Machine Design Vol 12-3

UNIVERSITY OF NOVI SAD
FACULTY OF TECHNICAL SCIENCES

ADEKO – ASSOCIATION FOR DESIGN, ELEMENTS AND CONSTRUCTIONS
machine design
Vol.12(2020) No.3
ISSN 1821-1259, E-ISSN 2406-0666
editors:
siniša kuzmanović
MILAN RACKOV
novi sad, 2020

Publication
“Machine Design”
editors
Siniša KUZMANOVIĆ, Ph.D. Eng., University of Novi Sad, Faculty of Technical Sciences
Milan RACKOV, Ph.D. Eng., University of Novi Sad, Faculty of Technical Sciences
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ISSN 1821-1259
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University Politehnica Timisoara, Eftemie Murgu University of Resita, University of Novi Sad,
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Prof. Mircea-Viorel DRAGOI, Ph.D. Prof. Biljana MARKOVIĆ, Ph.D. Prof. Simon VILMOS, Ph.D.
"Transilvania" University of Brasov, University of East Sarajevo, Budapest University of Technology and
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Prof. Ladislav GULAN, Ph.D. Prof. Athanassios MIHAILIDIS, Ph.D. Prof. Adisa VUČINA, Ph.D.
Slovak University of Technology, Aristotle University of Thessaloniki, Faculty of University of Mostar,
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Technical University of Cluj-Napoca, University of Niš, Keimyung University, Department of Industrial
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University of Zenica, University of Belgrade, University of Novi Sad,
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technical editorial board
Vasile ALEXA, Ph.D. Jana GULANOVA, Ph.D. Žarko MIŠKOVIĆ, MSc.
University Politehnica Timisoara, Slovak University of Technology, University of Belgrade,
Faculty of Engineering – Hunedoara, Faculty of Mechanical Engineering, Faculty of Mechanical Engineering,
Hunedoara, Romania Bratislava, Slovakia Belgrade, Serbia
Milan BANIĆ, Ph.D. Ivan KNEŽEVIĆ, MSc. Sorin RAŢIU, Ph.D.
University of Niš, University of Novi Sad, University Politehnica Timisoara,
Faculty of Mechanical Engineering, Faculty of Technical Sciences, Faculty of Engineering – Hunedoara,
Niš, Serbia Novi Sad, Serbia Hunedoara, Romania
Jozef BUCHA, Ph.D. Zoran MILOJEVIĆ, Ph.D. Roman RUZAROVSKY, Ph.D.
Slovak University of Technology, University of Novi Sad, Slovak University of Technology in Bratislava,
Faculty of Mechanical Engineering, Faculty of Technical Sciences, Faculty of Materials Science and Technology
Bratislava, Slovakia Novi Sad, Serbia STU, Trnava, Slovakia
Maja ČAVIĆ, Ph.D. Aleksandar MILTENOVIĆ, Ph.D. Milan TICA, Ph.D.
University of Novi Sad, University of Niš, University of Banja Luka,
Faculty of Technical Sciences, Faculty of Mechanical Engineering, Faculty of Mechanical Engineering,
Novi Sad, Serbia Niš, Serbia Banja Luka, Bosnia and Herzegovina
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Editors,
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CONTENTS:
Preliminary notes
1. Forming of a System of Equations Which Describes the Dynamic Behavior of Cable-Crane during
Load Lifting
Nikola BABIN, Jovan VLADIĆ, Radomir ĐOKIĆ, Tanasije JOJIĆ ....................................................................... 45

Research papers
2. Design Optimization and Manufacturing Issues of Blisters Obtained by the Thermoforming

Process
Aleksandar PETROVIĆ, Aleksandar MILTENOVIĆ, Milan BANIĆ ..................................................................... 53
3. Tooth Contact Analysis of Archimedean Worm Gear Drives for the Modification of the Number
of Threads on the Worm Helical Surface
Sándor BODZÁS ...................................................................................................................................................... 61
4. Specialized Elevators for People with Disabilities

