DESIGN AND FABRICATION OF CABLELESS

CLUTCH

A PROJECT REPORT

Submitted by

NAVEEN R (210519114304)
NAVIN KUMAR K (210519114305)
VIGNESH K (210519114062)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
DMI COLLEGE OF ENGINEERING
CHENNAI 600 123

ANNA UNIVERSITY: CHENNAI 600 025

JUNE 2022
DESIGN AND FABRICATION OF CABLELESS
CLUTCH

A PROJECT REPORT

Submitted by

NAVEEN R (210519114304)
NAVIN KUMAR K (210519114305)
VIGNESH K (210519114062)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
DMI COLLEGE OF ENGINEERING
CHENNAI 600 123

ANNA UNIVERSITY: CHENNAI 600 025

JUNE 2022
 BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF

CLABLELESS CLUTCH” is the Bonafide work of NAVEEN R
(210519114304), NAVIN KUMAR K (210519114305), and VIGNESH K
(210519114062) who carried out the project work under my supervision.

NAVEEN R (210519114304)
NAVIN KUMAR K (210519114305)
VIGNESH K (210519114062)

SIGNATURE SIGNATURE

[Link] KAMARAN,Phd., MR. E.M. PRADEEP, ME.,

PROFESSOR & [Link]&
HEAD OF DEPARTMENT. SUPERVISOR.

Dept of mechanical engineering, Dept

Dept of of mechanical
mechanical engineering,
engineering,
Dept of mechanical engineering,
DMI college of engineering , DMI
DMI college
college of of engineering,
engineering ,
DMI college of engineering ,
Palanchur, Chennai-600123 Palanchur,
Palanchur,Chennai-600123
Chennai-600123
Palanchur, Chennai-600123

Certified that the candidates were examined in the viva vice examinations held on

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMNET

First, we thank the God Almighty for blessing us with the

knowledge and skills to carry out project successfully.
We wish to record our deep sense of gratitude and profound thanks to
our beloved Founder and Chairman the most Rev. Fr. Dr. J. E. Arulraj,
for providing us the immense facilities in this Institution.
We are extremely indebted to our Correspondent Rev. Sr. M.K.
Teresa and Administrator Rev. Sr. P. Pradeepa for their valuable
suggestions and supports throughout our study in this Institution.
We are happy to extend our sincere thanks to the principal Dr. N.
Azhagesan, [Link]., Ph.D. for his continuous motivation and support
towards successful completion of our project work.
We are grateful to our Head of the Department Dr. T. Senthilkumar,
M.E., Ph.D. for his keen interest, inspiring guidance, constant
encouragement during all stages of our study.
We express our thankfulness to our project guide Mr. MZ.
Senthilkumaran, M.E., (Ph.D) for his valuable technical guidance and
cooperation, which helped us to complete this project work successfully.
We also extend our sincere thanks to all the Teaching and Non
-Teaching staff of the Department of Mechanical Engineering for their
valuable support throughout our course of study and accomplishment of
project work.
Finally, we are grateful to our beloved parents and friends for their
continuous support and encouragement to complete the project
successfull
 ABSTRACT

This project work involves in the fabrication of clutch shaft. To

obtain the same motion on the “clutch release shaft” at long
period of time especially the smooth power transmission from
the drive shaft. We usually use cable on the two wheeler. If
there is constant pressure in the cable. It will elongate over the
Period it will not provide a stable Movement. This will affect
the engage and disengaging of the clutch and it causes partially
disengaging so it will affect the gears in the gearbox. We sort
out this problem with using of stepper motor. Stepper give
same movement in clutch releasing shaft with using the gears.
Gears is fixed in releasing shaft so it turn 70 degree angle.

