DESIGN AND FABRICATION OF RESISTIVE

EXERCISE DEVICE
A PROJECT REPORT
Submitted by

N.UDAYASAI

1021220101

K.PRASANTH NAG

1021220109

S.ANJI REDDY

1021220114

N.JASHWANTH KUMAR

1021220149

in partial fulfillment for the award of the degree

of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

SRM UNIVERSITY
RAMAPURAM
MAY 2016

SRM UNIVERSITY
RAMAPURAM

BONAFIDE CERTIFICATE
Certified

that

this

project

report

DESIGN

AND

FABRICATION OF RESISTIVE EXERCISE DEVICE is the

bonafide

work

of

NAGUBANDI UDAYASAI (1021220101),

KAMMA PRASANTH NAG (1021220109), SAMALA ANJI REDDY

(1021220114), NARE JASWANTH REDDY (1021220149) who
carried out the project work under my supervision.

SIGNATURE
GUIDE
Mr.M.SOUNDAR, M.E
Assistant Professor (O.G)
Department of Mechanical Engineering

INTERNAL EXAMINER

SIGNATURE
HEAD OF THE DEPARTMENT
Mr.K.C.UDAIYAKUMAR, M.Tech.(Ph.D.)
Assistant Professor (S.G)
Department of Mechanical Engineering

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

We place on regard our deep sense of gratitude to our beloved Chancellor

Dr.T.R.PACHAMUTHU for providing us with the requisite infrastructure
throughout the course.
We take the opportunity to extend our hearty thanks to our Chairman, SRM
University

Ramapuram

Campus,

Dr.R.SHIVAKUMAR

for

his

constant

encouragement.
We take the opportunity to extend our hearty thanks to our Dean,
Dr.V.SUBBIAH BHARATHI for his constant encouragement.
We convey our sincere thanks to our Vice Principal (Academic)
Dr.L.ANTONY MICHAEL RAJ for his interest and support throughout this project.
We take the privilege to extend our hearty thanks to the Head of the
Department, Mr.K.C.UDAIYAKUMAR, M.Tech., (Ph.D.), Asst. Professor(S.G) for
his suggestions, support and encouragement towards the completion of the project
with perfection.
We take the privilege to extend our hearty thanks to the Project co-ordinator,
Mr.D.K.MOHAN KUMAR, M.E., M.B.A., (Ph.D.), Asst.Professor (Sr.G),
Mechanical Engineering Department for his suggestions, support and encouragement
towards the completion of the project with perfection.
We

express

gratitude

to

our

guide

Mr.M.SOUNDAR,

M.E.,

Asst.Professor (O.G), Mechanical Engineering Department for his sustained

encouragement, consecutive criticisms and constant guidance throughout this project
work.

TABLE OF CONTENTS
CHAPTER NO.

LIST OF CONTENTS

PAGE NO.

LIST OF TABLE

iii

LIST OF FIGURES

iv

ABSTRACT
1.

INTRODUCTION

1.1 Brief overview

1.2 Welding

1.2.1 Arc welding

1.2.2 Power supplies

1.2.3 Processes

1.2.4 Shield metal arc welding

1.2.5 Welding joint

1.3 Gears

1.4

1.3.1 Types of gears

1.3.2 Nomenclature of gears

10

Belt and pulley system

18

2.

LITERATURE REVIEW

20

3.

STATEMENT OF PROBLEM

22

4.

METHODOLOGY

23

4.1 Sequence of design

5.

23

4.1.1 Vacuum cylinders

24

4.1.2 Rack and pinion mechanism

24

4.1.3 screw rod and pulley mechanism

25

EXPERIMENTAL WORK

26

5.1 Introduction

26

5.2 Selection of material

26

5.2.1 Properties

26

5.2.2 Manufacturing cost

27

5.2.3 Quality

27

5.2.4 Availability of material

27

5.2.5 Space consideration

27

TABLE OF CONTENTS
CHAPTER NO.

LIST OF CONTENTS

PAGE NO.

5.2.6 Cost

27

5.3 Weight calculation

28

5.4 Design

30

5.5 Components

33

5.6 Specifications

34

5.6.1 Vacuum cylinder specifications

35

5.7 Fabrication

36

5.8 Construction

40

5.9 Working

40

5.10 Cost estimation

41

6.

RESULTS AND DISCUSSION

43

7.

ADVANTAGES AND LIMITATIONS

44

8.

CONCLUSION

45

9.

FUTURE SCOPE

46

REFERENCE

LIST OF TABLES
TABLE NO.

DESCRIPTION

PAGE NO.

5.1

Components of Resistive exercise device

33

5.2

Specifications

34

5.3

Vacuum cylinder specifications

32

5.4

Cost estimation

38

LIST OF FIGURES
FIGURE NO.

DESCRIPTION

PAGE NO.

1.1

Welding types

1.2

Welded butt joint

1.3

Gears

1.4

Warm gear

1.5

Rack and Pinion gearing

10

1.6

Gear nomenclature

10

1.7

Flat belt on belt pulley

18

1.8

Belt and Pulley system

18

1.9

Cone pulley

18

5.1

Basic design

30

5.2

Front view

31

5.3

Side view

31

5.4

Top view

32

5.5

Main frame

36

5.6

Lifting rod

36

5.7

Vacuum cylinders

36

5.8

Cylinder piston with rack

37

5.9

Flywheel setup and main arm

37

5.10

Clamp adjustment

38

5.11

Pulley setup

38

5.12

Final assembled and finished product

39

ABSTRACT
Fitness being the main concerned problem of the present generation. There is
an immediate necessity for economical and long lasting fitness machinery. Huge
weights, used as force providers today are not only increasing the cost of the
equipment but also increasing the wear and tear. So, using alternative methods to
create the force instead of weights would drastically decrease the cost of the
equipment.
The idea of the project is to replace the traditional weights with a vacuum or
air pressured equipment (ex: cylinders) and also to provide a mechanism to adjust the
force required ( this will eliminate the problem of changing the weights). The
mechanism would inherit the idea of flywheel and arm mechanism to alter the torque
relative to the arm position. Coupling various exercises with the mechanism would be
another task to be accomplished in order to provide economic and robust model.