Dragan ŽIVANIĆ, Nikola ILANKOVIĆ, Atila ZELIĆ, Kristina JAKIMOVSKA, Anita VASILEVA .................. 67
MANUSCRIPT FORMAT
machine design, Vol.12(2020) No.3, ISSN 1821-1259 pp. 45-52
DOI: 10.24867/MD.12.2020.3.45-52
Preliminary note
FORMING OF A SYSTEM OF EQUATIONS WHICH DESCRIBES THE DYNAMIC

BEHAVIOR OF CABLE-CRANE DURING LOAD LIFTING
Nikola BABIN1, * - Jovan VLADIĆ1 - Radomir ĐOKIĆ1 - Tanasije JOJIĆ1,
1 University of Novi sad, Faculty of Technical Sciences, Novi Sad, Serbia
Received (02.09.2020); Revised (10.11.2020); Accepted (12.11.2020)
Abstract: The analysis of the cable crane dynamic behavior during load-lifting is relatively underrepresented in the
scientific and professional literature [1]-[4]. Taking into account that usage of steel ropes on large spans (so-called
"horizontal rope") leads to systems with significantly higher elasticity than "conventional" steel structures and the fact
that the influence on equilibrium conditions, that is deformation (vertical displacement) of supporting ropes under
transverse load cannot be ignored (the application of second-order theory is necessary), makes the analysis of dynamic
behavior is much more complex [5], [6]. The paper presents the procedure of forming and solving differential
equations of motion for cable-crane when lifting a load located in the middle of the span. The process of lifting the load
from the ground in two phases was analyzed. The first phase refers to the movement of the supporting structure during
the increase of the lifting force which is acting on the load, which is located on the ground until the force in the rope
reaches the same weight of the load. The second phase refers to further movement of the supporting structure and load.
Key words: cable crane, supporting rope, hoisting rope, traction rope, differential equation of motion
1. INTRODUCTION material and large loads within inaccessible terrain i.e. to

bridge large spans. Load capacity ranges up to 40 and
Cable crane [7] consists of two high pillars (towers), more tons, and the span ranges from a few tens to 1000
which have tops connected by one or more ropes which meters. As a rule, they are used in the construction of
are used as supporting ropes on which the carriages move. dams [8], bridges, forestry and quarries.
The carriages are equipped with a lifting system and are The dynamic model [9]-[12] which was formed for the
driven by a traction rope. Cable cranes are used in places cable crane with elastic supports is shown in figure 1.
where it is necessary to transport large amounts of
Fig.1. Dynamic model of cable crane
2. EQUATIONS OF MOTION FORMING supporting rope on roller supports or equations of motion

of a supporting rope with concentrated mass will be
The formation of equations of motion for several clarified below. Similar problem occurs also in the
characteristic cases like equations of motion of a analysis of ropeway [13], [14] and ziplines [15].
*Correspondence Author’s Address: University of Novi sad, Faculty of Technical Sciences, Trg Dositeja Obradovica 6,
21000 Novi Sad, Serbia, babinm@eunet.rs
Nikola Babin, Jovan Vladić, Radomir Đokić, Tanasije Jojić: Forming of a System of Equations Which Describes the Dynamic Behavior of Cable-
Crane During Load Lifting; Machine Design, Vol.12(2020) No.3, ISSN 1821-1259; E-ISSN 2406-0666; pp. 45-52
2.1. Equations of motion of a supporting rope on c1 and c2 - equivalent stiffness of longitudinal guy-wire in
roller supports the horizontal direction,
S1 and S2 – hoisting rope forces,
A detailed analysis of the dynamic behavior of a steel Hd1 and Hd2– supporting rope forces.
rope stretched between fixed supports (the so-called
horizontal rope) is presented in [16], [17]. The linearized
differential equation of small oscillations of extensible
rope fixed between two horizontal supports according to
[17] is given in the form:
Fig.2. Simplified model of cable crane
l
2w 2w E  A w
m  2  H0  2   y "   y '  x  dx (1) If the following substitutions are made in the above
t x l 0
x differential equations:
- θ=0 – the inclination of supporting rope ends coupling
Figure 2 shows the case of the load acting at the level of
line,
the pillar top where the equations of supports motion with
- ψј-1=ψј=0 – the inclination angle of the supports
equivalent masses M1 and M2 can be written in the form:
trajectory (ends of traction rope),
d 2 u1 (t ) - j-1≡1, j≡2 – indexes of variables,
M1   c1  u1 (t )  H d 1 (t )  s1 (t ) - u(0,t)≡u1, u(l,t)≡u2 – displacement of supports
dt 2
(2) and after certain mathematical transformations, a system
d 2 u 2 (t ) of equations which describes the oscillation of system of a
M2   c2  u 2 (t )  H d 2 (t )  s 2 (t )
dt 2 supporting rope on movable supports can be written in the
form [17]:
where:
l
2w  2 w EA EA w
m  H st    u2  t   u1  t   y1   y1  y1  x  dx
t 2
x 2
l l 0
x
l
 EA  EA EA w
M 1  u1  t    c1    u1  t    u2  t   y1  x  dx
l 0 x
 (3)
 l  l
l
EA  EA  EA w
M 2  u2  t    u1  t    c2    u2  t    y1  x  dx
l 0 x

