Electromechanical design handbook

Electromechanical design handbook

Journal of Manufacturing Systems Vol. 14/No.2 BOOK REVIEW Electromechanical Design Handbook, 2nd ed. "... A product designer who is knowledgeable i...

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Journal of Manufacturing Systems Vol. 14/No.2

BOOK REVIEW

Electromechanical Design Handbook, 2nd ed.

"... A product designer who is knowledgeable in all the disciplines of electromechanical design practices is an asset to any company or organization. "Specialists in the various engineering disciplines are required to assist the electromechanical design engineers in formulating specific, specialized engineering functions and data for use by the electromechanical designer. "Electromechanical design practices include the integration of mechanical, electrical, and electronic engineering principles in the design of a consumer or industrial product. The term mechatronics has recently been used to indicate the same functions encountered in electromechanical design practices. Those individuals who use this term or try to imply that this is a new engineering subject should be aware of the fact that electromechanical design engineering practices have been used in the United States since the birth of electrical power usage more than 100 years ago. Since it is, in general, extremely difficult to separate electrical and electronic design practices for all applications, the term mechatronics should not be used to indicate the electromechanical design function. It must be understood that electrical components are always used in electronic systems, which also include purely electronic components. The integrated circuit itself, strictly speaking, is an electromechanical system component and is also considered an electronic component?'

R.A. Walsh, author McGraw-Hill, © 1995 xvi + 1050 pp. $120.50 In the preface, the author states: "American industry today, more than ever, needs people in the engineering professions who are trained in the multiple integrated disciplines of mechanical, electrical, and electronic engineering design practices (called electromechanical design engineering, not mechatronics).... America needs more highly trained electromechanical design engineers and fewer specialists in order to more effectively compete in the national and international markets. This has been the author's purpose and goal in writing this volume and its companion, the McGrawHill Machining and Metalworking Handbook?' The book contains 15 chapters, each with a number of sections. The first chapter, "Mathematics Reference and Measurement Systems Conversions" presents topics in algebra, trigonometry, analytic geometry, and basic calculus that are relevant to design practice rather than theory. Chapter 2, "Practical Engineering Mechanics," offers the material in statics and dynamics needed for mechanical design. This is followed by an example of a complex electromechanical product--aspects of the design of an automatic interrupter switching device--to show how a complex dynamic problem is simplified so that a prototype can be built and tested in the time available. Chapter 3, "Mensuration, Descriptive Geometry, and Optics," contains formulas for calculating the circumference, surface area, and volume of various shapes, some not usually found in textbooks. Descriptive geometry methods for finding the true length of a line, the angle between planes, and the resultant of non-coplanar forces are shown. Basic optics, with an accent on lenses, are also presented. "Engineering Materials, Properties, and Uses" Chapter 4, includes tables of properties of steels and other metals; plastics, rubbers, and other elastomers; wood; and several other materials, such as porcelain and mica. In addition, chemical composition of numerous steels and simple methods for identifying many plastics by the application of flame are presented. Chapter 5, "Strength of Materials," contains formulas, diagrams, and text to solve stress problems in a great majority of electromechanical design cases. Chapter 6 is "Electrical and Electronic Engineering Practices and Design Data." With 261 pages, it is a handbook of its own, opening with a foreword worth repeating, as follows:

The first 20 pages of the chapter present the basics of "practical" electricity, and the next 48 pages are devoted to electrical components and several important formulas (for example, the fusing time current of copper conductors) as well as 48 figures and 12 tables. Next is a 45-page section on electrical power system components, which discusses how loads on these components are mechanical as well as electrical, an aspect that is considered in some detail to ensure that it is not ignored by a designer. An example is given of switches and bus bars exposed to electromagnetic forces that can be, in cases such as short circuits, very large and even destructive. (Early power transformers sometimes literally exploded when shorted; this phenomenon is now used in "electromagnetic metal forming?') Another 145-page section on electronics and electronic components clarifies the meaning of this topic in the context of the handbook, as described by the author: "This section will detail the principles of electronic components, electronic design procedures, and practical electronic circuits and their construction, as applicable to consumer and industrial products?'