CHAPTER 1
INTRODUCTION
1.1Brief overview
Fitness being the main concerned problem of the present generation. There is
an immediate necessity for economical and long lasting fitness machinery. Huge
weights, used as force providers today are not only increasing the cost of the
equipment but also increasing the wear and tear. So, using alternative methods to
create the force instead of weights would drastically decrease the cost of the
equipment.
Numerous exercise devices have been designed and are on the market The vast
majority of these devices are designed for normal gravity conditions. For example,
many devices have been developed of the weight type wherein Weights are
employed in the resistance to the exertion of muscular force. Perhaps the simplest of
these are barbells, but a host of machines of this type have been developed which
employ.
Weight stacks of a variety of types against which muscular force is exerted
in exercising to achieve or maintain muscular development. Machines of the weight
type suffer from several common deficiencies, which detract from their desire ability.
Such machines are normally rather cumbersome and expensive. They do not possess
the deity of adjustability (i.e., they are limited to the Weight stack increments).
Perhaps the most obvious aspect of these types of devices is that they are very heavy
due to the inherent nature of the use of Weight stacks. Accordingly, a need has arisen
for an exercise device for zero or micro gravity conditions Which, for example,
simulates the lifting of free Weights in a 1-g environment and Which is compact With
relatively low mass, provides for numerous different exercises, is adjustable for
different loads, is adjustable for different sized individuals and Will operate for long
periods With minimal maintenance.
In accordance with the present invention, an exercise device is provided
which has loads applied by both a vacuum cylinder and fly Wheel. When used in a
space application, this device simulates the lifting of free Weights in a 1-g
environment. Also in accordance With the present invention, an exercise device is
provided which comprises a vacuum cylinder and a load adjusting arm base assembly.
1

Accordingly, an object of the present invention is to provide an exercise device for

space application, which simulates the lifting of free Weights in a 1-g environment.
Accordingly, a second object of the present invention is to provide an
exercise device having a vacuum cylinder and a unique load-adjusting feature, which
varies the otherwise constant load provided by a vacuum cylinder. A third object of
the present invention is to provide an improved exercising apparatus for terrestrial
applications such as, for examples: a home gym for personal use; rehabilitation and
physical therapy purposes; and an exercise device for a health club, hotel, or cruise
ship. Further objects and advantages are to provide improved elements and
arrangements thereof in an exercise apparatus. For the purpose described which is
dependable, economical, durable, and fully effective in accomplishing the intended
purpose.

1.2 Welding
Welding is a fabrication or sculptural process that joins materials, usually
metals or thermoplastics, by causing fusion, which is distinct from lower temperature
metal-joining techniques such as brazing and soldering, which do not melt the base
metal. In addition to melting the base metal, a filler material is often added to the joint
to form a pool of molten material (the weld pool) that cools to form a joint that can be
as strong, or even stronger, than the base material. Pressure may also be used in
conjunction with heat, or by itself, to produce a weld.
Although less common, there are also solid state welding processes such as friction
welding or shielded active gas welding in which metal does not melt.
Shielded metal arc welding (SMAW) - also known as "stick welding or electric
welding", uses an electrode that has flux around it to protect the weld puddle. The
electrode holder holds the electrode as it slowly melts away. Slag protects the weld
puddle from atmospheric contamination.

Gas tungsten arc welding (GTAW) - also known as TIG (tungsten, inert gas),
uses a non-consumable tungsten electrode to produce the weld. The weld area is
protected from atmospheric contamination by an inert shielding gas such
as argon or helium.

Gas metal arc welding (GMAW) - commonly termed MIG (metal, inert gas),
uses a wire feeding gun that feeds wire at an adjustable speed and flows an argonbased shielding gas or a mix of argon and carbon dioxide (CO2) over the weld
puddle to protect it from atmospheric contamination.

Flux-cored arc welding (FCAW) - almost identical to MIG welding except it

uses a special tubular wire filled with flux; it can be used with or without
shielding gas, depending on the filler.

Submerged arc welding (SAW) - uses an automatically fed consumable

electrode and a blanket of granular fusible flux. The molten weld and the arc zone
are protected from atmospheric contamination by being "submerged" under the
flux blanket.

Electro slag welding (ESW) - a highly productive, single pass welding process
for thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a
vertical or close to vertical position.
Many different energy sources can be used for welding, including a gas flame,

an electric arc, a laser, an electron beam, friction, and ultrasound. While often an
industrial process, welding may be performed in many different environments,
including in open air, under water, and in outer space. Welding is a hazardous
undertaking and precautions are required to avoid burns, electric shock, vision
damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet
radiation.

1.2.1 Arc welding

These processes use a welding power supply to create and maintain an electric
arc between an electrode and the base material to melt metals at the welding point.
They can use either direct (DC) or alternating (AC) current, and consumable or nonconsumable electrodes. The welding region is sometimes protected by some type of
inert or semi-inert gas, known as a shielding gas, and filler material is sometimes used
as well.
To supply the electrical power necessary for arc welding processes, a variety
of different power supplies can be used. The most common welding power supplies
3

are constant current power supplies and constant voltage power supplies. In arc
welding, the length of the arc is directly related to the voltage, and the amount of heat
input is related to the current. Constant current power supplies are most often used for
manual welding processes such as gas tungsten arc welding and shielded metal arc
welding, because they maintain a relatively constant current even as the voltage
varies. This is important because in manual welding, it can be difficult to hold the
electrode perfectly steady, and as a result, the arc length and thus voltage tend to
fluctuate. Constant voltage power supplies hold the voltage constant and vary the
current, and as a result, are most often used for automated welding processes such as
gas metal arc welding, flux cored arc welding, and submerged arc welding. In these
processes, arc length is kept constant, since any fluctuation in the distance between
the wire and the base material is quickly rectified by a large change in current. For
example, if the wire and the base material get too close, the current will rapidly
increase, which in turn causes the heat to increase and the tip of the wire to melt,
returning it to its original separation distance.
The type of current used plays an important role in arc welding. Consumable
electrode processes such as shielded metal arc welding and gas metal arc welding
generally use direct current, but the electrode can be charged either positively or
negatively. In welding, the positively charged anode will have a greater heat
concentration, and as a result, changing the polarity of the electrode has an impact on
weld properties. If the electrode is positively charged, the base metal will be hotter,
increasing weld penetration and welding speed. Alternatively, a negatively charged
electrode results in more shallow welds. Non consumable electrode processes, such as
gas tungsten arc welding, can use either type of direct current, as well as alternating
current. However, with direct current, because the electrode only creates the arc and
does not provide filler material, a positively charged electrode causes shallow welds,
while a negatively charged electrode makes deeper welds. Alternating current rapidly
moves between these two, resulting in medium-penetration welds. One disadvantage
of AC, the fact that the arc must be re-ignited after every zero crossing, has been
addressed with the invention of special power units that produce a square
wave pattern instead of the normal sine wave, making rapid zero crossings possible
and minimizing the effects of the problem.

One of the most common types of arc welding is shielded metal arc
welding (SMAW) it is also known as manual metal arc welding (MMA) or stick
welding. Electric current is used to strike an arc between the base material and
consumable electrode rod, which is made of filler material (typically steel) and is
covered with a flux that protects the weld area from oxidation and contamination by
producing carbon dioxide (CO2) gas during the welding process. The electrode core
itself acts as filler material, making a separate filler unnecessary.

