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Introduction
Abstract
Acknowledgment
Index
Application and further developments
Conclusion

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PROJECT REPORT
ON
CLOCK LOCK
Submitted to
Prof. K.S. Sangwan
Mentored by
Nitesh Sihag
Production Techniques (ME F243)

BITS Pilani

Group Members (Section 3, Group 6)

Vitul Bansal
Tarun Dogra
Siddharth

2013A4PS349P
2013A4PS233P
2013A4PS364P

Nishant Elkunchwar

2013A4PS221P

Shriram Ashirgade

2013A4PS257P

Arpan Jaiswal

2013A4PS035P

Introduction and concept:

The
Abstract:
This report contains detailed procedure of designing and manufacturing a
gravity powered light bulb. It includes the designing of the gear train
mechanism, which includes the determination of gear ratios based on the
wattage of the bulb, the operating time of the bulb and the distance
through which the suspended weight falls.
The later part contains the detailed drawings, the bill of materials and the
parts description which are included in the assembly. The manufacturing
of the parts is done on lathe, milling machine, powered hacksaw. The
machining of gears, chain drive mechanism and assembly of parts. Basic
concepts of gear, its working and designing is explained in this report. The
designing of gears and other components is done in CAD software. The
design is used as reference and the parts are manufactured by using
various machining process like milling, drilling, grinding etc. Then the
parts are assembled to make final product. These processes and working
of the clock lock is explained in detailed manner in this report.

Design and working of the mechanism

A weight is suspended by a chain and the chain rests on a
sprocket which acts as a pulley. The sprocket is connected to a
gear train through a shaft. The output of the gear train is
connected to a motor shaft, with the motor terminals connected
to a light bulb. The weight, when left free, falls under the
influence of gravity and rotates the sprocket. The rotational
velocity is modified according to the velocity required for the
motor and the emf is generated at the motor terminals which
glows the light bulb.

Calculations:
Wattage of the bulb (Pm) = 0.88 W

Torque of the motor (Tm) = 0.118 N m

Angular velocity at motor (Wm) = (Pm/Tm) = 7.41 rad/sec
Initial height of weight (h) = 3 m
Running time of prototype (t) = 5 minutes 30 sec
Required speed (v) = h/t = 9 mm/sec
Radius of sprocket (Rs) = 5 cm
Angular velocity of sprocket (Ws) = (v/Rs) = 0.18 rad/sec
Gear train ratio = (Wm/Ws) = 29.1
The gear ratio is taken as 30 for simplifying design and also to
account for frictional losses.
Gear train design:
A compound gear train was designed as follows where the number
indicates the number of teeth of the gear, the horizontal arrows
represent meshed gears and vertical arrows represent gears on
the same shaft.
****change 15 to 14 & 45 to

44****
Gear type = Spur gear
Pressure angle = 14.5o
Diametrical pitch = 16 DP
Module = 1.5875
Outer diameter = (number of teeth + 2)/DP in inches

Gear train is as follows:

1nd mesh

The 14 teeth gear on motor shaft is meshed with a 30 teeth gear on 2 nd

axle.
W1= (T1/T2)*Wm= (14/30)*7.41 = 3.458 rad/s

2nd mesh

The 14 teeth gear on axle 2 is meshed with 30 teeth gear on axle 3.

W2= (14/30)*3.458 = 1.614 rad/s

3rd mesh

The 14 teeth gear on axle 3 is meshed with 40 teeth gear on axle 4.

W3 = (14/40)*1.614 = 0.565 rad/s

4th mesh

The 14 teeth gear on axle 4 is meshed with 45 teeth gear on axle 5.

W4 = (14/44)*0.565 = 0.18 rad/s

Manufacturing process

Gears
Making the gear blank
Marking the outer diameter on acrylic sheet (using
formula: OD=(no. of teeths +2)/DP)
Rough cutting on do-all machine
Grinding the rough edges
Drilling the shaft hole
Turning on Lathe machine(after fixing it on
mandrel) for exact outer diameter
Gear cutting
Indexing was done using the indexing plate
attachment on the milling machine.
Teeth cutting done using 16 DP involute cutting
tool.
Support walls and base
The dimensions of the walls were determined by considering
the maximum limits of the gear train assembly.
Walls were marked and cut on the do-all machine.
Centers of shafts were marked for the bearings.
Holes of 22 mm diameter were drilled using the drilling
machine.
Shafts

 Marking and then cutting with powered hack-saw.

Drilling internal bores on both ends to hold the rod in the dead
center.
Turning to get uniform cross sectional diameter of 8 mm.
Aluminium coupling shafts
Motor shaft and 1st shaft in the gear train was coupled
with a coupler having 6 mm hole in one side and 8 mm
hole in the other side.
Another couple for the sprocket and last axle was
manufactured by turning the outer diameter to be same
as the internal diameter of the sprocket and a through
hole of 8 mm diameter was drilled for the shaft from the
gear train.

Bill of materials
S
r
n
o
1

Numb
er

Dimensi
on

Chain
(cycle)
MS Rod

4m

Aluminium
rods

Acrylic
sheet

Length =
25cm,
Dia =
8mm
Length =
2 in,
diameter
=
wehtwut
Length =
wrhgrw,
diameter
=
sejfweiy
50cm X
50cm ,
Thickness

Compone
nts

Sprocket

6
7
8
9

Hook
Bearing
Araldite
10 kg
weight
(cast iron)

1
1
10
1
1

= 8mm
Radius =
5 cm
NBC 608
-

Specifications of parts
1. Gears
Type = Spur gear
Module = 1.5875
Pressure angle = 14.5o
Face width = 8mm
Internal bore diameter = 8mm
Material = Acrylic sheet
Number of teeth
14
30
40
44
2. Shafts
Diameter = 8mm
Length = 20cm
Quantity = 5
Material = Mild Steel
3. Bearings
NBC 608
Internal diameter = 8mm
External diameter = 22mm
Width = 7mm
Number = 10
4. Chain
Length = 4m

5. Sprocket
Outer radius = 5cm

Quantity
4
2
1
1

Assembly

*******describe assembly process********