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The following are among the subjects covered:

recommendations are offered: to select the spring index (mean coil diameter to wire diameter) between 6.5 and 10, to remember to bake the spring after electroplating to avoid hydrogen embrittlement (and generally avoid electroplating unless essential), to ensure that a compression spring will not jam in its hole when fully compressed, and to apply special strengthening processes, especially shotpeening when the endurance limit in fatigue has to be raised. Like Chapter 6, Chapter 8, "Machine Element Design and Mechanisms," is a small handbook with its 206 pages. Sections cover the following topics:

• Coils, including formulas for winding helical and spiral (flat) coils because most coils need to be made locally. • Basic transistor configurations, diode circuits, conventional and Zener diode rectifiers, varistors and thermistors, and generic and digital integrated circuits, including examples of several electronic designs of devices using integrated circuits. • Printed circuit board manufacturing, with very detailed instructions. • Electrochemical battery systems, including typical charging circuits, data pertaining to various types of batteries, cross-reference information for 73 battery types made by four manufacturers (Eveready, Neda, Duracell, Rayovac), and a section devoted to electric battery-powered automobiles, a subject on which the author worked for 20 years. • Electrical measuring instruments, such as thermocouples, strain gauges, and load cells. A related section lists 16 basic categories of electrical and electronic test instruments, particularly the dual-trace, two-channel oscilloscope. • Electronic packaging techniques, with reference to highdensity, hermetic, high-strength, and shock-resisting designs invented and patented by the author 20 years ago for aerospace vehicles and military aircraft. • Basic electric circuit analysis and procedures, containing circuit analysis laws, theorems, and methods, such as the Th~venin and Norton theorems, Delta-Y and Y-Delta conversion, voltage dividers and doublers, and so on. • Bridge circuits for electrical element measurements: R, C, and L, including the d-c Wheatstone, a-c Wheatstone, Wien, Maxwell, Wien-Maxwell, and Wien-De Sauty bridge circuits. [Reviewer's note: Wien is misspelled as Wein in all cases and in the index.]

• Power transmission components and design procedures, with coverage on V-belt drives and timing belts. • Design of chain drives using standard chains and sprockets. • Shafts and shafting materials, including calculation of shaft twist angle, transverse deflection, bending stresses, and critical speed. Selection of shaft materials and hardness for different applications is discussed. • Hooke's, flanged, sleeve, and flexible couplings. • Various friction clutches, including electromagnetic. • Power screws and ratchets. • Gearing and design procedures, including a list of materials and coverage of manufacturing methods, gear principles, types, tooth forms, and loading formulas. • Selection of gear materials. • Forces and wear loads in gearing systems. • Gear loads and design procedures, including abundant material on gear calculation, material selection, heat treatment, and manufacturing processes for about 500 industrial applications. • Epicyclic gearing, also called planetary gearing. • Gear train calculations, including an example in which the Sports method is employed to find acceptable ratio approximation using integers. • Differential gearing. • Dimensioning of chain sprockets. • Ratchets, with reference to the earlier section. • Gear design software for PCs and CAD stations. • Standard dimensions of keyways and setscrews for gears (Fig. 8.128 in the book). • Chart for calculating the various power, force, torque, rpm, and velocities in gearing (Fig. 8.129 in the book). • Additional gear data, such details of the metric module gear tooth size system, and the customary diametral pitch system used in the U.S. A mention is made of the special case of pinions with small number of teeth, and an example of a stern pinion with eight teeth is shown.

Chapter 7, "Comprehensive Spring Design," covers the theory and practice of designing practically any mechanical spring, from an instrument hairspring to a car suspension coiled spring or torsion bar and even larger springs. The chapter begins with a classification of springs into nine basic categories--compression, extension, torsion, spiral, leaf, spring washers, hairsprings, torsion bars, and Belleville disks. Considering wire shape, external shape (cylindrical, conical), and other aspects, the number of actual shapes more than doubles. Major attention is paid to the spring design process and material selection. General spring design