1.2.2 Shield metal arc welding

The process is versatile and can be performed with relatively inexpensive
equipment, making it well suited to shop jobs and field work. An operator can become
reasonably proficient with a modest amount of training and can achieve mastery with
experience. Weld times are rather slow, since the consumable electrodes must be
frequently replaced and because slag, the residue from the flux, must be chipped away
after welding. Furthermore, the process is generally limited to welding ferrous
materials, though special electrodes have made possible the welding of cast iron,
nickel, aluminum, copper, and other metals.
A related process, flux cored arc welding (FCAW), uses similar equipment but
uses wire consisting of a steel electrode surrounding a powder fill material. This cored
wire is more expensive than the standard solid wire and can generate fumes and/or
slag, but it permits even higher welding speed and greater metal penetration.
Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, is a
manual welding process that uses a non-consumable tungsten electrode, an inert or
semi-inert gas mixture, and a separate filler material. Especially useful for welding
thin materials, this method is characterized by a stable arc and high quality welds, but
it requires significant operator skill and can only be accomplished at relatively low
speeds.
GTAW can be used on nearly all weldable metals, though it is most often
applied to stainless steel and light metals. It is often used when quality welds are
extremely important, such as in bicycle, aircraft and naval applications. A related
process, plasma arc welding, also uses a tungsten electrode but uses plasma gas to
make the arc. The arc is more concentrated than the GTAW arc, making transverse
control more critical and thus generally restricting the technique to a mechanized
5

process. Because of its stable current, the method can be used on a wider range of
material thicknesses than can the GTAW process and it is much faster. It can be
applied to all of the same materials as GTAW except magnesium, and automated
welding of stainless steel is one important application of the process. A variation of
the process is plasma cutting, an efficient steel cutting process.
Submerged arc welding (SAW) is a high-productivity welding method in
which the arc is struck beneath a covering layer of flux. This increases arc quality,
since contaminants in the atmosphere are blocked by the flux. The slag that forms on
the weld generally comes off by itself, and combined with the use of a continuous
wire feed, the weld deposition rate is high. Working conditions are much improved
over other arc welding processes, since the flux hides the arc and almost no smoke is
produced. The process is commonly used in industry, especially for large products and
in the manufacture of welded pressure vessels. Other arc welding processes
include atomic hydrogen welding, electro slag welding, electro gas welding, and stud
arc welding.

1.2.3 Welding joint

Fig 1.1 welding types

Welds can be geometrically prepared in many different ways. The five basic
types of weld joints are the butt joint, lap joint, corner joint, edge joint, and T-joint (a
variant of this last is the cruciform joint). Other variations exist as wellfor example,
double-V preparation joints are characterized by the two pieces of material each
tapering to a single center point at one-half their height. Single-U and double-U
preparation joints are also fairly commoninstead of having straight edges like the
6

single-V and double-V preparation joints, they are curved, forming the shape of a U.
Lap joints are also commonly more than two pieces thickdepending on the process
used and the thickness of the material, many pieces can be welded together in a lap
joint geometry.
Many welding processes require the use of a particular joint design; for
example, resistance spot welding, laser beam welding, and electron beam welding are
most frequently performed on lap joints. Other welding methods, like shielded metal
arc welding, are extremely versatile and can weld virtually any type of joint. Some
processes can also be used to make multi-pass welds, in which one weld is allowed to
cool, and then another weld is performed on top of it. This allows for the welding of
thick sections arranged in a single-V preparation joint, for example.

Fig 1.2 Weld butt joint

The cross section of a weld butt joint, with the darkest gray representing the
weld or fusion zone, the medium gray the heat-affected zone, and the lightest gray
base material.
After welding, a number of distinct regions can be identified in the weld area.
The weld itself is called the fusion zonemore specifically, it is where the filler metal
was laid during the welding process. The properties of the fusion zone depend
primarily on the filler metal used, and its compatibility with the base materials. It is
surrounded by the heat-affected zone, the area that had its microstructure and
properties altered by the weld. These properties depend on the base material's
behavior when subjected to heat. The metal in this area is often weaker than both the
base material and the fusion zone, and is also where residual stresses are found.

1.3 Gears

Fig 1.3 Gears

Two meshing gears transmitting rotational motion. Note that the smaller gear
is rotating faster. Although the larger gear is rotating less quickly, its torque is
proportionally greater. One subtlety of this particular arrangement is that the linear
speed at the pitch diameter is the same on both gears
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which
mesh with another toothed part to transmit torque. Geared devices can change the
speed, torque, and direction of a power source. Gears almost always produce a change
in torque, creating a mechanical advantage, through their gear ratio, and thus may be
considered a simple machine. The teeth on the two meshing gears all have the same
shape. Two or more meshing gears, working in a sequence, are called a gear train or
a transmission. A gear can mesh with a linear toothed part, called a rack, thereby
producing translation instead of rotation.
The gears in a transmission are analogous to the wheels in a crossed
belt pulley system. An advantage of gears is that the teeth of a gear prevent slippage.
When two gears mesh, if one gear is bigger than the other, a mechanical
advantage is produced, with the rotational speeds, and the torques, of the two gears
differing in proportion to their diameters.
In transmissions with multiple gear ratiossuch as bicycles, motorcycles, and
cars-the term "gear" as in "first gear" refers to a gear ratio rather than an actual
physical gear. The term describes similar devices, even when the gear ratio
is continuous rather than discrete, or when the device does not actually contain gears,
as in a continuously variable transmission.
An external gear is one with the teeth formed on the outer surface of a cylinder
or cone. Conversely, an internal gear is one with the teeth formed on the inner surface
of a cylinder or cone. For bevel gears, an internal gear is one with the pitch angle
exceeding 90 degrees. Internal gears do not cause output shaft direction reversal.

1.4 Types of gears

1.4.1 Spur
Spur gears or straight-cut gears are the simplest type of gear. They consist of a
cylinder or disk with teeth projecting radially. Though the teeth are not straight-sided
8

(but usually of special form to achieve a constant drive ratio, mainly involute but less
commonly cycloidal), the edge of each tooth is straight and aligned parallel to the axis
of rotation. These gears mesh together correctly only if fitted to parallel shafts.

