set of twist
Fine-cut
drills
in.
milling tool
in.
2.6
in.
X 3/16
in.
file
PROCEDURE
Figure 1-2 shows the drawing of a piece (called a
position of holes marked.
5/32
in.
diameter
making the
letters
in
The
plate
is
5.6
in.
name
long and 2.6
in.
plate) with specifications
and the
wide. There will be four holes of
The letters 0, S, and U will be milled with a milling tool,

The periods will be 7/64 in. holes drilled to a depth of 1/16 in.
the four corners.
1/32
in.
deep.
2.6"
Fig. 1-2
Drawing of the
Name Plate
The set-up point will be a point X which is 0.8 in. from A B and 0.8 in. from A.C. The program sheet can be seen in Figure 1-3. The following M function codes have been used in programming for this project.
06
52
53
For tool change
55
02
For high speed feed between the
For tool down for milling

For tool up
letters
For tape rewind
when the
tool
is
up
EXPERIMENT
MACHINE TOOLS
NUMERICAL TAPE CONTROL
PROGRAM
COMPANY NAME
annpESS
PREPARED BY
DATE
PART NAME
CK'D BY
PART NO.
OPER. NO.
REMARKS:
DATE
SHEET
OF
DEPT.
TAPE NO.
SEO.
NO.
TAB
OR
OR
EOB
OR
INCREMENT
OR
EOB
0500
TAB
"X"
INCREMENT
TAB
OR
EOB
0500
EOB
2000
EOB
2000
TAB
Y"
"M"
FUNCT.
EOB
INSTRUCTIONS
EOB
RWS
EOB
TAB
TAB
TAB
TAB
Tool hoses, 5/32

-
TAB
5000
in. drill
EOB
TAB
06
EOB
Change
drill
to 7/64
and
Adjust tool travel

5
TAB
0600
TAB
TAB
1400
EOB
TAB
1400
EOB
Q
O
TAB
0900
TAB
TAB
10
TAB
11
TAB
12
TAB
13
TAB
14
TAB
15
TAB
16
TAB
17
0600
EOB
0900
TAB
56
EOB
Change hoses to "auxiliary"

Change tool for milling.
Reduce feed speed and
adjust tool travel
TAB
TAB
TAB
0200
EOB
TAB
0600
EOB
0200
TAB
0200
EOB
0400
EOB
0200
TAB
0200
EOB
TAB
0600
EOB
0200
TAB
0200
TAB
0400
TAB
18
TAB
1200
TAB
19
TAB
TAB
20
TAB
TAB
0100
EOB
21
TAB
0200
TAB
0200
EOB
22
TAB
0400
EOB
23
TAB
0200
TAB
0200
EOB
24
TAB
TAB
0200
EOB
25
TAB
0100
TAB
0100
EOB
26
TAB
0600
EOB
0200
Fig. 1-3
EOB
0700
TAB
53
EOB
TAB
55
EOB
TAB
52
EOB
Program for the
"OSU" Name Plate
EXPERIMENT
ADDRESS.
PART NAME
CK'D BY
MACHINE TOOLS
PROGRAM
COMPANY NAME.
PREPARED BY
DATE
PART NO.
OPER. NO.
REMARKS:
DATE
OF
SHEET
DEPT.
TAPE NO.
SEQ.
NO.
TAB
OR
EOB
27
TAB
28
TAB
OR
"X"
INCREMENT
0100
"Y"
TAB
OR
INCREMENT
EOB
TAB
0100
EOB
TAB
0200
EOB
0200
EOB
TAB
OR
EOB
OR
"M"
FUNCT.
EOB
29
TAB
0200
TAB
30
TAB
0400
EOB
31
TAB
0200
TAB
0200
EOB
32
TAB
TAB
0100
TAB
53
EOB
33
TAB
TAB
0300
TAB
55
EOB
34
TAB
TAB
TAB
52
EOB
35
TAB
TAB
0800
EOB
36
TAB
0200
TAB
0200
EOB
37
TAB
0400
EOB
38
TAB
0200
TAB
0200
EOB
39
TAB
TAB
0800
TAB
53
EOB
40
TAB
TAB
1000
TAB
02
EOB
0600
3600
Fig. 1-3
Program for the
"OSU" Name Plate

5
INSTRUCTIONS
(Cont'd)
EXPERIMENT
MACHINE TOOLS
Compare them with the program
1.
Prepare the program sheets.
2.
Punch the program on the tape using the hand punching machine. (If there is a mistake,
"delete" that particular sequence.) Punching of sequence numbers is optional and is for
in figure 1-3.
the sake of convenience only.

3.
4.
Mark the starting point of the tape with

end and get completely wrong results.
Mount the work on the
a pen.
It is
easy to feed the tape from the other
table and with the positioning switch
on manual, "job" the
table
to the "set-up" point.