v
 TABLE OF CONTENT
CHAPTER TITLE PAGE
ABSTRACT V

LIST OF TABLE VI

1 INTRODUCTION OF CLUTCH 1

1.1 CLUTCH 1

1.2 MAIN PART OF THE CLUTCH 2

1.2.1 DRIVING MEMBER 2

1.2.2 DRIVEN MEMBER 2

1.2.3 OPERATING MEMBER 3

1.3 HOW THE CLUTCH WORKS IN A VEHICLE 3

1.4 WORKING PRINCIPLE OF CLUTCH 3

1.5 CLUTCH PLATE OR DISC 3

1.6 CLUTCH PLATE ASSEMBLY 4

1.7 LITERATURE REVIEW 5

1.7.1 SCOPE OF THE PROJECT 5

1.7.2 OBJECTIVE 5

1.8 COMPONENTS OF THE PROJECT 6

1.8.1 STEPPER MOTOR 7

vi
1.8.2 CONSTRUCTION & WORKING PRINCIPLE 7

1.8.3 DRIVING TECHIQUES 8

1.8.4 SINGLE EXCITATION MODE 9

1.8.5 STEPPER MOTOR CIRCUIT 10

1.8.6 PARAMETER OF STEPPER MOTOR 13

1.8.7 ADVANTAGE 14

1.8.8 DISADVANTAGE 15

1.8.9 APPLICATION 15

1.9 ARDUINO 16

1.9.1 ARDUINO PIN DIAGRAM 17

1.9.2 HOW TO PROGRAM AN ARDUINO 18

1.9.3 5 STEPS TO PROGRAM AN ARDUINO 19

1.10 BREADBOARD 20

1.10.1 SPECIFICATION & FEATURES 21

1.10.2 TYPE OF BREADBOARD 21

1.10.3 ADVANTAGE 22

1.10.4 DISADVANTAGE 23

1.10.5 APPLICATION 24

1.11 STEPPER MOTOR DRIVE 24

vii
1.11.1 TB6560 STEPPER MOTOR DRIVE 24

viii
1.11.2 TB6560 SPECIFICATION 24

1.11.3 TB6560 CONNECTION 24

1.11.4 TB6560 MICROSTEP SETTING 25

1.12 DESIGN AND FABRICATION 28

1.12.1 SPUR GEAR 28

1.12.2 FORMULA USED 28

1.12.3 BASE STRUCTURE 29

1.12.4 WELDING PROCESS 29

1.12.5 CUTTING PROCESS 29

1.13 3D MODEL 30

1.14 PROGRAM USED 31

1.15 CONCULUSION 32

ix
 INTRODUCTION OF CLUTCH

Clutch Figure 1

 It is a mechanical device used in the transmission system of a

vehicle. It engages and disengages the transmission system
from the engine. It is fixed between the engine and the
transmission.

 The power produced inside the engine cylinder is ultimately

aimed to turn the wheels so that the vehicle can move on
the road. The reciprocating motion of the piston rotates a
crankshaft by rotating the flywheel through the connecting
rod.

 The circular movement of the crankshaft is now to be

transferred to the rear wheels. It is transmitted through the
clutch, gearbox, universal points propeller shaft or driveshaft,
differential, and axles extending to the wheels.

1
 With the help of all these parts, the use of engine power for
the driving wheel is called power transmission. The
utilization of engine power to the driving wheels through all
these parts is called power transmission.

 The power transmission system is normally the same on all

passenger cars and trucks. But its design and arrangement
may vary according to the method of drive and type of
transmission units.

Main Part of a Clutch

 The main parts of a clutch are classified into three groups

1. Driving members
2. Driven members
3. Operating members.
Driving member

 The driving member has a flywheel mounted on the crankshaft of the

engine. The flywheel is fixed to a cover which supports a pressure
plate or driving disc, pressure springs and releasing levers.

 The whole assembly of the flywheel and the cover rotate all the times.
The clutch housing and the cover provided with an opening. From this
opening, the heat is evaporated generated by the friction during the
clutch operation.

Driven member

 The driven member has a disc or plate, called the clutch plate. It is
free to slide alongside on the splines of the clutch shaft. Driven
member carries friction materials on both of its surface. When a
driven member is held between the flywheel and the pressure plate,
it helps to rotate the clutch shaft through the splines.

2
 Operating member

 The operating members have a foot pedal, linkage, release or

throw-out bearing, release leavers and the springs essential to ensure
the proper operation of the clutch.

How Clutch Works in a Vehicle

Clutch is a mechanical device used in the transmission system of a vehicle.
It engages and disengages the transmission system from the engine. It
is fixed between the engine and the transmission.

 When the clutch is engaged, the power is transmitted from the

engine to the driving wheels through the transmission system
and the vehicle starts moving.
 When the clutch is disengaged, the power is not transmitted to
the rear or driving wheels and the vehicle stops while the engine
is still running.
 The clutch is disengaged when starting the engine, when
stopping the vehicle, when shifting the gears and when idling the
engine.
 The clutch is engaged when the vehicle is to move and is
kept engaged when the vehicle is moving. Clutch also allows
the continuous taking up of the load.
When properly operated, it prevents jerky motion of the vehicle and thus
avoids putting undue strain on the remaining parts of the power
transmission system.

Working Principle of Clutch

 The clutch works on the principles of friction, when two friction
surfaces are bought in contact with each other and pressed they are
united due to the friction between them. If one is revolved, the
other will also revolve.

 The friction between the two surfaces depends upon the area of the
surfaces, the pressure applied upon them and coefficient of friction
of the surface materials, The two surfaces can be separated and
brought into contact when required.

3
 One surface is considered as a driving member and the other as a
driven number. The driving member is kept rotating when the
driven member is brought in contact with the driving member, it
also starts rotating. When the driven member is separated from the
driving member it stops revolving. This is how a clutch operates.