1.4.2 Worm

Fig 1.4 Worm gear

Worm gear resembles screws. A worm is meshed with a worm wheel, which
looks similar to a spur gear. Worm-and-gear sets are a simple and compact way to
achieve a high torque, low speed gear ratio. For example, helical gears are normally
limited to gear ratios of less than 10:1 while worm-and-gear sets vary from 10:1 to
500:1. A disadvantage is the potential for considerable sliding action, leading to low
efficiency.
A worm gear is a species of helical gear, but its helix angle is usually
somewhat large (close to 90 degrees) and its body is usually fairly long in the axial
direction. These attributes give it screw like qualities. The distinction between a worm
and a helical gear is that at least one tooth persists for a full rotation around the helix.
If this occurs, it is a 'worm'; if not, it is a 'helical gear. A worm may have as few as one
tooth. If that tooth persists for several turns around the helix, the worm appears,
superficially, to have more than one tooth, but what one in fact sees is the same tooth
reappearing at intervals along the length of the worm. The usual screw nomenclature
9

applies: a one-toothed worm is called single thread or single start; a worm with more
than one tooth is called multiple thread or multiple start. The helix angle of a worm is
not usually specified. Instead, the lead angle, which is equal to 90 degrees minus the
helix angle, is given.

1.4.3 Rack and pinion

Fig1.5 Rack and pinion gearing

A rack is a toothed bar or rod that can be thought of as a sector gear with an
infinitely large radius of curvature. Torque can be converted to linear force by
meshing a rack with a pinion: the pinion turns; the rack moves in a straight line. Such
a mechanism is used in automobiles to convert the rotation of the steering wheel into
the left-to-right motion of the tie rod(s). Racks also feature in the theory of gear
geometry, where, for instance, the tooth shape of an interchangeable set of gears may
be specified for the rack (infinite radius), and the tooth shapes for gears of particular
actual radii are then derived from that. The rack and pinion gear type is employed in
a rack railway.

1.5 Nomenclature of gears

10

Fig 1.6 Gear Nomenclature

Rotational frequency, n
Measured in rotation over time, such as RPM.
Angular frequency,
Measured in radians/second. 1 RPM= /30 rad/second
Number of teeth, N
How many teeth a gear has, an integer. In the case of worms, it is the number
of thread starts that the worm has.
Pinion
The smaller of two interacting gears.
Path of contact
Path followed by the point of contact between two meshing gear teeth.
Pressure line
Line along which the force between two meshing gear teeth is directed. In
general, the line of action changes from moment to moment during the period of
engagement of a pair of teeth. For involute gears, however, the tooth-to-tooth force is
always directed along the same linethat is, the line of action is constant. This
implies that for involute gears the path of contact is also a straight line, coincident
with the line of contact
Axis
11

Axis of revolution of the gear; center line of the shaft.

Pitch point
Point where the line of action crosses a line joining the two gear axes.
Pitch circle
Circle centered on and perpendicular to the axis, and passing through the pitch
point. A predefined diametric position on the gear where the circular tooth thickness,
pressure angle and helix angles are defined.
Pitch diameter, d
A predefined diametric position on the gear where the circular tooth thickness,
pressure angle and helix angles are defined. The standard pitch diameter is a basic
dimension and cannot be measured, but is a location where other measurements are
made. Its value is based on the number of teeth, the normal module (or normal
diametric pitch), and the helix angle. It is calculated as:
d=

Nm
cos

in metric units

Module or modulus, m
Since it is impractical to calculate circular pitch with irrational numbers,
mechanical engineers usually use a scaling factor that replaces it with a regular value
instead. This is known as the module of the wheel and is simply defined as:
m= p/
Where, m is the module and p the circular pitch. The units of module are
customarily millimeters.
The distance between the two axes becomes:
a=m ( z 1 + z 2 ) / 2
Where a is the axis distance, z1 and z2 are the number of cogs (teeth) for each
of the two wheels (gears). These numbers (or at least one of them) is often chosen
among primes to create an even contact between every cog of both wheels, and
thereby avoid unnecessary wear and damage. An even uniform gear wear is achieved
by ensuring the tooth counts of the two gears meshing together are relatively prime to
each other; this occurs when the greatest common divisor (GCD) of each gear tooth
count equals 1, e.g. GCD(16,25)=1; If a 1:1 gear ratio is desired a relatively prime
gear may be inserted in between the two gears; this maintains the 1:1 ratio but
12

reverses the gear direction; a second relatively prime gear could also be inserted to
restore the original rotational direction while maintaining uniform wear with all 4
gears in this case. Mechanic engineers at least in continental Europe use the module
instead of circular pitch. The module, just like the circular pitch, can be used for all
types of cogs, not just evolved based straight cogs.
Operating pitch diameters
Diameters determined from the number of teeth and the center distance at
which gears operate Example for pinion:
d w=

2a
2a
=
u+1 z 2
+1
z1

Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial
direction. More generally, the surface formed by the sum of all the pitch circles as one
moves along the axis. For bevel gears it is a cone.

Angle of action
Angle with vertex at the gear center, one leg on the point where mating teeth
first make contact, the other leg on the point where they disengage.
Arc of action
Segment of a pitch circle subtended by the angle of action . The complement
of the angle between the direction that the teeth exert force on each other, and the line
joining the centers of the two gears. For involute gears, the teeth always exert force
along the line of action, which, for involute gears, is a straight line; and thus, for
involute gears, the pressure angle is constant.
Outside diameter, D0
Diameter of the gear, measured from the tops of the teeth.
Root diameter
Diameter of the gear, measured at the base of the tooth.
Addendum, a
Radial distance from the pitch surface to the outermost point of the tooth

13

a = (DO-D)/2
Dedendum, b
Radial distance from the depth of the tooth trough to the pitch surface. b= (Droot diameter) /2. Like hydraulic cylinders, something forces a piston to move in the
desired direction. The piston is a disc or cylinder, and the piston rod transfers the
force it develops to the object to be moved. Engineers sometimes prefer to use
pneumatics because they are quieter, cleaner, and do not require large amounts of
space for fluid storage.
Because the operating fluid is a gas, leakage from a pneumatic cylinder will not
drip out and contaminate the surroundings, making pneumatics more desirable where
cleanliness is a requirement. For example, in the mechanical puppets of the
Disney Tiki Room, pneumatics are used to prevent fluid from dripping onto people
below the puppets.

1.6 Types of cylinders

1.6.1 Single-acting cylinders
Single acting cylinders (SAC) use the pressure imparted by compressed air to
create a driving force in one direction (usually out), and a spring to return to the
"home" position. More often than not, this type of cylinder has limited extension due
to the space the compressed spring takes up. Another downside to SACs is that part of
the force produced by the cylinder is lost as it tries to push against the spring.

1.6.2 Double-acting cylinders

Double-acting cylinders (DAC) use the force of air to move in both extend and
retract strokes. They have two ports to allow air in, one for outstroke and one for
instroke. Stroke length for this design is not limited, however, the piston rod is more
14

vulnerable to buckling and bending. Additional calculations should be performed as

well.
Others
Although SACs and DACs are the most common types of pneumatic cylinder, the
following types are not particularly rare

Through rod air cylinders: piston rod extends through both sides of the
cylinder, allowing for equal forces and speeds on either side.