l  l 
2.2. Equations of motion of a supporting rope

with concentrated mass
One of the most significant cases for dynamic cable crane
analysis [11] is the process of load lifting from the ground
when the carriage is in the middle of the span. The cable
crane is observed in the position of static equilibrium on
horizontal supports у1=у2=0 where the deflection of the
supporting rope in the middle of the span ys is a result of
the ropes deadweight and concentrated force in the middle Fig.3. Oscillatory system of supporting rope with
of the span which comes from the weight of carriage and concentrated mass and roller supports
reduced masses of hoisting and traction ropes. Figure 3
shows a case of a supporting rope on roller supports with The first differential equation in the system (3) for the
a concentrated mass in the middle of the span. case of a supporting rope whose ends are fixed on roller
supports when a concentrated mass M acts in the middle
of the span, takes the form [12], [18]:
 l 
l 2 w x  , t 
2 w  2 w EA EA w  2 
m  2  H st  2   u2 (t )  u1 (t )  y1   y1  y1( x)dx  M  (4)
t x l l 0
x t 2
System of partial differential equations can be solved if  2 w 

the form of displacement w(x,t) is represented as a    x( x )
t 2
product of independent functions:
and after replacement in (4) and after certain
w( x, t )   (t )  x( x)
transformation it gives:
that is:
l 
mred  M  x 2    (t )  kred   (t )  k s1  u1 (t )  k s1  u2 (t )  0 (5)
2
where, according to [11]:

46
8  E  A  f0       2  EA x  l  x   2Q  l  2x  2Q 
k s1  ks 2  f0   q   and tg S  q  
l  1  2      2 H 
2
2
l l  2H  l 
EA EA where Q  M  g - concentrated mass load in the middle
kc1  c1  kc 2  c2 
l l of the span, where the maximum deflection in the middle
l l 2 of the span equals:
EA
kred  H st   x   x  dx 
2
 y1  x  x  dx
l l2  q 2Q 
0 0 f max    
32 8H  cos  l 
1    1   
H  2 The process of lifting a load from the ground can be
kred  st   
1  2   
2
l 2 divided into two phases:
1. the motion of the supporting structure until the moment
 4  2 1  when the force in the hoisting rope reaches force which
         1     
F     is equal to the weight of the load
 1  
 2  2. further motion of the supporting structure and load after
 1  2     8    1      the moment when the load is uplifted from the ground
 4 
If the rope is loaded with a concentrated mass of load and 2.3. First phase - motion of the cable crane
carriage, which is fastened in the middle of the span, fig. construction elements until the moment of
3, a discontinuity occurs at the place where additional load uplifting from ground
mass is acting. In this case, the function w  x, t  should be
Observing the first case where the deformation of
replaced by two continuous functions at intervals, i.e.:
supporting rope in the vertical direction in the middle of
w1 ( x, t )  x1 ( x)   (t ) for 0  x 
l the span is w  t  , and the tops of the columns as
2 supporting points of supporting rope have displacements
l (6)
w2 ( x, t )  x2 ( x)   (t ) for  x  l u1  t  and u2  t  , then there is a hoisting rope force
2
increase, as a result of the total deformation of the entire
whereby the condition must be met: system. The magnitude of this force represents the
disturbing force of this system, and it can be expressed as
l l the restitution force in the equivalent spring with stiffness
x1    x2    1
2 2 c3. For some elongation, according to figure 1 and [12]
and [18], it amounts:
Considering (6), and the fact that the deflection line is
symmetric to the cross-section x  l / 2 , the values of the l 
F0  0,5  v1  t  w  , t   0,5  u1  t   0, 5  u2  t   c3 (10)
integral of 0  l are: 2 
l l/2
For the defined model of the cable crane motion, the total
 m  x ( x)dx  2   m x ( x ) dx  mred
2 2
1 (7) force in the hoisting rope increases from zero to the value
0 0
F0 = Q until the moment when the load is uplifted from
If the oscillation shape function expression is now the ground, whereby it is divided into two rope legs. If it
adopted as: is assumed that the system is symmetrical for the case
when the carriage is in the middle of the span, and losses
 x in turning sheave are neglected, it can be assumed that:
x ( x )  a  x  b  sin (8)
l
F0
where the constants a and b are determined so that the S1 (t )  S2 (t )  (11)
2
2  
condition is mett for X l  1 . It follows that for the
This way, an additional force S1  t  , that is S2  t  appears
reduced mass in equation (5) can be written: at the supports A and B. Besides the supporting rope force
l H d  t  an additional load from carriage weight and forces
mred  mred  M  x    mred  M (9)
2 in hoisting ropes is transferred to the supporting rope.
Based on that, the system of equations that defines the
This leads to the conclusion that, in the case of a motion of such model becomes:
concentrated mass in the middle of the span, a system of
equations (3) with a reduced mass defined based on mred  (t )  kred   (t )  ks1  u1 (t )  ks1  u2 (t )  S1 (t )  S2 (t )
expression (9) is obtained. M 1  u1 (t )  ks1   (t )  kc1  u1 (t )  ks 2  u2 (t )  S1 (t ) (12)
The constants a and b, and thus the coefficients in the M 2  u2 (t )  ks1   (t )  ks 2  u1 (t )  kc 2  u2 (t )  S2 (t )
differential equation (5), can be determined from the
similarity form conditions of the oscillation function with Above mentioned is valid up to a moment from t  0 to
the catenary form for static conditions. Static deflection t  t0 , at which the force F0 is equal to the weight of the
and catenary inclination are [5], [16]: load Q, i.e.:
47
t  t0 and F0  Q (13) Using Lagrange's equations of the second kind, the

differential equation of motion of the load with mass
This way, by connecting equation (10) to the system (12), “M0” is obtained in the form:
and considering the conclusion (13), we can determine the
time at which the first phase of rope tensioning ends and d2y
M0   c3  y  0,5  v1  c3  t 
observe the motion of the system, until the beginning of dt 2
the load uplifting from the ground. (15)
l 
 w  , t   0, 5  u1  t   0,5  u2  t   c3  Q
2.4. Second phase - motion of the system after the 2 
moment when the load is uplifted from The force F defined by expression (14) represents the
ground total current force in the legs of the hoisting ropes, which
is transmitted to it by turning sheaves, which are
In fact, this phase represents the process of load lifting supported to the carriage construction, so that on the
and begins from the moment of loads uplift from the supporting rope next to the reduced mass
ground. The equations of motion for the supporting rope mred  mred  M , reacts also the external force
and supports remain the same as in the first phase, but it F  t   S1  t   S 2  t  . In this case, the model of cable
must be taken into account when determining the
constants that there are displacements w0, u10 and u20 with crane supporting structure can be given as in figure 5.
appropriate velocities at the beginning of this second
phase. In this phase the load has already uplifted from the
ground and at some point of time t  t0 it has some
coordinate “y” in the fixed coordinate system.
Fig.5. Cable crane supporting structure model for the