 The friction surfaces of the clutch are so designed that the driven
member slips on the driving member when the pressure is first
applied. As pressure increases the driven member is brought
slowly to the speed of the driving member.

 When the speeds of the members become equal, there’s no slip, the
two members are in firm contact and the clutch is now fully
engaged.

 The driving member of a clutch is the flywheel. It is mounted on the

crankshaft the driven member is the pressure plate. This is mounted
on the transmission shaft. The clutch plates are between the two
members.

 When the clutch is engaged, the engine to the rear wheels through
the transmission system. When the clutch is disengaged by pushing a
clutch pedal, the engine is disconnected from the transmission.
Thus, the power stops flowing to the rear wheels while the engine is
still running.

Clutch Plate or Disc

 The clutch plate is the driving member of the clutch and is gripped
between the flywheel and the pressure plate. It is mounted on the
clutch shaft through the splines. When it is gripped, rotates the
clutch shaft and the power is transmitted from the engine to the
transmission through the clutch.

4
 Figure 2
 A pressure plate consists of two sets of facing or friction material
mounted on steel cushion springs. The facing and cushion springs
are riveted to a spring base disc and spring retainer plate which are
slotted for the insertion of the torsion spring.

Figure 3
 These springs contact the hub flanges that fit between the spring
retainer plate and the disc and serve to transmit the twisting force
applied to the facings to the splined hub. The spring action serves
to reduce torsional vibrations and shocks between the engine and
the transmission during clutch operation.

5
  The facing and the plates rotate with respect to the hub to the limit
of the compression of the springs or to the limit of the spring stops.

 When the clutch is engaged, the pressure on the facing

compresses the cushion springs sufficiently to cause the unit to
decrease in thickness by 1 to 1.5 mm. This construction helps to
make engagement smooth and chatter less.

LITERATURE REVIEW
Creating the method of cable less clutch, SCOPE

OF THE PROJECT

 It will provide stable movement throughout life time. they will be

not loosening properties occurring in the material ever.

 It will give same motion of clutch releasing shaft for a long period
of time.

 We sort out the cable elongation, cable wear and tear problem,
and increase the gear life due to constant movement of actuator.

 Avoid the cable adjustment or changes for certain period.

OBJECTIVE

 Clutch Cable can become stretched or broken.

 Cable wear and tears.

 Occur Gears damages.

 Did not deviate completely.

 A clutch will wear over time as the friction.

6
  It is difficult to shift gears.

COMPONENTS OF THE PROJECT

STEPPER MOTOR

 A stepper motor is an electromechanical device it converts electrical

power into mechanical power. Also, it is a brushless, synchronous
electric motor that can divide a full rotation into an expansive number
of steps. The motor’s position can be controlled accurately without any
feedback mechanism, as long as the motor is carefully sized to the
application. Stepper motors are similar to switched reluctance
motors. The stepper motor uses the theory of operation for magnets to
make the motor shaft turn a precise distance when a pulse of electricity
is provided. The stator has eight poles, and the rotor has six poles. The
rotor will require 24 pulses of electricity to move the 24 steps to make
one complete revolution. Another way to say this is that the rotor will
move precisely 15° for each pulse of electricity that the motor receives.

Construction & Working Principle

 The construction of a stepper motor is fairly related to a DC motor.
It includes a permanent magnet like Rotor which is in the middle &
it will turn once force acts on it. This rotor is enclosed through a no.
of the stator which is wound through a magnetic coil all over it. The
stator is arranged near to rotor so that magnetic fields within the
stators control the movement of the rotor.

Figure 4
7
 The stepper motor can be controlled by energizing every stator one
by one. So the stator will magnetize & works like an
electromagnetic pole which uses repulsive energy on the rotor to
move forward. The stator’s alternative magnetizing as well as
demagnetizing will shift the rotor gradually &allows it to turn
through great control.

 The stepper motor working principle is Electro-Magnetism. It

includes a rotor which is made with a permanent magnet whereas a
stator is with electromagnets. Once the supply is provided to the
winding of the stator then the magnetic field will be developed
within the stator. Now rotor in the motor will start to move with the
rotating magnetic field of the stator. So this is the fundamental
working principle of this motor.

 In this motor, there is a soft iron that is enclosed through the

electromagnetic stators. The poles of the stator as well as the rotor
don’t depend on the kind of stepper. Once the stators of this
motor are energized then the rotor will rotate to line up itself with
the stator otherwise turns to have the least gap through the stator.
In this way, the stators are activated in a series to revolve the
stepper motor.

Driving Techniques
 Stepper motor driving techniques can be possible with some
special circuits due to their complex design. There are several
methods to drive this motor, some of them are discussed below by
taking an example of a four-phase stepper motor.