Cushion end air cylinders: cylinders with regulated air exhaust to avoid
impacts between the piston rod and the cylinder end cover.

Rotary air cylinders: actuators that use air to impart a rotary motion.

Rodless air cylinders: These have no piston rod. They are actuators that use a
mechanical or magnetic coupling to impart force, typically to a table or other
body that moves along the length of the cylinder body, but does not extend
beyond it.

Tandem air cylinder: two cylinders are assembled in series in order to double
the force output.

Impact air cylinder: high velocity cylinders with specially designed end covers
that withstand the impact of extending or retracting piston rods.

Rodless cylinders
Some rodless types have a slot in the wall of the cylinder that is closed off for
much of its length by two flexible metal sealing bands. The inner one prevents air
from escaping, while the outer one protects the slot and inner band. The piston is
actually a pair of them, part of a comparatively long assembly. They seal to the bore
and inner band at both ends of the assembly. Between the individual pistons, however,
are camming surfaces that "peel off" the bands as the whole sliding assembly moves
15

toward the sealed volume, and "replace" them as the assembly moves away from the
other end. Between the camming surfaces is part of the moving assembly that
protrudes through the slot to move the load. Of course, this means that the region
where the sealing bands are not in contact is at atmospheric pressure
Another type has cables (or a single cable) extending from both (or one)
end[s] of the cylinder. The cables are jacketed in plastic (nylon, in those referred to),
which provides a smooth surface that permits sealing the cables where they pass
through the ends of the cylinder. Of course, a single cable has to be kept in tension.
Still others have magnets inside the cylinder, part of the piston assembly, that
pull along magnets outside the cylinder wall. The latter are carried by the actuator that
moves the load. The cylinder wall is thin, to ensure that the inner and outer magnets
are near each other. Multiple modern high-flux magnet groups transmit force without
disengaging or excessive resilience.
Construction
Depending on the job specification, there are multiple forms of body
constructions available

Tie rod cylinders: The most common cylinder constructions that can be used in
many types of loads. Has been proven to be the safest form.

Flanged-type cylinders: Fixed flanges are added to the ends of cylinder,

however, this form of construction is more common in hydraulic cylinder
construction.

One-piece welded cylinders: Ends are welded or crimped to the tube, this form
is inexpensive but makes the cylinder non-serviceable.

Threaded end cylinders: Ends are screwed onto the tube body. The reduction
of material can weaken the tube and may introduce thread concentricity problems
to the system.

16

Material
Upon job specification, the material may be chosen. Material range from
nickel-plated brass to aluminum, and even steel and stainless steel. Depending on the
level of loads, humidity, temperature, and stroke lengths specified, the appropriate
material may be selected.
Rod stresses
Due to the forces acting on the cylinder, the piston rod is the most stressed
component and has to be designed to withstand high amounts of bending, tensile and
compressive forces. Depending on how long the piston rod is, stresses can be
calculated differently. If the rods length is less than 10 times the diameter, then it may
be treated as a rigid body which has compressive or tensile forces acting on it. In
which case the relationship is:
F=A

Where,
F is the compressive or tensile force.
A is the cross-sectional area of the piston rod.
is the stress.
However, if the length of the rod exceeds the 10 times the value of the
diameter, then the rod needs to be treated as a column and buckling needs to be
calculated as well.
Instroke and Outstroke
Although the diameter of the piston and the force exerted by a cylinder are related,
they are not directly proportional to one another. Additionally, the typical
mathematical relationship between the two assumes that the air supply does not
become saturated. Due to the effective cross sectional area reduced by the area of the
piston rod, the instroke force is less than the outstroke force when both are powered
pneumatically and by same supply of compressed gas.
17

The relationship between the force, radius, and pressure can derived from simple
distributed load equation:
Fr =P A e

Where,
Fr is the resultant force
P is the pressure or distributed load on the surface
Ae is the effective cross sectional area the load is acting on
Outstroke
Using the distributed load equation provided. Ae can be replaced with area of
the piston surface where the pressure is acting on.
Fr =P( r 2)

Where:
Fr represents the resultant force
T represents the radius of the piston
is pi, approximately equal to 3.14159.
Instroke

On instroke, the same relationship between force exerted, pressure

and effective cross sectional area applies as discussed above for outstroke. However,
since the cross sectional area is less than the piston area the relationship between
force, pressure and radius is different. The calculation isn't more complicated though,
since the effective cross sectional area is merely that of the piston surface minus the
cross sectional area of the piston rod.

18

For instroke, therefore, the relationship between force exerted, pressure, radius
of the piston, and radius of the piston rod, is as follows:
Fr =( r 21 r 22 ) =P( r 21r 22 )

Where:
Fr represents the resultant force.
r1 represents the radius of the piston.
r2 represents the radius of the piston rod.

is pi, approximately equal to 3.14159.

A pulley is a wheel on an axle or shaft that is designed to support movement

and change of direction of a taut cable or belt along its circumference. Pulleys are
used in a variety of ways to lift loads, apply forces, and to transmit power. In nautical
contexts, the assembly of wheel, axle, and supporting shell is referred to as a "block."
A pulley may also be called a sheave or drum and may have a groove between
two flanges around its circumference. The drive element of a pulley system can be
a rope, cable, belt, or chain that runs over the pulley inside the groove.
Hero of Alexandria identified the pulley as one of six simple machines used to
lift weights. Pulleys are assembled to form a block and tackle in order to
provide mechanical advantage to apply large forces. Pulleys are also assembled as
part of belt and chain drives in order to transmit power from one rotating shaft to
another.

1.7 BELT AND PULLEY SYSTEMS

19

Fig 1.7 Flat belt on a belt pulley

Fig 1.8 Belt and pulley system

Fig 1.9 Cone pulley driven from above by a line shaft

A belt and pulley system is characterized by two or more pulleys in common
to a belt. This allows for mechanical power, torque, and speed to be transmitted across
axles. If the pulleys are of differing diameters, a mechanical advantage is realized.
A belt drive is analogous to that of a chain drive, however a belt sheave may
be smooth (devoid of discrete interlocking members as would be found on a chain
sprocket, spur gear, or timing belt) so that the mechanical advantage is approximately
given by the ratio of the pitch diameter of the sheaves only, not fixed exactly by the
ratio of teeth as with gears and sprockets.
In the case of a drum-style pulley, without a groove or flanges, the pulley often
is slightly convex to keep the flat belt centered. It is sometimes referred to as a
crowned pulley. Though once widely used on factory line shafts, this type of pulley is
20

still found driving the rotating brush in upright vacuum cleaners, in belt
sanders and band saws. Agricultural tractors built up to the early 1950s generally had
a belt pulley for a flat belt (which is what belt pulley magazine was named after). It
has been replaced by other mechanisms with more flexibility in methods of use, such
as power take-off and hydraulics.
Just as the diameters of gears (and, correspondingly, their number of teeth)
determine a gear ratio and thus the speed increases or reductions and the mechanical
advantage that they can deliver, the diameters of pulleys determine those same
factors. cone pulley and step pulleys (which operate on the same principle, although
the names tend to be applied to flat belt versions and V belt versions, respectively) are
a way to provide multiple drive ratios in a belt-and-pulley system that can be shifted
as needed, just as a transmission provides this function with a gear train that can be
shifted. V belt step pulleys are the most common way that drill presses deliver a range
of spindle speeds