second phase
Roller supports are, in addition to the forces Hd, also

loaded by hoisting rope forces S1 (t) and S2 (t). After time
t0 has elapsed, new system of equation, according to the
differential equations system of motion until the moment
of load uplifting from the ground (12), has form:
Fig.4. Motion of the system from the moment when the
load is uplifted from the ground mred   t   kred    t   k s1  u1  t   k s1  u2  t   F  t 
1
M 1  u1  t   k s1    t   kc1  u1  t   ks 2  u2  t   F t 
The load which is transmitted from the carriage to the 2
supporting rope is F. Assuming that the system is total 1
symmetrical and neglecting the losses in turning sheaves, M 2  u2  t   k s1    t   ks 2  u1  t   kc 2  u2  t   F  t  (16)
2
the load which is transmitted from hoisting rope to the
supports amounts F/2. The magnitude of this load is,  l 
M 0  
y  c3  y  0,5  v1  c3  t  w  , t   c3 
according to [11] and [18], determined in the same way as 2 
in the previous case based on the difference between the 0,5  c3  u1  t   0,5  c3  u2  t   Q
wounded rope and the displacement of the load “u”,
which represents a disturbing force at some point in time Introducing new coefficients defined by expressions:
“t” defined by the expression: A1  mred A2  kred  c3 A3  k s1  0,5  c3
 l  
F  t    0, 5  v1  t  w  , t   y  t   0, 5  u1  t   0, 5  u 2  t    c3 (14) A4  k s1  0,5  c3 A5  c3 A6  0,5  v1  c3
  2  
The kinetic energy of the load amounts: B1  M 1 B2  k s1  0,5  c3 B3  kc1  0, 25  c3
1  dy 
2
B4  k s 2  0, 25  c3 B5  0,5  c3 B6  0, 25  v1  c3
Ek  m 
2  dx  C1  M 2 C2  k s1  0,5  c3 C3  k s 2  0, 25  c3
while the potential energy is defined by the restitutional
force in the equivalent spring: C4  kc 2  0, 25  c3 C5  0,5  c3 C6  0, 25  v1  c3
 l  
2
D1  M 0 D2  c3 D3  c3
0,5  v1  t  w  , t   y  t   0,5  u1  t   0,5  u2  t  
 2 
Ep    c
3
D4  0,5  c3 D5  0,5  c3 D6  0,5  v1  c3
2
and substituting them into the system (16) as well as the
and external force: defined value for F(t) by the expression (14), the system
F  Q of equations is obtained in the following form:
48
A1   t   A2    t   A3  u1  t   A4  u2  t   A5  y  t   A6  t  0
B1  u1  t   B2    t   B3  u1  t   B4  u2  t   B5  y  t   B6  t  0
(17)
C1  u2  t   C2    t   C3  u1  t   C4  u2  t   C5  y  t   C6  t  0
y  t   D2  y  t   D3    t   D4  u1  t   D5  u2  t   D6  t  Q  0
D1  
The system of differential equations (17) describes the