Single Excitation Mode

 The basic method of driving a stepper motor is a single excitation
mode. It is an old method and not used much at present but one has
to know about this technique. In this technique every phase
otherwise stator next to each other will be triggered one by one
alternatively with a special circuit. This will magnetize &
demagnetize the stator to move the rotor forward.
8
Full Step Drive
 In this technique, two stators are activated at a time instead of one
in a very less time period. This technique results in high torque &
allows the motor to drive the high load.

Half Step Drive

 This technique is fairly related to the Full step drive because the two
stators will be arranged next to each other so that it will be
activated first whereas the third one will be activated after that. This
kind of cycle for switching two stators first &after that third stator
will drive the motor. This technique will result in improved
resolution of the stepper motor while decreasing the torque.

Micro Stepping
 This technique is most frequently used due to its accuracy. The variable
step current will supply by the stepper motor driver circuit toward
stator coils within the form of a sinusoidal waveform. The accuracy of
every step can be enhanced by this small step current. This technique is
extensively used because it provides high accuracy as well as decreases
operating noise to a large extent.

Stepper Motor Circuit & Its Operation

 Stepper motors operate differently from DC brush motors, which rotate
when voltage is applied to their terminals. Stepper motors, on the other
hand, effectively have multiple toothed electromagnets arranged
around a central gear-shaped piece of iron. The electromagnets are
energized by an external control circuit, for example, a microcontroller.

9
 Stepper Motor Circuit

Figure 6

 To make the motor shaft turn, first one electromagnet is given power,
which makes the gear’s teeth magnetically attracted to the
electromagnet’s teeth. At the point when the gear’s teeth are thus
aligned to the first electromagnet, they are slightly offset from the next
electromagnet. So when the next electromagnet is turned ON and the
first is turned OFF, the gear rotates slightly to align with the next one
and from there the process is repeated. Each of those slight rotations is
called a step, with an integer number of steps making a full rotation.

 In that way, the motor can be turned by a precise. Stepper motor

doesn’t rotate continuously, they rotate in steps. There are 4 coils with
a 90o angle between each other fixed on the stator. The stepper motor
connections are determined by the way the coils are interconnected. In
a stepper motor, the coils are not connected. The motor has a
90o rotation step with the coils being energized in a cyclic order,
determining the shaft rotation direction.

 The working of this motor is shown by operating the switch. The coils
are activated in series in 1-sec intervals. The shaft rotates 90 o each time
the next coil is activated. Its low-speed torque will vary directly with
current.

10
Types of Stepper Motor
There are three main types of stepper motors, they are:

1. Permanent magnet stepper

2. Hybrid synchronous stepper
3. Variable reluctance stepper

Permanent Magnet Stepper Motor

 Permanent magnet motors use a permanent magnet (PM) in the rotor
and operate on the attraction or repulsion between the rotor PM and
the stator electromagnets.

 This is the most common type of stepper motor as compared with

different types of stepper motors available in the market. This motor
includes permanent magnets in the construction of the motor. This kind
of motor is also known as tin-can/can-stack motor. The main benefit of
this stepper motor is less manufacturing cost. For every revolution, it
has 48-24 steps.

Variable Reluctance Stepper Motor

 Variable reluctance (VR) motors have a plain iron rotor and operate
based on the principle that minimum reluctance occurs with
minimum gap, hence the rotor points are attracted toward the stator
magnet poles.

 The stepper motor like variable reluctance is the basic type of motor
and it is used for the past many years. As the name suggests, the
rotor’s angular position mainly depends on the magnetic circuit’s
reluctance that can be formed among the teeth of the stator as well
as a rotor.

Hybrid Synchronous Stepper Motor

 Hybrid stepper motors are named because they use a combination of
permanent magnet (PM) and variable reluctance (VR) techniques to
achieve maximum power in small package sizes.

11
 The most popular type of motor is the hybrid stepper motor because it
gives a good performance as compared with a permanent magnet rotor
in terms of speed, step resolution, and holding torque. But, this type of
stepper motor is expensive as compared with permanent magnet
stepper motors. This motor combines the features of both the
permanent magnet and variable reluctance stepper motors. These
motors are used where less stepping angle is required like 1.5, 1.8 & 2.5
degrees.

How to Select a Stepper Motor?

 Before selecting a stepper motor for your requirement, it is very
significant to examine the torque-speed curve of the motor. So this
information is available from the designer of the motor, and it is a
graphical symbol of the torque of the motor at a specified speed. The
motor’s torque-speed curve should match closely the necessities of the
application; or else, the expected system performance cannot be
obtained.