CHAPTER 2
LITERATURE REVIEW

21

Keiser

[1]

discloses an exercising device that employs pneumatics in creating

resistance to the muscular force exerted during the exercising operation. Keisers
pneumatic system includes an external source of compressed gas, such as compressed
air, a reservoir having an internal chamber of adjustable capacity connecting in
receiving relation to the gas from the external source, and a means for selecting the
volume of the gas in the reservoir.
Colosky J real

[2]

discloses a gravity-independent exercise unit designed for

use in micro gravity, or on the ground, by Which to counter muscle atrophy and bone
degradation due to disuse or misuse. Coloskys exercise device utilizes at least one
modular resistive pack, each pack containing at least one constant force torque
spring. Each torque spring is Wound up upon a separate storage drum within the
pack and each spring is attached to a single output drum. Each output drum is attached
to an output shaft and each output shaft is mechanically connected to a cable drum.
There is also a series of mechanical selection devices to select the amount of
resistance. The unit is compact and of low mass. However, the complexity and
number of internal mechanisms necessary for Coloskys design is less than optimal.
Hence, maintenance issues arise, particularly in a microgravity environment wherein
it is undesirable to have large number of internal parts with the potential of these parts
around in an unmanageable manner.
Beal

[3]

discloses a user-manipulated modular exercise machine With two reel

assemblies, each including a spirally-Wound spring with applies to the real a reactive
torque of changing magnitude as the reel rotates in response to pulling input forces
applied to a pull-cord by the user. A cam-operated spring compensating mechanism
provides for essentially a constant force during operations in various exercise modes.

CHAPTER 3
STATEMENT OF PROBLEM
22

Fitness is the main concern of the present generation. Machines which we use
are of more weight and very costly. There is an immediate necessity for economical
and long lasting fitness machinery.
Huge weights, used as force providers today are not only increasing the cost of
the equipment but also increasing the wear and tear. So, using alternate methods to
create the force instead of weights would drastically decrease the cost of the
equipment.
In present model we replace regularly using weights by vacuum cylinders. It is
possible to do different exercises. Replacing weights by vacuum cylinders reduces
wear and tear. We can change weights manually as much as we need by changing
force acting position.
We can develop required amount of force for doing exercise by using rack and
pinion and fulcrum-lever mechanism. In rack and pinion joint we have gears and
flywheel which develop more force for doing exercise.
One of the most advantage of the project is that we can use the device even in
the zero gravity environment (space). This equipment can be used in the space by the
astronauts for physical fitness.

CHAPTER 4
METHODOLOGY
23

The aim of the project is to do multiple exercises in home environment. We are

replacing weights with vacuum cylinders which reduces wear and tear. This reduces
the cost of the equipment. In order to replicate the present equipment, various
mechanisms and parts are used to make a compact device.
The steps required can broadly classified in to following steps:

Design of the vacuum cylinders

Rack and pinion mechanism connected to flywheel

Screw rod mechanism to adjust the weights

Lifting rod and clamp mechanism

Pulley mechanism

The machine to be designed must accomplish the above mentioned works with
minimum human effort, time and also in the right sequence. Many auxiliary
components are included to different mechanisms. The final method will be so
designed such that it reduces the complications of any previously existing designs and
provide a relatively cheaper solution.
The various components to be designed being interdependent on each other each
individual part must be designed separately such that it comes up in solving the
problems. All the components must be integrated in a functional manner which again
will aid to minimize the problems. This design process will be elaborately discussed
in the coming sub chapters.

Vacuum
cylinders

Rack and pinion

with flywheel
mechanism
24

Resistive
exercise
device
Arm
mechanism

Lifting rod with

clamp
mechanism

Pulley setup

Fig 4.1 Methodology

4.1 Sequence of design
The sequence of design plays a very important role. So, a perfect sequence with clear
proof of reason must be established in order to proceed with the methodology.
The sequence of design and manufacturing
Vacuum cylinders
Vacuum cylinders being the initial origin part of the methodology proposed, it provides
the pressure force which is used to do exercises. It is designed in such a way that the
piston cylinder is connected to the rack and pinion mechanism.

Rack and pinion mechanism with flywheel

The rack is connected to the vacuum cylinders pistons and with the help of the pinion
shafts and gears are connected from shafts to the other flywheel shaft and thus the
flywheel is rotated.
Screw rod mechanism
The screw rod are connected to the rack with the help of bearings and thus with the
help of nuts the screw rod are rotated and thus weights can be adjusted.
Lifting rod and clamp mechanism
The lifting rod is connected to the wishbone arm with the help of the clamp
mechanism. The clamp mechanism is used to adjust the lengths at different heights.
Pulley mechanism
The pulley setup is arranged at the bottom of the equipment such a way that the
cylinder piston is connected gym wire and is used to different exercises.
25

4.1.1 Vacuum cylinders

The vacuum cylinders mechanism is the main requirement of the present equipment it
is designed and fixed at the top of the equipment attached to the frame.
Requirement
The cylinders are required with high pressure and without the leakage. It should be
double acting and have more compact and easy movement with less wear and tear.
Basic Idea
The basic idea is to fix the vacuum cylinders at the top of the main frame. The piston
are connected to the rack. So that the capacity of the cylinders should be high. The
pressure taken in the cylinders are 1Mp and stroke length is 160mm.

4.1.2 Rack and pinion mechanism with flywheel

Requirement
The rack and pinion mechanism is used to balance the forces and also to provide extra
force to the lifting person. The movement of the flywheel is the main thing to produce
extra force.
Basic idea
The basic idea of this mechanism is to rotate the flywheel. To rotate the flywheel
gears and rack and pinion is used.
The rack is connected to small gears and then the shaft connected to the gears is
connected bigger gear which is connected to the other shaft which is connected to the
flywheel thus the flywheel is rotated.

