What are mechanical kits, safety and components?

Part ofDesign and TechnologyMechanical control systems

Key points

  • Construction kits allow for quick and easy assembly, but they are limited by the components available in the kit.
  • Working models can be custom-built to precise specifications, but they are time-consuming to create and mistakes can be costly.
  • Virtual models (CAD/CAM) eliminate material costs and allow for easy modifications, but they require training in CAD/CAM software.
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What are mechanical kits?

  1. Construction Kits (like Meccano or Lego Technic): These offer quick assembly and testing of ideas. Users can easily modify designs and see immediate results. The advantage is that users can experiment safely and quickly, while the main disadvantage is that the components are limited to what's in the kit, and the final product might not perfectly match the design intentions.
Small metal aeroplane made using meccano on blue background
Image caption,
A metal aeroplane made using Meccano construction kit
Designers using lego to make a model
Image caption,
Building a model using Lego construction kit
  1. Working models: these are custom-built using resistant materials like wood, metal, or plastic. The advantage is that users can create exactly what they envision and learn practical manufacturing skills. However, working models can take longer to make, require more skill, and mistakes can be costly in terms of materials and time.
Designer working from sketches to build a cardboard model
Image caption,
Designer building a working model in cardboard
  1. Virtual models (CAD/CAM ): using software to design and test mechanisms offers the advantage of zero material cost and easy modification. Users can simulate movement and spot problems before building. The disadvantage is that users don't get hands-on experience with physical materials and might miss practical construction challenges. In addition, users need to undergo training in /software to be able to use it properly.
Designer working with CAD to design an orange chair with large computer screen in front
Image caption,
Furniture designer working with CAD to design a contemporary chair
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How to adhere to mechanical safety

When building and using mechanical systems, users need to understand several key safety aspects:

  • Moving parts protection: all rotating parts need proper guards to prevent entanglement or injury. This includes covering gears, belts, and pulleys.
  • Stability: ensuring the base is secure and the mechanism is properly mounted to prevent tipping or collapse during operation.
  • Material selection: using appropriate materials that can withstand the forces involved without breaking or failing.
  • Operational safety: understanding safe operating procedures, including startup, shutdown, and emergency stops.
Two students in blue overalls using a drill press, one operating the other observing
Image caption,
Using a drill press correctly with safety guard, clothing covering and eye protection
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What are mechanical components?

Wheel and axle

Symbol for a wheel and axle - labelled
Figure caption,
Symbol for a wheel and axle

This fundamental mechanism consists of a wheel fixed to a central shaft. It's used to reduce effort in rotary motion, like in a door handle or steering wheel.

An illustration of a cartwheel and axle - labelled
Figure caption,
A wheel and axle

Gears

Symbol for a meshed gear - two sets of concentric circles of differing sizes interlocking
Figure caption,
Meshed gear symbol
Two metal gears of different sizes connected to create a meshed gear mechanism
Image caption,
A meshed gear mechanism

These toothed wheels transmit rotary motion and can change speed, direction, and force. Different types (spur, bevel, worm) serve different purposes in machines.

Two metal gears of different sizes connected to create a meshed gear mechanism
Image caption,
A meshed gear mechanism

Cams and followers

 Symbol for Eccentric cam, Heart-shaped cam and Pear-shaped cam
Figure caption,
Symbols for eccentric, heart-shaped and pear-shaped cams
Symbols for roller follower, flat follower and knife follower
Figure caption,
Symbols for roller follower, flat follower and knife follower

These mechanisms convert rotary motion to . The follower's shape (flat, knife, roller) affects the motion quality.

A cam mechanism showing directional arrows to demonstrate a camshaft which rotates and a follower which moves up and down.
Figure caption,
A cam mechanism

Levers

Lever, Pivoted lever and fixed pivot lever symbols
Figure caption,
Symbols used for different types of lever
A father and daughter sitting on opposite sides of a seesaw, the daughter lifted into the air and the father near the ground.
Image caption,
A seesaw is a class 1 lever

These simple machines amplify force or change its direction.

There are three classes of levers and some applications include scissors (first class), wheelbarrows (second class) or fishing rods (third class).

A father and daughter sitting on opposite sides of a seesaw, the daughter lifted into the air and the father near the ground.
Image caption,
A seesaw is a class 1 lever

Belts and pulleys

Belt and pulley diagram
Figure caption,
Belt and pulley diagram
Belt and pulley mechanism in operation
Image caption,
Transmission belt pulley of a vintage industrial band saw machine in motion

These transfer rotary motion between parallel shafts and can change speed and direction. Examples include bike gears and conveyor systems.

Belt and pulley mechanism in operation
Image caption,
Transmission belt pulley of a vintage industrial band saw machine in motion

Shafts

Symbol for shaft. Circle intersected by 4 straight lines and dot in middle
Figure caption,
Symbol for shaft
Stepper motor with endless screw shaft and bearing
Image caption,
Shaft connected to motor

These transmit rotary motion and between components.
Their diameter and material affect their strength and performance.

Stepper motor with endless screw shaft and bearing
Image caption,
Shaft connected to motor
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Test yourself

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