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on retaining rings; set, clamp and split collars; machinery bushings, shims, and arbor spacers; and specialty fasteners, such as self-tapping sheetmetal screws, screw-washer assemblies (SEMS), and Tinnerman speed nuts. Chapter 10's coverage of welding, brazing, and soldering includes basic information about the nature, capabilities, and limitations of these processes that a product designer must know to avoid costly mistakes. A one-page section introduces adhesive bonding. Chapter 11, entitled "Sheet Metal Design, Layout, and Fabrication Practices," discusses the innumerable parts that are made of sheetmetal in large quantities as well as in small batches and individually. Sooner or later, every mechanical or electromechanical designer faces the need to design sheetmetal parts. The chapter provides such designers with sufficient information to design sheetmetal parts that can be manufactured at reasonable cost. The first two sections cover various types of ferrous and nonferrous metal sheet materials and applications for which they are suitable. Modern sheetmetal manufacturing machinery (shears, punch presses, press brakes) and sheetmetal fabrication methods (cutting, punching, forming) are presented next. Topics that come closer to the designer's work include cylinders, cones, connections between shapes, and triangulation of warped surfaces (nondevelopable), which at times can be quite difficult. [There may exist CAD geometric modeling programs that do this; this reviewer does not recall encountering them.] Chapter 12 provides brief but adequate descriptions of the various processes used by electromechanical design engineers: casting, extrusion, plastic welding, and powder metallurgy processes. Chapter 13, "Engineering Finishes, Plating Practices, and Specifications" considers the fact that a product is not complete until it receives its final finish. A major objective of a finish is to protect the product from corrosion. Indeed, the designer must consider the corrosion aspect when first selecting the material. The number of finishing processes is quite large; in addition to painting, the book lists 50-grouped in seven basic categories--from mechanical finishing to electroplating to hot-dip plating. Chapter 14, "Manufacturing Machinery and Dimensioning and Tolerancing Practices," is a short tour of a manufacturing facility. Brief descriptions and 20 photographs show various machine tools and tell what they do. The last chapter, Chapter 15, entitled "Subjects of Importance to the Design Engineer," covers the following subjects:

Gear wear and failure. Gear manufacturing processes, gear lubrication, and gear summary sheets. Cam development, layout, and design. Antifriction bearings, including discussion of plain bearings, with life and heat dissipation equations and pressure velocity (PV) values for several metallic and nonmetallic bearing materials. Rolling element antifriction bearings and their selection and sources. Mechanisms and linkages, covering design, operating principles, and analysis, including material on several ratchet systems, various intermittent and unidirectional drives, straight line linkages, Geneva mechanisms, clamps, motion locks, detents, quick return mechanisms, an adjustable dwell cam, screw thread backlash eliminators, and several actual examples of products in which some of the mechanisms are employed. Kinematic analysis of the main linkage types is performed, and space mechanisms are discussed briefly. The coverage is quite extensive and sufficient for many not-very-unusual applications, Chapter 9, "Pneumatics, Hydraulics, Air Handling, and Heat," includes basic equations and formulas needed to select compressor size, design airflow pipes, calculate stresses in pressurized cylinders, select pumps for water, oil, and other liquids, and design flow channels and pipes for liquids. Air handling information is provided to assure the required air changes in various industrial areas. Similarly, heat transmission equations, formulas, and tables needed to secure cooling, heating and ventilation of space and equipment are provided. The first section of Chapter 10, "Fastening and Joining Techniques and Design Data" is on threaded fasteners, such as bolts, screws, and nuts. Numerous figures and tables present the more common screws, bolts, nuts, and wrenches and keys of the U.S. (inch) and metric (ISO) systems. The text provides important information about materials and their strength according to standards, tightening torques, wrench clearances, and so on. A warning is given about the danger inherent in using fasteners coming from questionable sources, because they can be of substandard quality even if they carry "correct" markings. An example is shown of a "counterfeif' 0.500 inch diameter steel bolt whose head split at installation. Other sections in Chapter 10 cover thread systems (American standard and metric), rivets, and pins. An experienced designer can save quite a bit of money by simplifying products through judicious choice of pins. Next are sections

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• Societies, associations, institutes, and specification authorities. • ANSI standards applicable to product design in engineering and manufacturing processes and inspection. • Frequently used electrical and mechanical standards. • Patent application information. • Product liability. • Importance of a product prototype. • Computers in design. • An example of electromechanical system design, including a product's history from concept to final production.

• Quality control systems, particularly ISO 9000. • Independent testing laboratories. • Tables of engineering drawing sizes and formats. The 1700-item index of this outstanding reference book follows Chapter 15.

Moshe M. Barash Purdue University

BOOKS RECEIVED

Organization and Management o f Advanced

Winning with Quality

Manufacturing

J.W Wesner, et al., authors AT&T, Addison-Wesley Publishers, © 1995 xvi + 300 pp. No price given

W. Karwowski and G. Salvendy, editors John Wiley & Sons, © 1994 xii + 426 pp. $79.95

Design Paradigms--Case Histories of Error and Judgment in Engineering

Design of Work and Development of Personnel in Advanced Manufacturing G. Salvendy and W Karwowski, editors John Wiley & Sons, © 1994 xiii + 578 pp. $79.95

H. Petroski, author © 1994, H. Petroski, Cambridge University Press, publisher viii + 208 pp. $17.95

Professor John L. Burbidge, an Associate Editor of the Journal of Manufacturing Systems, passed away January 15, 1995, in the United Kingdom.

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