Types of Wiring
 The stepper motors are generally two-phase motors like unipolar
otherwise bipolar. For each phase in a unipolar motor, there are two
windings. Here, center-tapped is a common one lead in between two
windings toward a pole. The unipolar motor has 5 to 8 leads.

 In the construction, where the common of two poles are divided

however center-tapped, this stepper motor includes six leads. If
the two-pole center taps are short inside, then this motor includes
five leads. Unipolar with 8 leads will facilitate both series & parallel
connection while the motor with five lead or six lead has stator coil’s
series connection. The operation of the unipolar motor can be
simplified because while operating them, there is no requirement of
reversing the flow of current within the driving circuit which are known
as bifilar motors.

12
Parameters of Stepper Motor
 The stepper motor parameters mainly include step angle, steps for each
revolution, steps for each second, and RPM.

Step Angle

 The step angle of the stepper motor can be defined as the angle at
which the motor’s rotor turns once a single pulse is given to the stator’s
input. The resolution of the motor can be defined as the number of
steps of the motor and the number of revolutions of the rotor.

Resolution = Number of Steps/Number of Revolution of the Rotor

 The motor’s arrangement can be decided through the step-angle & it is

expressed within degrees. The resolution of a motor (the step number)
is the no. of steps which make within a single revolution of the rotor.
When the step-angle of the motor is small then the resolution is high for
the arrangement of this motor.

 The exactness of the arrangements of the objects through this motor

mainly depends on the resolution. Once the resolution is high then the
accuracy will be low.

 Some accuracy motors can create 1000 steps within a single revolution
including 0.36 degrees of step-angle. A typical motor includes 1.8
degrees of step angle with 200 steps for each revolution. The different
step angles such as 15 degrees, 45 degrees, and 90 degrees are very
common in normal motors. The number of angles can change from two
to six and a small step angle can be attained through slotted pole parts.

13
Steps for Each Revolution

 The steps for each resolution can be defined as the number of step
angles necessary for a total revolution. The formula for this is
360°/Step Angle.

Steps for Each Second

 This kind of parameter is mainly used for measuring the number

of steps covered within each second.

Revolution per Minute

 The RPM is the revolution per minute. It is used to measure the

frequency of revolution. So by using this parameter, we can
calculate the number of revolutions in a single minute. The main
relation between the parameters of the stepper motor is like the
following.

Steps for Each Second = Revolution per Minute x Steps per Revolution
60
Advantages
The advantages of stepper motor include the following.

 Ruggedness
 Simple construction
 Can work in an open-loop control system
 Maintenance is low
 It works in any situation
 Reliability is high
 The rotation angle of the motor is proportional to the input pulse.
 The motor has full torque at standstill.
 Precise positioning and repeatability of movement since good
stepper motors have an accuracy of 3 – 5% of a step and this error
is noncumulative from one step to the next.
 Excellent response to starting, stopping, and reversing.
 Very reliable since there are no contact brushes in the motor.
Therefore the life of the motor is simply dependant on the life of
the bearing.

14
  The motor’s response to digital input pulses provides open-loop
control, making the motor simpler and less costly to control.
 It is possible to achieve very low-speed synchronous rotation with a
load that is directly coupled to the shaft.
Disadvantages

The disadvantages of stepper motor include the following.

 Efficiency is low
 The Torque of a motor will declines fast with speed
 Accuracy is low
 Feedback is not used for specifying potential missed steps
 Small Torque toward Inertia Ratio
 Extremely Noisy
 If the motor is not controlled properly then resonances can occur
 Operation of this motor is not easy at very high speeds.
 The dedicated control circuit is necessary
 As compared with DC motors, it uses more current

Applications
 The applications of stepper motor include the following.

1. Industrial Machines – Stepper motors are used in automotive

gauges and machine tooling automated production equipment.

2. Security – new surveillance products for the security industry.

3. Medical – Stepper motors are used inside medical scanners,

samplers, and also found inside digital dental photography, fluid
pumps, respirators, and blood analysis machinery.

4. Consumer Electronics – Stepper motors in cameras for automatic

digital camera focus and zoom functions.

15
Arduino
 An Arduino is actually a microcontroller based kit which can be
either used directly by purchasing from the vendor or can be made at
home using the components, owing to its open source hardware
feature. It is basically used in communications and in controlling or
operating many devices.

Arduino Architecture:
 Arduino’s processor basically uses the Harvard architecture where the
program code and program data have separate memory. It consists of
two memories- Program memory and the data memory. The code is
stored in the flash program memory, whereas the data is stored in the
data memory. The Atmega328 has 32 KB of flash memory for storing
code (of which 0.5 KB is used for the bootloader), 2 KB of SRAM and 1
KB of EEPROM and operates with a clock speed of 16MHz.


Arduino Architecture

Figure 7

16
Arduino Pin Diagram
 A typical example of Arduino board is Arduino Uno. It consists of
ATmega328- a 28 pin microcontroller.

