MCP101 Project

MECHANICAL INTEGRATOR

Group - 21B
Harshin Posina 2024CS10604
Peduru Kirthi Kiron 2020CS10366
Shivam Pakad 2024CE10068
Aman Kumar Sah 2024EE30120
Lakshya 2024CH71155
Sitaram 2024ME11067

Department of Mechanical Engineering

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1. Title: Mechanical Integrator

2. Background
The Ball and Disk Integrator was devised by James Thomson, the brother of William
Thompson a.k.a. Lord Kelvin who used a series of these machines to build the
Harmonic Analyzer, a machine that could predict the tides using a Fourier transform of
the height of the tides in the past.

The disk rotates at a constant speed, and the ball is held in contact with the disk. The
speed of rotation of the ball is thus proportional to its distance from the center of the
disk. An output cylinder is also in contact with the ball, The total rotation of the ball is
transferred to the cylinder, and thus the value of the integral can be read off of the
cylinder.

3. Novelty
 We simplified the design to make it easier to build without sacrificing functionality.
 We changed from a ball to a disk, which could be made using laser cutting.
 We changed the moving portion from the ball to the base disk to be able to combine
the function of the ball and output cylinder directly into a follower + output disk
assembly.
 By keeping the view of the assembly unobstructed, it allows for the machine to be
used as an illustrative tool for the explanation of integration.

4. Methodology

Materials and Tools

Materials: Steel rods (6mm), galvanized sheet metal (0.5mm), acrylic sheets (2mm and
3mm), O-rings, motor, potentiometer.
Processes: Laser Cutting, Drilling, Manual Sheet Shearing and Forming, Spot Welding

Design and Planning

Modelled the integrator in FreeCAD, finalizing dimensions and adjusting the design for
easy assembly and visibility.

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 Designed the acrylic carriage box and discs with laser-cut tabs and mounting holes.

Parts' Preparation
Frame: Sheared and drilled the sheet metal and bent it to form the frame.
Acrylic Parts: Laser-cut the carriage box, three 70mm discs, a 68mm disc (with O-ring),
and 8mm spacers for alignment.

Assembly
Disk Assembly: Sandwiched the 68mm disc with O-rings between two 70mm discs for
smooth rotation.
Frame and Carriage: Spot-welded metal support pieces on the frame, inserted rods with
bushings, and attached the laser-cut carriage box.
Motor Installation: Fixed the motor in the acrylic carriage and mounted a 150mm disc
to the motor, placing the setup on the metal rod rails fixed to the frame.

Finishing and Testing

Checked alignment, filed sharp edges, and tested for smooth sliding between the disks
and the motor's functioning.

5. Result / Work Done

The procedure first started by planning and designing the project. Using FreeCAD, we
designed and modelled the mechanical integrator, focusing on accuracy to ensure
proper alignment and fit during assembly. The materials were carefully selected to
balance durability and ease of fabrication; we chose steel rods, sheet metal, and acrylic
sheets for the structural components. Electronics were also sourced, including the motor
and potentiometer, which play crucial roles in the operation of the device.

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Figure 1: The electronics Figure 2: The FreeCAD model

The parts we prepared were a metal sheet-made frame for the integrator, a larger disc
(Driving Disc of 150mm dia) and four smaller discs (Follow-up and Output discs three
70mm and one 68mm dia) and acrylic bushing. Their making and the further assembly
is discussed below.

For the metal sheet frame, we began by shearing and drilling the galvanized sheet metal
to the required size. After the cuts, we bent the sheet to form the frame structure,
ensuring it was stable and had the necessary shape to support the moving parts of the
integrator. The frame was designed to be sturdy enough to hold the rods and other
components in place while allowing for smooth operation of the motor and discs

Figure 3: Ini al sheet metal frame, and rods.

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The acrylic discs and other parts were prepared by laser cutting. We cut four discs: three
70mm discs and one 68mm disc, which was fitted with an O-ring. The O-ring on the
68mm disc provided just enough friction to ensure smooth rotation without slipping.
We also cut 8mm spacers to help with alignment between the discs. All parts were
carefully measured and cut to ensure precise fitting during assembly, allowing them to
rotate freely when the motor was running.