5.
Feed the tape into the reader, put the positioning and tool switches on "auto" and the
feed switch on "high".
6.
7.
and go through the program without the tool
Start the reader
Notice and mark the position of the table at every tool operation cycle.
pencil in place of the tool with help
8.
Correct any mistakes
9.
Mount the
in
Start the tool
1 1
Start the reader.
tool travel.)
positioning or programming.
machine).
(drill
12.
Follow instructions
13.
Compare with drawing from time
14.
mark the
(The use of
tool in the machine.
10.
.
in position.
in
the programming sheet.

to time.
At the end of the program switch off the tool and reader, remove the work, and remove
the tool,
15.
Clean and polish the work as necessary.
16.
With
a file,
smooth
all
four edges and
mount on
wooden block
of suitable
size.
Use slow feed rate (3 in. per minute) for milling, and 18 in. per minute or high feed for positioning and drilling.
Do not forget to adjust the tool travel before milling and before drilling
periods.
PROBLEMS
1.
Figure 1-4 shows a circle of 2
in.
diameter
with a point A at an angular distance of

17 from the horizontal axis.
Plot the
centers
2.
Make
ten
along
drilled
circle,
of
a detailed
Discuss
and
the
holes to
first hole.
drawing of the three
on
why you
be
circumference of this
being the center of the
mill the initials

3.
equidistant
initials
on your own name. Write
Fig.
1-4
program to
a metal plate.
should use low speed for milling and high speed for positioning
drilling.
experiment
INTRODUCTION.
machine
This project
is
designed to enable the student to gain experience
tools, constructing miniature
circuits,
Fabrication of components
DISCUSSION.
SIGNAL INJECTOR
and testing and
tools.
among
these tools
quires the use of
it is
is
the engine lathe. Besides
and
grinding,
ers
boring, thread cutting,
drilling,
milling.
Though they
the laboratory or workshop.
and makes.
1.
portant function of a lathe
im-
metal parts by a turning operation. This basic

function
is
performed by
all
lathes.
depend on the
size
2.
and sophistication
common
work that can be
turned.)
tions of turning and
standard on
all
maximum
The
drilling,
Be familiar with the emergency stop

control switch of
fore starting
4.
take only small pieces of work. (The size of a
determined by the
Always wear safety glasses when working on lathes, drilling machines, or

grinders.
3.
is
must
rolled up,
parts of a lathe.
Knowledge of the controls and parts of

the lathe as shown in Figure 2-1 is essential
Smaller mabefore starting work on one.
and can
fewer
features
chines generally have
lathe
must be
coat.
of a particular machine and, hence, on price.
Figure 2-1 shows the
loose clothing. Ties

sleeves
in,
All other
possible operations like boring, grinding, and

milling
Do not wear
be tucked
and watches and rings must be taken

off.
If possible, wear an apron or shop
the reshaping of
is
The following
improperly used.
if
safety rules are suggested for enforcement in
and amount of sophistication, most lathes

have some parts which are common to all de-
Remember, however, that the most
Lathes, grind-
and other machine tools can be very dan-
gerous
differ in
size
signs
While working on or near machine tools

very important that safety rules and pre-
cautions are strictly observed.
turning metals, wood, and plastics, lathes can
be used for
operating
Safety
re-
many machine and hand

The most versatile and commonly used
in
components.
fitting different
machine tools
all
work on them.
The
Follow instructions.
do
a job
is
be-
safest
way
to
the correct way.
size of
basic opera-
5.
however, are
lathes.
not roughhouse.
Most accidents
happen when you are

less.
Do not try
off guard or care-
Do
to
hurry
job.
Machines cannot v?ork at more than

This project will require you to turn two
Any undue
their designed speed.
metal components and one plastic component
ing may end
in
rush-
unnecessary accidents.
for the signal injector, besides drilling holes.
Use of other hand tools
will also
be required
6.
for successful completion of the project. A

thorough familiarity with the type of lathe
you
will
work on
is
Do not
neglect
small
injuries.
Cuts,
burns, and scratches should be attended

to immediately and dressed properly.
absolutely essential to
produce quality work and avoid accidents.
7.
Keep your work area
clean.
EXPERIMENT 2 SIGNA L INJECTOR
COMPOUND REST FEED HANDLE