Figure 8
 Arduino Uno consists of 14 digital input/output pins (of which 6 can
be used as PWM outputs), 6 analog inputs, a 16 MHz crystal oscillator, a
USB connection, a power jack, an ICSP header, and a reset button

 Power Jack: Arduino can be power either from the pc through a USB or
through external source like adaptor or a battery. It can operate on a
external supply of 7 to 12V. Power can be applied externally through
the pin Vin or by giving voltage reference through the IORef pin.

 Digital Inputs: It consists of 14 digital inputs/output pins, each of which

provide or take up 40mA current. Some of them have special functions
like pins 0 and 1, which act as Rx and Tx respectively , for serial
communication, pins 2 and 3-which are external interrupts, pins
3,5,6,9,11 which provides pwm output and pin 13 where LED is
connected.

 Analog inputs: It has 6 analog input/output pins, each providing a

resolution of 10 bits.

 ARef: It provides reference to the analog inputs

 Reset: It resets the microcontroller when low.

17
How to program an Arduino?
 The most important advantage with Arduino is the programs can be
directly loaded to the device without requiring any hardware
programmer to burn the program. This is done because of the presence
of the 0.5KB of Bootloader which allows the program to be burned into
the circuit. All we have to do is to download the Arduino software and
writing the code.

 The Arduino tool window consists of the toolbar with the buttons like
verify, upload, new, open, save, serial monitor. It also consists of a text
editor to write the code, a message area which displays the feedback
like showing the errors, the text console which displays the output and
a series of menus like the File, Edit, Tools menu.

5 Steps to program an Arduino

 Programs written in Arduino are known as sketches. A basic sketch
consists of 3 parts
1. Declaration of Variables

2. Initialization: It is written in the setup () function.

3. Control code: It is written in the loop () function.

 The sketch is saved with .ino extension. Any operations like verifying,
opening a sketch, saving a sketch can be done using the buttons on the
toolbar or using the tool menu
 The sketch should be stored in the sketchbook directory.
 Chose the proper board from the tools menu and the serial port
numbers.
 Click on the upload button or chose upload from the tools menu.
Thus the code is uploaded by the bootloader onto the microcontroller.

18
Few of basic Arduino functions are:
 Digital Read (pin): Reads the digital value at the given pin.
 Digital Write (pin, value): Writes the digital value to the given pin.
 Pin Mode (pin, mode): Sets the pin to input or output mode.
 Analog Read (pin): Reads and returns the value.
 Analog Write (pin, value): Writes the value to that pin.
 Serial Begin (baud rate): Sets the beginning of serial
communication by setting the bit rate.

7 Reasons why Arduino is being preferred these days

1. It is inexpensive
2. It comes with an open source hardware feature which enables
users to develop their own kit using already available one as a
reference source.
3. The Arduino software is compatible with all types of operating
systems like Windows, Linux, and Macintosh etc.
4. It also comes with open source software feature which enables
experienced software developers to use the Arduino code to
merge with the existing programming language libraries and
can be extended and modified.
5. It is easy to use for beginners.
6. We can develop an Arduino based project which can be
completely stand alone or projects which involve direct
communication with the software loaded in the computer.
7. It comes with an easy provision of connecting with the CPU of
the computer using serial communication over USB as it
contains built in power and reset circuitry.
8. So this is some basic idea regarding an Arduino. You can use it
for many types of applications. For instance in applications
involving controlling some actuators like motors, generators,
based on the input from sensors.

Breadboard

 As the name suggests, the term breadboard can be derived from

two terms namely bread & board. Initially, this was used to cut the
bread into pieces. Further, it was called a breadboard & it was
used in electronics projects and electronic devices in the year

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 1970. A breadboard is also known as a solderless board because the
component used on the breadboard does not need any soldering
to connect to the board, so it can be reused.

Figure 9
 The arrangement of different components on a breadboard can be
done by inserting their terminals into the breadboard, so it is
frequently known as a plugboard. Breadboard definition is a
plastic board in rectangular shape that includes a lot of small holes
in it to allow you to place different components to build an
electronic circuit is known as a breadboard. The connection on the
breadboard is not permanent but they can be connected without
soldering the components.

 If you make any mistake while connecting the components, you

can place or remove the components effortlessly. For beginners of
electronics, this device is very helpful to make mini-projects. If a
designer builds a simple circuit that they desire to analyze, then a
breadboard gives a quick solution. The breadboard diagram is
shown below.

The material used to make the breadboard is white plastic. At present, most
of the breadboards are solderless types, so we can directly plug in the
components directly and connected them through the exterior power
supply. The different kinds of breadboards are accessible according to
the specific point holes. For instance 400 point type, 830 point type, etc.