4.1.3 Screw rod and pulley mechanism

Requirement
The screw rod mechanism is used to adjust the weights such a way that cylinders
positions can be moved and thus the forces are changed. The pulley set up is used to
do arm exercises which is fixed at the bottom.
Basic idea
The basic idea of the mechanism is the screw rods are connected with rack with the
help of the bearings and thus with the help of the bolts which is connected to the main
arm such that the movement of screw rod with handle moves the vacuum cylinder
The pulley setup is such a way that the piston cylinder is connected to the gym wire
which is connected to the handle which is used to pull with hands and used to do
different exercises.
26

CHAPTER 5
EXPERIMENTAL WORK
5.1 Introduction
Material science and engineering plays a vital role in the modern age of
science and technology. Various kinds of materials are used in industry, housing,
27

agriculture, transportation, etc., to meet the plant and individual requirements. The
rapid development in the field of quantum theory of solids have opened vast
opportunities for better understanding and utilization of various materials.

5.2 Selection of material

The various factors which determine the choice of materials are discussed
below.
5.2.1 Properties
The material selected must possess the necessary properties for the proposed
application. The various requirement to satisfied- low weight, surface finish, rigidity,
ability to withstand environmental attack form chemicals, service life, reliability etc.
The following four types of principle properties of material decisively affect their
selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal
conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc,
The various mechanical properties concerned are strength in tensile,
compressive shear, bending torsion and buckling load, fatigue resistance, impact
resistance, elastic limit, endurance limit and modulus of elasticity, wear resistance and
sliding properties.
The various properties concerned from the, manufacturing point of view are,
1. Cast ability
2. Weld ability
3. Bras ability
4. Surface properties
5. Shrinkage
6. Deep drawing
5.2.2 Manufacturing cost

28

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may demand the
use of special materials.
5.2.3 Quality
This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of
components which can be fabricated much more economically by or hand forging the
steel.
5.2.4 Availability of material
Some materials may be scare of in short supply. It then becomes obligatory for
the designer to use some other materials which though may be not a perfect substitute
for the material designed. The delivery of materials and the delivery date of the
product should also be kept in mind.
5.2.5 Space consideration
Sometimes high strength material has to be selected because the forces
involved are high and space limitations are there.
5.2.6 Cost
As like any other problem, in selection of the cost of material plays an
important part and should not be ignored.

5.3 Weight calculation

Initially the total lengths of arm and cylinder should be known
The total length of arm = 550mm
Divide the total length of arm into 5 parts = 550/5=110mm
Mark the points on the arm with difference of 110mm
Maximum pressure = 1MPa
The total stroke length =160mm
When the arm length is moved the stroke length of cylinder decreases and so
the volume changes with changing in force
So the change in length at maximum to minimum points is 30mm, 20mm, 10mm
So initially the total force = pressure x area
Area = A= r

We have bore=50mm so radius =25mm

29

3
Total force = 1x10^6 x x ( 25 x 10 )

=196.349 N

2
Volume r L

= x (25x10^-3)^2 x 160x10^-3
Volume = 3.1x10^-4m3
We know
P1/p2 =v1/v2
V2 for length of 120mm
V2=2.3 x 10^-4
So we have relation,
p1/p2= v1/v2, take v1 =3.1x10^-4
1x10^6/p2=1.3
P2=741935.4 N/m^2
Force =p2x area
So force F2=145.678N
So f=mg so where m= mass, g=acceleration due gravity=9.8m/s2
=145.678/9.8
=14.8kg
So total maximum weight =14.8kg
Similarly finding the volume of,
v3=1.76 x 10^-4 m3, v4=1.37x10^-4 m3, v5=1.17x10^-3 m3
And pressures,
p3=567741.8 pa, p4=441935.3pa, p5=377419.19pa
So forces we are getting are,
F3=111.475N,F4=867.7N,F5=741.05N
So weights are =11.37kg, 8.2kg, 7.5kg

5.4 Design
30

Fig 5.1 Basic design

We designed the shape of the device such a way that cylinders will be fixed to
the top of the frame and lifting arm will be connected to the cylinders in such a way
that easy to do the exercises. The pulley set up is attached down of frame such that the
required exercise can be done. The flywheel setup is fixed to the cylinders on rack and
pinion set up to get perfect mechanism.

31

Fig 5.2 front view

Cylinders and flywheel set up is placed at the top of the frame total setup. The
lifting arm is fixed wishbone arm and is designed to handle easily.

Fig 5.3 side view

32

The set up fixed with bolts and nuts. The wishborn arm is fixed to the
frame by nuts and bolts.The pulley setup is fixed at the bottom.

Fig 5.4 top view

The top view shows exact location of wishborn arm and lifting arm.The frame
also Attached perfectly and the support base at the down is attached to the frame.

33

5.5 Components of resistive exercise device

Table 5.1 Components of resistive exercise device
S.NO

PART NAME

QUANTITY

BASE FRAME

MAIN FRAME

VACCUM CYLINDERS

GEARS

FLYWHEELS

RACKS

IRON PLATES

GEAR SHAFTS

SCREW RODS

10

BEARINGS

11

PULLEYS

12

GYM WIRE

13

NUTS AND BOLTS

14

IRON PIPE

15

ARM

AS MANY
REQUIRED

34

5.6 Specifications
Table 5.2 Specifications
S.NO

PART NAME

SPECIFICATION

SQUARE PIPE

ROUND PIPE

VACUUM CYLINDERS

SMC -160

GEAR

DIA 6mm

GEARS

DIA 8mm

FLYWHEELS

DIA 15mm

RACKS

350mm

IRON PLATES

370mmx100mm

GEAR SHAFTS

350mm

10

SCREW RODS

550mm

11

BALL BEARINGS

SKF-6202

12

PULLEY

100mm

13

PULLEY

50mm

14

GYM WIRE

200mm

15

NUTS AND BOLTS

16

IRON PIPE

35FEET
5FEET

AS MANY
REQUIRED
1050mm

35

5.6.1 Vacuum cylinder specifications

Table 5.3 Vacuum cylinder specifications
MEDIUM

COMPRESSED AIR,NON LUBRICANT

OPERATING PRESSURE

0.5 TO 10 bar

ACTION

DOUBLE

BORE

50mm

STROKE

160mm

DIMENSIONS

339x65x65mm

BARRELS

ANODIZED ALUMINIUM PROFILE

PISTON ROD

HARD CHROMED STEEL

36

5.7 Fabrication

Fig 5.5 main frame

Fig 5.6 Lifting rod

The fabrication of main frame work is done

The wishbone arm is done and is attached to the main frame

Fig 5.7 vacuum cylinders

The vacuum cylinders are welded with supporting parts and the bolts and nuts
are fixed and it is to be fixed to the frame. Thus the cylinders position is to be
fixed

37

Fig 5.8 cylinder piston with rack

The fixing of vacuum cylinders is done to the frame with the help of joints and
bolts and nuts.