SPEED CHANGE LEVERS
COMPOUND REST
FEED REVERSE LEVER
CROSS SLIDE
SADDLE
HEADSTOCK
TAILSTOCK SPINDLE CLAMP
DEAD CENTER
TAILSTOCK SPINDLE
TAILSTOCK HANDWHEEL
TAILSTOCK
TAILSTOCK CLAMP
WAYS
BED
QUICK CHANGE GEARBOX
LEADSCREW
FEED ROD
STARTING SHAFT
CARRIAGE
CARRIAGE HANDWHEEL
FEED DIRECTIONAL LEVER
BASE
Fig. 2- 1
Most of the
Engine Lathe
accidents that happen in
Taper Cutting
the laboratory or shop are due to either not
following the safety
your machine
well.
rules
You can
or
One
not knowing
help to cut
possible
down
ting.
on accidents by following the rules yourself

and requesting others to do the same. Be very
familiar with the machine tool before starting
work on it. Know all its features and capabilities,
as well as
its
It
of the
on
is
many
good
lathe
operations which
is
is
called taper cut-
turning a round metal piece on a
lathe in such a
way
that one end has a bigger
diameter than the other end.
There are generally three methods of cut-
limitations.
ting tapers
on engine
lathes: (1) off-setting the
EXPERIMENT 2 SIGNAL INJECTOR
tail
method
stock, thereby setting the lathe centers
and
attachment;
(called
setting
(3)
compound
on
rest
the tool
bigger and
post
more
is
2.
methods
brief outline of each of the three
given below.
1.
further operations
are required to be
done on the work
The use of the taper attachment is another method of cutting tapers. This
fits
with
plied
on the lathe and
specifications
tions for settings which
amount of
taper
following
formula
inches per foot
of taper and the length of the work.

gives the
in
and
t.i.p.f.
depend on the
inches per foot.

gives
Setover =
-smaller
portion
the taper
3.
in inches.
dia. (in.)
X 12
which normally moves
ter holes
thus producing a taper.
Angle =
usage.
work, the cen-
Because of
^'
tan"^
g^^'
As
do not bear
As the
tool
normal
parallel
work
tend to lose their true position
some
after
method of
The compound rest is
rest in the third
parallel to
\ards the dead center than towards the
fully into the ends of the
used for setting the
equation.
the bed of the lathe, cuts deeper to-
setover,
is
an angle given by the following
set at
when
inches
cutting tapers.
the centers are offset like this, the
live center,
in
The same formula
compound
Note: All dimensions
the centers,
this, this
is
fed in at an angle to the
movement,
it
into the predetermined
turns the
amount
taper.
MATERIALS
1
Engine
lathe,
complete with three-jaw
chuck and tool
bits
Micrometer
0-1 in.
6-in. Steel rule
Set of twist
drills
Outside caliper
Set of hand tools
Plastic rod,
Pin jack
in.
long, 3/4
in.
diameter
File (fine cut)
Bench
2 Miniature ceramic disk capacitors, 0.04 juF
Soldering iron
Fine emery cloth
Aluminum
OD
vise
5/8
ID 9/16
Miniature ceramic tubular capacitor,
100 PF
tubing, 3-1/2
in.,
in
(large dia.-small dia.)
2 X (length of taper portion)
tool,
The
(t.i.p.f.).
length of the taper
When
sup-
larger dia. (in.)
work X
is
instruc-
amount
of setover in inches.
total length of
precision
for
if
attachment
method is
used for taper cutting when the work
The amount of setis sufficiently long.
over (or off-set) depends on the amount
Offsetting-the-lathe-centers
The following formula
favored
subsequent to the taper cut.
ex-
pensive lathes) at an angle relative to the work.
not
is
work, especially
out of alignment; (2) using the taper-cutting
in.
long,
2 Carbon resistors for base
22 kilohm, 1/2 watt
in.
resistors,
of

Aluminum
1/2
in.
rod, 7/8
2 Carbon resistor for collector
long
Brass rod, 5/16
Steel coil spring, 1/4
1/4
diameter,
in.
OD
in.
diameter, 3/4
in.
long with
and ID 3/16
in.
long
in.
resistors,
470 ohm, 1/2 watt

2 Audio transistors
1
Leakproof pen
light battery, 1.5 volt
in.
PROCEDURE
1.
a)
Hold the tube vertically

above the jaws.
the bench vise with one end showing about one inch
in
(A couple of small, wooden blocks with V-notches
will help to pro-
vide a good grip.)

b)
Smooth
the edges and remove burrs with a fine-cut
c)
Remove
the tube and clamp
d)
Remove
the tube from the vise and measure
should be 3.5
with the
e)
f)
^
Make
long.
in.
Make
file.
its length with a steel rule.