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Specifications & Features

The specifications & features of a breadboard, include the following.

 Distribution Strips are two

 Wire Size is 21 to 26 AWG wire
 Tie Points are two hundred
 Withstanding Voltage is 1,000V AC
 Tie points within IC are 630
 Insulation Resistance is DC500V or 500MΩ
 Dimension is 6.5*4.4*0.3 inch
 Rating is 5Amps
 ABS plastic through color legend
 ABS heat Distortion Temperature is 183° F (84° C)Hole or Pitch
Style is 2.54mm

Types of Breadboard

Breadboards are classified into two types like a solderless breadboard

and a solder-able breadboard.

Solderless Breadboards

This is the most commonly used breadboard for prototyping as well as

testing electronic circuits without soldering the components. These are
available in different shapes, sizes as well as ratings.

The circuits on these breadboards are not permanent so we can check &
test the functionality of a circuit before confirming its design onto a PCB.
These breadboards include rows & columns with holes that allow the
leads of components & wire gauges.

If the terminal of the component does not place into the hole of a
breadboard, then a connecting wire can be soldered to the lead of a
component that will insert in the breadboard hole.

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Advantages

The advantages of solderless breadboards include the following.

 It doesn’t require soldering to connect the components on board.

 If the circuit is not working properly then, we can easily check
and rectify them by taken out the components & replace them
easily.

Disadvantages

The disadvantages of solderless breadboards include the following.

 Components that are connected to the breadboard can

come loose once the breadboard is pushed or moved.
 This kind of breadboard is available with high parasitic
capacitances because of the capacitances among
different components which are being close to each
other.
 These breadboards are restricted to below or 10 MHz frequencies.

Applications

The applications or uses of a breadboard include the following.

 The main application of a breadboard is to form simple

electrical connections among different components so that you
can check your circuit before soldering it to the board.
 These boards allow different components to be simply placed
or removed or the term prototyping instantly comes to mind
permanently.
 If a designer designs a simple circuit or module then they need
to check, so this board offers a fast & cheap solution

TB6560 Stepper Motor Driver with Arduino

 In this tutorial, you will learn how to control a stepper motor
with the TB6560 micro stepping driver and Arduino. This driver is
easy to use and can control large stepper motors like a 3 A NEMA
23.
 I have included a wiring diagram and 2 example codes. In the first
example, I will show you how you can use this stepper motor
driver without an Arduino library. In the second example, we will
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take a look at the Accel Stepper library. This library is fairly easy
to

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 use and allows you to add acceleration and deceleration to the
movement of the stepper motor.
 After each example, I break down and explain how the code works,
so you should have no problems modifying it to suit your needs.
 If you would like to learn more about other stepper motor
drivers, then the articles below might be useful:

About the driver

 The TB6560 micro stepping driver is built around the Toshiba

TB6560AHQ chip and it can be used to drive two-phase bipolar
stepper motors.
 With a maximum current of 3 A continuous, the TB6560 driver
can be used to control quite large stepper motors like a NEMA 23.
Make sure that you do not connect stepper motors with a current
rating of more than 3 A to the driver.
 The chip has several safety functions built-in like over-current,
under-voltage shutdown, and overheating protection. However,
it does not have reverse-voltage protection, so make sure that
you connect the power supply correctly. You can find more
specifications in the table below

TB6560 Specifications

Operating voltage 10-35 VDC Recommended

Max output current 3 A Per phase, 3.5 A Peak
Microstep resolution Full, 1/2, 1/8, and 1/16
Protection Low-voltage shutdown,
overheating and over-current
protection

69*43mm, ⌀ 3.5 mm
Dimensions 75*50*35mm
Hole spacing

 Note that the TB6560 is an analog driver. In recent years, digital

drivers like the DM556 or DM542 have become much more
affordable. Digital drivers usually give much better performance
and quieter operation. They can be wired and controlled in the

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 same way as the TB6560, so you can easily upgrade your system
later.

Wiring – Connecting TB6560 to stepper motor and Arduino

 The wiring diagram below shows you how you can connect the
TB6560 stepper motor driver to the Arduino and a stepper
motor.
Figure 2 Figure 9

Figure 10

 In this tutorial, we will be connecting the driver in a common

cathode configuration. This means that we connect all the
negative sides of the control signal connections together to
ground.
TB6560 Connections

TB6560 Connection
VCC 10-35 VDC
GND Power supply ground
EN- connected
EN+ connected

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CW- Arduino GND
CW+ Pin 2 Arduino
CLK- Arduino GND
CLK+ Pin 3 Arduino
A-,A+ Coil 1 Stepper motor
B-,B+ Coil 2 Stepper motor

TB6560 microstep settings

 Stepper motors typically have a step size of 1.8° or 200 steps per
revolution, this refers to full steps. A micro stepping driver such as
the TB6560 allows higher resolutions by allowing intermediate
step locations. This is achieved by energizing the coils with
intermediate current levels.