The cylinder pistons are connected to the rack with the help of arc welding

Fig 5.9 flywheel set up and main arm

The gears are attached to the frame with the help of shafts and two plates are
attached at the middle of the racks. Here the rack is drive the small gear and
the shaft which is attached to it rotates so the bigger gear attached to the same
38

shaft rotates and the it drives the other smaller gear and the shaft attached to it
is connected to the flywheel and thus the flywheel rotates

The racks are attached to main arm with the help of screw rod and the same
screw is attached to another screw rod and it is connected to the handle. When
the handle rotates the screw rod rotates and thus rack screw is moved on the
arm

Fig 5.10 clamp adjustment

The lifting rod adjusting mechanism is made. In this the clamp is made such a
way that it can be adjusted in the different positions. The lifting rod is
connected to the clamp on other side. Thus lifting rod can be adjusted with
required position. At the down bearing is connected so that it can be moved in
rotational direction

Fig 5.11 pulley setup

39

The pulley set up is attached at the bottom of the main frame with two pulleys
and one cylinder at gym wire which is connected the piston cylinder and
moved on the pulleys.

Fig 5.12 final assembled and finished product

The total assembled and finished part of resistive exercise device is done and
the multiple exercises can be done and it can be easily handled.

40

5.8 Construction
The resistive exercise device involves vacuum cylinders, rack and pinions,
gears, flywheels, screw rods, main arm, wishbone arm, and lifting rod. The cylinders
are connected to the main arm via rack and pinion mechanism. Total six gears are
used to transfer the drive to the flywheel from rack. The pinion gear rotates the idle
gear which drive the gear that is connected to the flywheel. The main arm contains
screw rods that are connected to rack. The main arm is connected to the wishbone
arm. The wishbone arm is again connected to lifting rod with adjusting clamp
mechanism.
One more vacuum cylinder is attached at top of base frame. The cylinder piston is
connected to two pulleys with the help of gym wire which moves on the pulleys. The
wire is connected to the handle which is pulled during exercise.

5.9 Working
When the lifting rod is lifted the wishbone arm moves the main arm, so the
rack is moved. The piston cylinder moves up and down creating vacuum pressure
inside the vacuum cylinder. The rack is connected to the gears so that the motion of
the rack rotates the gears. The gears are connected to interrelate the shafts. The shaft
is connected to the flywheel so that when the gears are rotated the flywheel attached
to the shaft is also rotated creating extra resistive force to the person who is lifting the
rod. The main arm contains the screw rods which are connected to the handle so that
when the handle is rotated the screw rod rotates and changes the length. By adjusting
the length the weights can be changed. The clamping mechanism at the lifting rod
helps to adjust the height of lifting rod.
The vacuum cylinder which is attached at the top of the base is connected to
the gym wire. When the wire is pulled the cylinder piston is moved down and pulled
back due to vacuum force .Thus this helps to do arm and back exercise.

41

5.10 Cost estimation table

Table 5.4 Cost estimation table
S.NO

PART NAME

QUANTITY
1

AMOUNT

SQUARE PIE

FLAT ROD

VACUUM CYLINDERS

VACUUM CYLINDER

600

GEARS

1500

FLYWHEELS

600

RACKS

300

IRON PLATES

300

GEAR SHAFTS

250

SCREW RODS

300

10

BEARINGS

350

11

PULLEYS

400

12

GYM WIRE

100

13

NUTS AND BOLTS

14

IRON PIPE

15

TOTAL

1
2

AS MANY
REQUIRED
2

2000
700
3600

400
300
11,780

Labour cost
For the completion of our project we had to go for lathe, drilling, welding and cutting
and thus we paid for mentioned work to the labours.
Overhead charges:
42

Rent for workshop

= 1000Rs

Labour cost

= 400 per day

For 15 days

= 12x400=4800Rs

Painting cost

= 300

So total cost

= material cost +labour cost + overhead cost

= 11,680+4800+1000+300
= 17,780

Total cost

= Rs17,780

CHAPTER 6
RESULTS AND DISCUSSION
RESULT
43

The resistive exercise device is tested and multiple exercises can be done

The total six exercises can be done

When the listing rod is fixed up of the clamp then we can do solder press

When lifting rod is fixed at the middle then we can do squad exercise

When lifting rod is fixed down and clamp is rotated down then bar bill row can be
done or it is also called late muscle work out.

When the person slept on the floor then clamp rotates up then bench press
workout can be done

At the down of pulley setup by pulling the wire arm and back muscle work out
can be done

Maximum weight that the exercise device can do =14.8kg

DISCUSSION

The resistive exercise device works with maximum output but the rotating time
for adjusting handle for changing of weights take more time.

By using the motor which is attached to screw rod helps to rotate so that it takes
less time to change the weights.

CHAPTER 7
ADVATAGES AND LIMITATIONS
44

ADVANTAGES

The cost of the component is very less

Different type of exercises can be done in single device

The maintenance is very low and easy adjustment of loads.

The main arm and clamping mechanism make the device easy to operate.

The device is used to list heavy loads and also easy to handle and make it effective
and consistent.

Used in space for multiple exercises.

LIMITATIONS:

During the changing loads the time taken to rotate the handle is more.

Rack and pinion set up moves with high friction and also gears moves with high
friction.

When load adjusting handle is rotated the screw rod is rotates producing rattling
sound.

CHAPTER 8
CONCLUSION
45

This project work has provided us an excellent opportunity and experience to use our
limited knowledge. We gained a lot of practical knowledge regarding planning,
purchasing, assembling and machining while doing this project work.

The design and fabrication of resistive exercise device is working with satisfactory
conditions. We are able to understand the difficulties in maintaining the tolerance and
also quality. We have used maximum of available facilities.

In conclusion remarks of our project work, let us add a few more lines about our
impression project work. Thus we developed a resistive exercise device by using more
techniques, they can be modified and developed according to application.

CHAPTER 9
FUTURE SCOPE
46

The resistive exercise device has many applications which is very useful in
further.

It can be widely used in space and also used on earth.

With useful modifications such as using motor for screw rod and also
computerized mechanism for calculating no of counts in exercise.

The materials and other clamping mechanisms can be changed to make it

advanced.

Separate arm mechanism for pulley set up can be installed which connects upper
vacuum cylinder pistons and can get more effectiveness.

47

REFERENCES

Keiser, may 24 1981, discloses an exercise device with pneumatics creating

resistance to muscular force, United states patent number 4,257,593.

Colosky,16 august 2001 discloses exercise device with springs that are
mechanically connected to a cable drum particularly in micro gravity

environment, U.S. patent number 93114.

Beal, july 13 1993 discloses a user manipulated modular exercise machine with

spirally wound springs, U.S. patent number 5226867.

Meher CG(2004), Effective physical treatment for backpain.journal Orthop clin

north vol 5, No 1,2005, 35(1):57-64.

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