The tube
more than 3.5 in., remove the excess metal
measurements to insure that the edges are true all around.
several
is
at a distance of
mark.
1/8-in. hole at the
Drill a
again with the other end above the jaws of the vise.
the length
If
mark on the tube
it
file.
5/32
in.
from one of the edges.
(A V-block helps to keep the tube steady when
drilling the hole.)
The
finished tube
is
shown
in
Figure 2-2.
3-1/2-IN.
STEEL TUBING,
OD
IN.,
= 5/8
ID = 9/16 IN.
1."
32
Fig.
2.
a)
Hold the aluminum rod
in
2-2 Finished Tube
the three-jaw chuck of the lathe with at least 3/8
truding from the edge of the chuck.
much
extra effort
is
The three-jaw chuck
required to center the work.
If
the
is
in.
pro-
self-centering so not too
work
is
not square, loosen
the jaws, straighten the piece and tighten the jaws of the chuck again.
b)
Mount
the
tail
the round nose tool on the tool post and adjust

center of the lathe.
its height to compare with

Remember, when working with aluminum, the height of
the tool bits should be slightly higher than center to avoid chatter.
c)
Start the
motor and smooth the outer end of the aluminum rod with
10
a slight cut.
d)
Turn the work to an outer diameter of 5/8

1.
Do
not feed the tool
in
more than 1/32
in.
up to
in.
for a single cut.
a length of
7/32
in.
Remember:
cut of 1/32
in.
into
a round piece reduces the diameter by 1/16 in.
e)
measurement with the
2.
Take
3.
Take the
final
i)
to 19/32
lip
tool back
on the
tool post and finish the diameter of the
in.
center from the
size drill bit into this
Mount a 3/8
work piece.
in.)
in.
Remove the dead

in.
h)
a micrometer.
the parting tool (ground to a width of 1/16
Mount the round nose

outer
g)
measurement with
on the tool post and adjust it

at a right angle to the work. Slide it to a distance of 5/32 in. from the right edge of
the work. Slowly feed the tool 1/16 in. into the work. Remove the tool and measure with the micrometer. The outer diameter of the work at this 1/16 in. groove
Mount
should be 1/2
f)
calipers after every cut.
chuck and
tail
stock and
drill a
Remove the work and chuck
a drill chuck.
hole through the
the chuck and
in. drill bit in
mount
drill a
work
Mount
3/16
piece.
hole to a depth of 1/8
in.
into the
the finished portion so that the other side can be
machined.
j)
With the round-nosed
k)
With the
5/32
in.
right
between the groove and the edge.
Chamfer the edge with
m)
With a 5/16
finished
diameter to 5/8
in.
hand finishing tool turn the face of the work to reduce the
I)
The
tool, finish the overall
smooth
in. drill bit, drill
file.
a hole to a
body of the switch can be seen
depth of 7/32
Figure 2-3.
in
1/2 DIA.
19/32 DIA.
5/8 DIA.
5
32
32
_1_
16
Fig.
2-3
Body of Switch
11
in.
size to
EXPERIMENT2 SIGNAL INJECTOR

3.
Hold the brass piece

in
step
2,
in
the three-jaw chuck and machine
according to the specification shown
a hole to a
depth of 1/16
in
into the smaller end.
in.
it
using the procedure outlined
Figure 2-4. With a 1/8
Chamfer the
in. drill bit, drill
larger edge.
5/32
9/32 DIA.
9_
32
16
2-4 Plunger for the Switch
Fig.
4.
Assemble the switch as shown
in
Figure 2-5.
With a centerpunch,
flare the smaller
edge
of the plunger.
2-5 Assembly of Switch
Fig.
5.
a)
Hold the
plastic
round
in
three-jaw chuck so that about 5/8
in.
extends from the
edge of the jaws.

b)
Mount
c)
Reduce the speed of the
d)
Turn the righthand face of the work.
e)
Turn the work to reduce the diameter to 5/8

measure with outside calipers after each cut.
f)
Set the
a round-nosed tool
compound
on the
lathe to
rest at
tool post.
between 500 and 600 RPM.
(5/8-9/32) X 12
1/2 X 24
g)
Cut the taper so that the diameter of the
h)
Remove the dead
center from the
hole through the
With 1/4
in.
X 24
Take small (1/32
an angle given by
Tan
Drill a
in.
tail
right face
stock and
work with the
is
9/32
mount
12
a 1/4-in. drill.
1/4-in. drill.
tap, thread the hole to a depth of 3/8
in.
in.
in.)
cuts and
k)
Remove
the
work from the chuck and hold
it
the chuck with the other end ready
in
to be machined.
up to the edge of the
I)
With a round-nose tool turn the diameter to 9/16
m)
Turn the face of the work with the same tool to reduce the length between the edge
of the taper and the face to 1/4
Mount
o)
Use a fine emery cloth to polish the work.
p)
Remove the
q)
a 7/16-in. drill bit to bore a hole into the
work
taper.
in.
n)
plastic
in.
work to
depth of 7/16
in.
piece from the chuck.
and tap a 4-40 hole on the collar of this plastic insulator at a distance of 5/32
from the edge of the taper. This hole should align with the hole drilled earlier in
Drill
in.
the tube.
6.
a)
Hold
b)
With a thread cutting die of 1/4

oil
a standard pin jack in a
bench
vise
in.
with the sharp end held between the jaws.
X 24
size,
cut threads on the jack.
(Use cutting
for lubrication while cutting threads.)
c)
Apply
d)
Remove
drop of solder on the end of the