 For instance, driving a motor in 1/2 step mode will give the
200-steps-per-revolution motor 400 microsteps per revolution.
 You can change the TB6560 microstep setting or excitation mode
by switching the dip switches on the driver on or off. See the table
below for details. Make sure that the driver is not connected to
power when you adjust the dip switches!

Microstep table.

S3 S4 MICRO STEP
RESOLUTION
OFF OFF Full step

OFF OFF 1/2 Step

ON ON 1/8 Step

OFF ON 1/16 Step

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  Generally speaking, a smaller micro step setting will result in a
smoother and quieter operation. It will however limit the top
speed that you can achieve when controlling the stepper motor
driver with an Arduino.

TB6560 current settings

 You can adjust the current that goes to the motor when it is
running by setting the dip switches SW1, SW2, SW3, and S1 on or
off. I recommend starting with a current level of 1 A. If your motor
is missing steps or stalling, you can always increase the current
level later.

Control spinning direction:

 To control the spinning direction of the stepper motor we set

the DIR (direction) pin either HIGH or LOW. For this, we use the
function digital Write ().
 Depending on how you connected the stepper motor, setting the
DIR pin high will let the motor turn CW or CCW.

Control number of steps or revolutions:

 In this example sketch, the for loops control the number of steps
the stepper motor will take. The code within the for loop results
in 1 (micro) step of the stepper motor. Because the code in the
loop is executed 1600 times (steps Per Revolution), this results in
1 revolution. In the last two loops, the code within the for loop is
executed 8000 times, which results in 8000 (micro) steps or 5
revolutions.
 Note that you can change the second term in the for loop
to whatever number of steps you want.

For (int i = 0; i < 800; i++)

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Control speed:

 The speed of the stepper motor is determined by the frequency of

the pulses we send to the STEP pin. The higher the frequency, the
faster the motor runs. You can control the frequency of the pulses
by changing

Delay Microseconds ()

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 DESIGN AND FABRICATION

Spur gear
Spur gears or straight-cut gears are the
simplest type of gear. They consist of a cylinder or disk with teeth
projecting radially. Viewing the gear at 90 degrees from the shaft length
(side on) the tooth faces are straight and aligned parallel to the axis of
rotation. Looking down the length of the shaft, a tooth's cross section is
usually not triangular. Instead of being straight (as in a triangle) the sides
of the cross section have a curved form (usually involute and less
commonly cycloidal) to achieve a constant drive ratio. Spur gears mesh
together correctly only if fitted to parallel shafts.[1] No axial thrust is
created by the tooth loads. Spur gears are excellent at moderate speeds
but tend to be noisy at high speeds.

Figure 11

Formula Used:

Pinion gear Z1 = 40 Teeth

Pinion gear Z2 = 20 Teeth

Gear calculation =

3.14/180 x 70 degree =2.443

2.44 x 180/3.14 = 140

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 140-360 = 220 degree

Base structure

Figure 12

Welding process

Welding is a fabrication process whereby two or

more parts are fused together by means of heat, pressure or both
forming a join as the parts cool. Welding is usually used on metals and
thermoplastics but can also be used on wood. The completed welded
joint may be referred to as a weldment.

Cutting process

Cutting, or to cut, in the context of fabrication,

may be considered as 'to divide' or 'to sever'. This is an important
operation in producing sheets to size, removing waste material, making
weld joint preparations and in removing defects.

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3D modeling

Figure 13
31
Program used in Arduino:

Figure 14

32
 Challenges and Decision Making

Following are the issues and challenges being encountered during

the execution of project:

1. Issues in equipment:

As far as sustainability is concerned for the prototype, it was made

sure that selection of components, like pinion and gear or mild steel ,
clutch casing or aluminum, Supporting frame were made according to
choose the proper materiel

2. Design Problems:

During the fabrication and assembling cable less clutch machine, we

faced challenges in the matting of parts because of wrong tolerances we
maintained in the first attempt.

Then we redesigned gear and motor supporting plates and gear meet
the close tolerances to ensure a close fit during assembly.

Moreover, we faced problem in designing complex parts like clutch lever

and micro switch alignment. But later on, things get smooth when we
successfully done with the testing cable less clutch machine.

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 CONCULUSION
Stepper motor can be operated at different speeds with help of
microcontroller with the precise angle because of the small
step angle present in the motor. Also, it can be rotated in
different direction clockwise or anticlockwise. And this can be
used for connect and disconnect the clutch. Controlling speed
of stepper motor with Arduino can be studied throughout this
project.

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