For the acrylic carriage, we designed and laser cut the box to which the motor was fixed
and supported the other components. The carriage was made by assembling six
perfectly calculated and designed acrylic faces that fit together perfectly with tabs and
mounting holes to make assembly easier. Holes were made to the faces so that the
rails(iron rods) could be slid through the carriage such that the carriage could traverse
smoothly on the track. It was then mounted on the frame with precision, allowing the
motor to sit securely and function without misalignment. This design also ensured that
the discs were properly aligned with the motor, allowing for smooth and controlled
rotation.

Figure 1: The acrylic box

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 During assembly, we made the follow up disc by sandwiching the 68mm disc with O-
rings between the two 70mm discs to create a smooth rotating mechanism. The metal
support pieces were spot-welded to the frame, and the rods were inserted with bushings
to ensure stability. We attached the laser-cut acrylic carriage to the frame and secured
the motor within it. A 150mm disc, the driving disc was then mounted on the motor,
and the entire setup was placed on the metal rod rails fixed to the frame, ensuring the
motor and discs were properly aligned for smooth motion.

Finally, after assembling the integrator, we checked the alignment and performed some
finishing tasks. Sharp edges were filed down to prevent any damage or interference
with the movement. We tested the motor and the discs to ensure they operated smoothly
and that the integrator was functioning as intended. The result was a fully functional
mechanical integrator.

6. Discussion
A couple of issues arose as we were building the project.
1. If the spacing between the follower disc shaft and the guide rods was not accurate,
the follower would lose contact with the disc and the machine would not work. Our
solution was to use laser cutting to accurately make spacers and make up for any
inaccuracy in the frame.
2. The rods were sliding out of the frame, but frictionless rotation of the shafts were
still needed. Our solution was to make bushings that would stop the rod from
moving laterally without adding much friction.
3. We needed to make a follower disc that would roll without slipping on the main
disc. We initially wanted to use an O-ring but could not source one of the required
size. Our solution was to cut up the smaller O-rings we could source and stick it to
the disc. Additionally, we made the follower disc with a 1mm recess for putting the
O-ring in place.

This project gave us a chance to build a mechanical integrator. We took a traditional

ball-and-disk integrator and made a simpler version, keeping it easy to build without
losing its main function. For example, we used laser-cut acrylic discs and a custom

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 frame to make it more hands-on and clear for learning purposes. This way, we could
use an older computing concept in a more modern, straightforward way, perfect for
demonstrations and teaching.

Working on this project taught us a lot about mechanical systems and design. From
picking materials to putting everything together, each step showed us how important
accuracy and planning are in engineering. We got practical experience with building,
solving problems, and understanding how integration works physically, which will help
us in future projects with similar mechanical systems.

7. Applications
A series of such machines were used in tide prediction by modelling the complex
motion of tidal forces, accounting for factors like the gravitational pull of the moon and
the sun. The integrator helped calculate the timing and height of tides by continuously
updating the position of the ball, representing the cumulative effects of these forces
over time.

By the early 20th century, naval fire control systems like the Dreyer table used ball-
and-disk integrators to calculate target range and speed. This technology later
influenced devices like the Norden bombsight and missile guidance systems.

As an illustrative tool, the ball-and-disk integrator can be used to demonstrate the

principles of integration and continuous motion in educational settings. Its transparent
mechanical operation helps visualize the physical significance of integrals as well as
how mechanics can also be used to compute and manipulate data.

8. Future Direction/Further improvements

The output system of the integrator can be changed to make it plot a graph by using a
rack and pinion linkage connected to a writing implement held over a roll of paper. This
modification would allow the system to generate a real time graphical plot of the
integration process. As the ball moves along the disk, its position would drive the rack
and pinion mechanism, translating rotational motion into linear motion that moves the
writing implement across the paper.

Another potential improvement to the ball-and-disk integrator involves replacing the

follower disc with a sprocket-shaped wheel that has rubber balls threaded through a
string along its edge. This modification would significantly reduce friction during
lateral motion, as the rubber balls would move along the string with minimal resistance,

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creating a near-frictionless lateral translation. In the current model, the follower disc
faces considerable friction when it moves laterally across the surface of the disk, as well
as significant wear and tear, which can introduce inaccuracies and energy losses in the
system. By using the sprocket design, the lateral movement of the wheel is decoupled
from the rotational motion.