the jack from the vise and
fit it
jack.
into the insulator.
This completes the assembly of the probe which can be seen
1/4
Fig.
2-6 Probe Assembly
13
in
Figure 2-6 below.
X 24
THREAD
5/64
EXPERIMENT 2
ELECTROMECHAN ISMS/FABRICATION
SIGNAL INJECTOR
2
32
3_
16
"IS
1
3
8
"*
3
"
32
_1_
16
Fig.
7.
a).
Take
in
2-7 Circuit Board Dimension
a piece of plastic circuit
board and cut
it
according to the dimensions shown
Figure 2-7,
b)
Drill
c)
Drill
two
1/16-in. diameter holes near the left
two
hand corner as seen
diameter holes along the center
1/4-in.
line
in
Figure 2-7.
of the board as
shown
in
Figure 2-7.
one 1/32-in. hole between the
d)
Drill
e)
Take
a 3/16-in.
(with
epoxy
glue).
1/4-in.
1/4-in. holes as
shown
Figure 2-7.
in
1/16-in. piece of sheet brass
and glue
This piece will serve as a battery connector.
the position of the battery connector.
Fig.
2-8 Wiring of Circuit Board
14
it
to the board
See figure 2-7 for
f)
Mount the four
shown
resistors as
through the corner holes.

sides of the board.
g)
Figure 2-8.
Insert the
two
from each
lead
on each
in
side of the
in
two
its
farther end.
Insert the capacitor
Form
the
resistors.
shown
through the 1/32-in. hole
Each capa-
front of the circuit board.
board and should face each other.
common
in
the
2-9 Wiring Diagram

a
loop with one lead of the tubular capacitor
Put a drop of solder on the lead.
and solder the remaining lead to
a collector resistor.
connector by wrapping several turns of number 20 tinned copper
wire around the circuit board and tubular capacitor. This can be seen as
2-10.
both
Figure 2-9.
Form the probe connector by making

over
I)
set of
side of the board through the 1/4-in. holes as
capacitors into the slot
one
Fig.
k)
and R^ represent the
X on
Solder the connector, transistor, capacitor and resistor leads as indicated

wiring diagram
j)
each case run the rear lead
transistors.
disl<
citor should have

i)
in
Insert the emitter lead of the rear transistor
between the two

h)
Figure 2-8.
in
Solder these leads to the battery connector
In Figure 2-8, Rj^
Insert the transistors

in
in
Figure
Fig.
8.
2-10 Front and Side View of the Circuit Board after Completion
m)
Connect the emitter leads to the
n)
Check
o)
Check the completed
a)
all
Press-fit
common
connector using an insulated wire.
the connections.
circuit against Figure 2-1.
the tube and the switch assembly.
should give a fairly good press

over the switch collar helps
making the press
fit
if
difference of 1/32
there
is
not a good press
c)
Insert the circuit
fit.)
in
diameters
end which
fits
Excessive pressure
in
should be avoided, however.
nsert the battery into the case with the positive terminal
b)
in.
(Slight heat applied to the tube
fit.
toward the switch assembly.
board with the edge of the board aligned with the
1/8-in. hole in
the tube.
d)
Mount the probe assembly and
e)
Insert a
number 4-40 X 1/8
align the hole
in.
on the
collar with the hole
long machine screw only far enough to secure the
probe assembly to the tube.

f)
Screw
in
on the tube.
the probe tip until the contents of the tube are tight.
16
EXPERIMENT2 SIGNAL INJECTOR
CIRCUIT BOARD
2-11 Assembly Sequence of the Signal Injector
Fig.
g)
Tighten the machine screw until

the circuit board.
9.
Figure 2-1
With
i)
Test the signal injector.
a)
Connect
a wire
it
makes contact with the common connector of
shows the assembly sequence of the
emery cloth clean and
h)
a fine
PROBE ASSEMBLY
signal injector.
polish the assembly.
from the case of the
signal injector to the
common
connector of a
cathode ray oscilloscope.

b)
Connect the probe
c)
The waveform shown
tip of the signal injector to the vertical input of the oscilloscope.

in
Figure 2-12 should be viewed
depressed.
Fig. 2-
12 Waveform of the Signal Injector
17
when the
switch plunger
is
Fourier analysis of the waveform should be done to determine if the waveform produced by the injector matched the theoretical waveform. What are the factors which
ANALYSIS GUIDE.
produce a different waveform?
PROBLEMS
1.
2.
What changes
3.
the circuit and/or
changed from PNP to
sistor
is
What
will
to
in
in
the procedures will be necessary
if
the tran-
NPN?
be the resultant waveform as a result of changing the transistor from
NPN?
Does the polarity of the battery affect the waveform?
18
PNP
experiment
INTRODUCTION.
PREPROGRAMMED PLAYER ORGAN
This project
cate an electromechanical device;
DISCUSSION. Design and
will
provide an opportunity to the student to design and fabri-
in particular, a
fabrication are
device which will operate a player organ.
two
Another factor involved

charge
of the important functions an electromechanical
technician
is
duction
used for suitable classroom experience.
reaches
design and fabrication of a
The
preprogrammed
represented by
player organ described in this experiment
voltage
is
one of those examples.
Unijunction relaxation oscillation can be
Rg-|,
and across the
circuit
diagram of this
waveforms
which
voltage
is
charge through R^.

capacitor
and the
is
size
UJT
UJT
Therefore, the
Rg-j
is
set of
breaking into conduc-
sawtooth waveform occurs at the
The charging
The
begins to
this
is
actually the
voltage across Cg, therefore, appears as a
sawtooth waveform, and this
rate of the
form we
determined by the setting of

of the capacitor
UJT because
charge/discharge curve of the capacitor
possesses a high
capacitor
the
through
tion, and the capacitor discharging through the
emitter of the
as
charge
a relatively small resistor pro-
across the resistor
resistor.
impedance
reached, and the capacitor
spikes caused by the
at the emitter
resistors.
Tfie emitter of the
is
accumulated
its
(This
As the sup-
C^ through R^,
viding a quick discharge rate.
called the heart of an organ tone generator.
oscillator with the
the waveforms.
usually around 3 volts.)
is
discharges
shows the
Vp on
ply potential begins to charge
the firing level
Figure 3-1
pos-
when the voltage at the emitter

some predetermined value which is
There are a number of projects which can be
just
The UJT
the supply potential.
is
the rate of
sesses the characteristic of breaking into con-
upon to perform
called
in
will
will
be concerned with
be the wavein
generators.
itself.
VOLTAGE AT THE EMITTER
'RBI
VOLTAGE ACROSS Rg,
Figure 3- 1 Circuit Diagram of Unijunction Transistor

Relaxation Oscillator and Resultant Waveforms
19
the tone
EXPERIMENTS PREPROGRAMMED ORGAN
'DD
FET
HIGH IMPEDANCE FET AMPLIFIER

VOLTAGE GAIN 10 WITH
3 WITHOUT Cj
FREQUENCY RESPONSE 3dB
26 HZ TO 23 KHZ
Cj
-1I
_J
Fig.
The above tone
3-2 Circuit Diagram of an
must be fed
oscillator
on the
in-
gain
stage field effect transistor (FET) amplifier.
tend to load
down
circuits
is
device and does not load the signal-creating

device.
Thus,
it
amplifier stage
can be seen
a single
added to each
is
Looking at the diagram,

is
why
we
coupling capacitor.
The
oscillator.
FET by
gate
is
is
lost
by the biasing
resistor
Some
Rg but can
However,
can be neglected and the gain of the stage can

be stabilized. The frequency response of the
FET
stage
see that the signal
coupled to the gate of the
by the sup-
if one is not concerned with the gain of the

stage but merely the high impedance coupling
to the power amplifier, the bypass capacitor
impedance
a very high
set
stage approximately equal to ten.
the oscillator, causing the
The FET
is
be retained by the addition of a source bypass capacitor C^. This makes the gain of the
frequency of the oscillation to change or stop

altogether.
characteristic curves
ply potential and the value of Rq.
to an amplifier. Figure 3-2 shows a simple one-
Most amplifiers and tone-shaping
FET Amp/ifier
is
limited
by the
size of the coupling
capacitors and the interelectrode capacitance
a small
of the FET.
placed very
near the ground potential by the gate leak

resistor
Rq.
Bias of the stage
the source resistor
Rg and
is
Figure 3-3 shows the circuit diagram and
obtained by
the waveform of one of the tone generators.
the operation range
9V -
OUTPUT OF TONE GENERATOR
TYPICAL ORGAN TONE GENERATOR

Fig.
3-3 Tone Generator and the Resultant Waveform
20
It
can be seen that Figure 3-3
a simple
is
connbination of the two previous circuits.
constantly
The
operation, and as a key of the
in
player organ
is
depressed, the oscillator
is
con-
output waveform has an amplitude of approxi-
nected to the power amplifier.
mately 9 volts peak-to-peak. The frequency
is
amplifier does not have an internal speaker,
determined by the setting of the 180-kilohm
the output of the power amplifier should be
potentiometer which can vary the range of the
connected to an external speaker.
oscillator within
sists
two
octaves.
generator circuits, each tuned to
from
power supply
Fig.
circuit
respec-
constantly
is
derived
be played,
which
is
how each oscillator is

operation. When the note is to
Figure 3-4 shows
its
Supply potential
regulated to 12 volts.
shown
in
simply connected to the power
The method of
amplifier.
zener-
All the oscillators are
in
it is
SHORTING PLATE
this
Key Board
TYPICAL KEY
ON KEYBOARD
BAR PIVOT
GENERATOR
Fig.
3-5 Amplifier to Tone-Generator Connection Through
21
connection
Figure 3-5.
3-4 Power Amp/ifier and Tone-Generator Connect/on Through
TO TONE
the power
The organ con-
mainly of a series of 25 of these tone
tive frequency.
If
Key Board
is
long metal plate
the rear of
all
is
the keys.
This plate
is
con-
nected to the input of the power amplifier.

At the rear of each key is a screw which is
connected to the respective individual tone

generators. When the key is depressed, it con-
power amplifier.
pivot bar on which they
nects this generator to the
keys are on
All the
The
rock.
keys return to their original posi-
tion after playing
screw and a
due to the weight of the
coil spring
The preprogramming
placed above and to
connected to the gen-
These components are all housed in a

small toy piano case. A drawing of the houserators.
plete the circuit
hole
programming unit
jack.
is
in
when
the paper.
driven by a small
is
corresponding
Each brush
is
connected
gear train
capstan.
total gear reduction of the double

is
625.
the fact that there are
by
from
pair of 50-tooth
thread worms.
25 per every
This
is
worm
derived
two gear reductions
wheels and
a pair of
This gives a gear reduction of
set of
3-6 The Housing of a Player Organ
22
DC motor turns the
and wheel gear train
oscil-
a multipin jack.
Fig.
there
the input of the power amplifier.
Connection to the
made by
can
back into the organ to an individual tone generator, and the shorting plate is connected to
power supply, and the switches. Connection to the power amplifier is made
phone
reel as
This capstan drives a sheet of paper over

a metal plate on top of which is a set of steel
wire brushes that short with the plate to com-
lators,
a gear train
be seen in Figure 3-7.
The
through
is
which drives a capstan and take-up
ing can be seen in Figure 3-6.
Contained within this case are the
unit
worm and
wheel.
The
re-
CLUTCHED
PULLEY
SPACER
TAKE UP REEL
CAPSTAN
BRUSH SHORTING
PLATE
BEARING
COLLARS
Fig.
3-7 Paper Tape Drive
ductions are then multiplied, giving the resul-
allow the capstan to determine the
slips to
tant reduction of 25
X 25 = 625. The output
speed.
of the gear train
directly coupled to the
nism that
is
This
capstan, which determines the speed of the
paper
paper and keeps the paper moving at a con-
retainers
stant rate.
up
reel,
The paper
which
shafts but
is
is
is
taken up on the take-
to
turned by one of the faster
coupled
in
such a manner that
is
is
is
done by
a clutch-type
constantly slipping.
The
mechareel
of
placed between a pair of cone-shaped
which turn freely to allow the paper
come
off the
reel
easily.
One cone
is
spring-loaded to firmly hold the reel of paper
while
it
23
it is
turning.
Fig.
Looking
Figure 3-8,
at
3-8 Sideview of Tape Transport
we
couple of the drive connponents and their

operations a little more closely. Here we see
the steel wire brushes and their mounting.
also
the
see
plate
shorting
hole in the paper.
when
is
brushes.
This makes
rewind the paper.

to
the
it
much
power
amplifier
in
is
either side of the roller fastened to
The paper tape
down
against
is
is
regular 3-in. wide
adding machine paper, which is easy to obtain

and easy to program by punching rectangular
holes at predetermined distances to create any
con-
desired note.
through a
Figure 3-9 shows a two-octave
program punched
To make
in a section
things a
little
of the tape.
simpler, the paper
can be lined with two bars of musical
This allows the cap-
3"
-t=>-i=r
Fig.
is
derived from a coil
When
Figure 3-8, the pressure roller for
the capstan can be seen.
on
when a
desired. The
the capstan.
shielded wire.
Also
it
loading paper, or
the bearing plates holding firmly
con-
easier to load or
This shorting plate
way when
forward or rewind speed
spring
drops down away from the
plate
However,
pressure roller tension
released from the solenoid, the
shorting
nected
fast
activated,
pushes the plate up against the brushes.

the power
is
times.
all
out of the
on which the
This shorting plate
nected to a solenoid which,
at
We
brushes make connection when meeting
on the paper
can be moved back
Stan to have constant pressure
can see a
3-9 Programmed Two-Octave Tape
24
staff

and the holes
will
correspond to the particular
note on the musical

for possible
It
staff.
The top
line
is
other means of programming can be devised.
An
kept
motor function programming.
program
card
should be pointed out, however, that
mechanism could be
interesting
connected
punched
and transmitted
through a computer.
MATERIALS
NOTE: The number
of components depends on the
components
Basically, the following
Exact numbers and specifications
will
will
be
number
of stages included in the design,
be required for completion of the project,
left
to
you to
design.
Unijunction transistors
Potentiometers
FET
Toy organ
Power supply
Gear
Resistors
Program input device
train
Capacitors
PROCEDURE
1.
a)
Design and fabricate a unijunction oscillator capable of producing the required

quencies.
b.
You may need more than one
Use printed
circuit
boards for the oscillators and tone generators.
The number of
suggested layout for different tone generators.

at will.
The layout can
also be
fre-
oscillator for different stages.
changed with
change
in
Figure 3-10
is
design.
-
3RD TONE
'GENERATOR
TONE
GENERATOR
1ST
Tt

4TH TONE
"GENERATOR
2ND TONE
generator"
CONTINUED
Fig. 3-
CONTINUED
10 Printed Circuit Board Layout
25
units can be increased

FET
amplifier.
2.
Design and fabricate an
3.
Hook up
the amplifier to the toy organ and test the circuit.
4.
Hook up
the programming device and test
5.
Program the player organ and
it.
test its overall operation.
PROBLEMS
1.
Diagram
2.
How
system
in
which
a stepping relay
is
used as a programming device.
could the speed of the paper across the metal bar be varied
tempos
3.
a similar
if
various musical
are desired.
manually in the
What modification could be made so that the organ could be played
Draw a circuit diagram
conventional manner or programmed to play automatically??
of this modification.
26
EXPERIMENT
Name
Date:
Class
Instructor
PROGRAM
COMPANY NAME
flnnRESS
PREPARED BY
DATE
PART NAME
CK'D BY
PART NO.
QPER.NO.
REMARKS:
DATE
SHEET
OF
DEPT.
TAPE NO.
SEQ.
NO.
TAB
OR
EOB
OR
"X"
INCREMENT
TAB
OR
EOB
Fig. 1-3
OR
"Y"
INCREMENT
TAB
OR
EOB
Program for the
"M"
FUNCT.
EOB
"OSU" Name Plate
INSTRUCTIONS
EXPERIMENT
Name
Instructor
Class
Date:
rniuiPANY
PROGRAM
ADDRESS
NAME
PREPARED BY
DATE
PART NAME
CK'D BY
REMARKS:
OPER.NO.
PART NO.
DATE
OF
SHEET
DEPT.
TAPE NO.
SEQ.
NO.
TAB
OR
EOS
OR
"X"
IVLnulVltllM
TAB
OR
EOB
OR
"Y"
NCREMENT
TAB
OR
EOB
"M"
FUNCT.
INSTRUCTIONS
EOB
Fig. 1-3
Program for the
"OSU" Name Plate
(Cont'd)
EXPERIMENT
Date:
I'
Name
Class
Instructor
EXPERIMENTS
Name
Date:
Class
Instructor
Y
DELMAR PUBLISHERS
A
Division of Litton Educational Publishing, Inc.
P.O. Box 5087, Albany,
New York 12205

Advanced Electromechanisms Fabrication PDF

Cargado por

Información del documento

Descripción original:

Título original

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

Advanced Electromechanisms Fabrication PDF

Cargado por

Copyright:

Formatos disponibles

ELECTR

TERC EMT STAFF

DELMAR PUBLISHERS, MOUNTAIiSlVIEW AVENUE, ALBANY, NEW YORK

By Technical Education Research Centers,

claimed until Feb.

the public donnain.

All rights reserved.

the copyright hereon

any form or by any means

mechanical, including photocopying, recording, taping,

written permission of Technical Education Research

Library of Congress Catalog Card

THE UNITED STATES OF AMERICA

Published simultaneously In Canada by

Nostrand Reinhold, Ltd.

project presented or reported herein was per-

from the U.S. Office of

Education, Department of Health, Education, and

by the U.S. Office of Education should be

technical personnel in today's industries.

occupations have emerged

with systems and

mechanical, hydraulic, pneumatic, thermal, and

skills is especially significant

requirements well beyond the capability of

electronics. This need for

for the youngster

preparing for a career

one of a series of closely related publications designed

effective use of these

laboratory guides for a full-time, post-secondary school study program that

electronics, mechanics, physics,

mathematics, technical writing, and electromechanical applications.

unique feature of the manuals

the close correlation of

technical laboratory study with mathematics and physics concepts.

examples using modern industrial applica-

The reinforcement obtained from multiple applications of the concepts

college or technical school students can

satisfactory progress in a well-

coordinated program using these manuals as the primary instructional material.

the potential of these

core of studies for two-year

instrumentation, automation, mechanical design,

This form of technical core program has the advantage

of reducing instructional costs without the corresponding decrease in holding

power so frequently found

general core programs.

This manual, along with the others

the result of six years

of research and development by the Technical Education Research Centers,

a national nonprofit, public service corporation with head-

as a direct result of experience gained with students in technical schools

colleges throughout the country.

The Electromechanical Series

an on-going educational program

have been developed for this program:

For further information regarding the

program or for assistance

Cambridge, Massachusetts 02138

such, the laboratory portion of

any technology program