movement of the observed parameters of the crane cable x1h  K1  sin  t   
in both periods of movement. It is assumed that y=0 for x2h  K 2  sin t   
the first period of movement, until the moment of load (20)
uplifting from the ground. This way, the time t0 can be x3h  K 3  sin t   
determined from the system (17). With that time the x4h  K 4  sin t   
values ϕ(t0)=ϕ0, u1(t0)=u10 and u2(t0)=u20 can be
determined, and with it the second period of motion If we replace the corresponding values from (20) into (19)
begins when u≠0. The solution of the system for t>t0, is and divide by sin (ωt + α) we get:
searched as a solution to the whole system (17). The
initial motion conditions are used to determine the  A1  K1   2  A2  K1  A3  K 2  A4  K 3  A5  K 4  0
constants which appear in the system solutions. They are  B2  K1  B1  K 2   2  B3  K 2  B4  K 3  B5  K 4  0
defined as follows [12]: (21)
C2  K1  C3  K 2  C1  K 3   2  C4  K 3  C5  K 4  0
In the first phase of D3  K1  D4  K 2  D5  K 3  D1  K 4   2  D2  K 4  0
At the moment t= t0,
motion when t=0, the
when the lifting begins, from which, after the grouping of members, follows:
initial conditions of
the following initial
motion are for the
motion parameters are K1  A2  A1   2  K 2   A3  K 3  A4  K 4  A5  0
position of static
valid:
equilibrium:
K1   B2  K 2  B3  B1   2  K3   B4  K 4  B5  0
 (0)  0 (0)  0  (t 0 )  0 (t0 )  0 (22)
u1 (t0 )  u10 u1 (t0 )  u10 K1  C2  K 2  C3  K3  C4  C1   2  K 4  C5  0
u1 (0)  0 u1 (0)  0
u 2 (t0 )  u20 u2 (t0 )  u20 K1  D3  K 2   D4  K 3   D5  K 4  D2  D1   2  0
u 2 (0)  0 u2 (0)  0 y (t 0 )  0 y (t0 )  0
In order for the system of algebraic equations (22) to have
3. PROCEDURE FOR SOLVING A SYSTEM a non-trivial solution, the characteristic determinant of the
system must be equal to zero, i.e.:
OF EQUATIONS
A2  A1   2 A3 A4 A5
The solution of the obtained system (17) is found by  B2 B3  B1   2  B4 B5
solving a homogeneous and inhomogeneous system. If we   2
 0 (23)
C2 C3 C4  C1   2 C5
introduce notations for variables: D3  D4  D5 D2  D1   2
  x1 u1  x2 u2  x3 y  x4 (18)
After rearranging the determinant (23), the frequency
then the homogeneous part of the system (17) becomes: equation is obtained in the form:
A1  
x1h  A2  x1h  A3  x2h  A4  x3h  A5  x4h  0 A  8  B   6  C   4  D   2  E  0 (24)
 B2  x  B1  
h
1 x  B3  x  B4  x  B5  x  0
h
2
h
2
h
3
h
4 where A, B, C, D, E are constants which are determined
(19)
C2  x1h  C3  x2h  C1  
x3h  C4  x3h  C5  x4h  0 by system parameters.
After solving equation (24), four values of the square of
D3  x1h  D4  x2h  D5  x3h  D1  
x4h  D2  x4h  0
the frequency are obtained: ω12, ω22, ω32, ω42. General
We assume the solution of the homogeneous system (19) solution of the system (19) follows in the following form:
in the form:
x1h  K11  sin 1 t  1   K12  sin 2 t   2   K13  sin 3 t   3   K14  sin 4 t   4 
x2h  K 21  sin 1 t  1   K 22  sin 2 t   2   K 23  sin 3 t   3   K 24  sin 4 t   4 
x3h  K 31  sin 1 t  1   K 32  sin 2 t   2   K 33  sin 3 t   3   K 34  sin 4 t   4  (25)
x4h  K 41  sin 1 t  1   K 42  sin 2 t   2   K 43  sin 3 t   3   K 44  sin 4 t   4 
After the introduction of the coefficients for the forms of ratio of amplitudes, the system (25) takes the form:
natural oscillations, which are the dimensionless
49
x1h  K11  sin 1 t  1   K12  sin 2 t   2   K13  sin 3 t   3   K14  sin 4 t   4 
x2h  b21  K11  sin 1 t  1   b22  K12  sin 2 t   2   b23  K13  sin 3 t   3   b24  K14  sin 4 t   4 
x3h  b31  K11  sin 1 t  1   b32  K12  sin 2 t   2   b33  K13  sin 3 t   3   b34  K14  sin 4 t   4  (26)
x4h  b41  K11  sin 1 t  1   b42  K12  sin 2 t   2   b43  K13  sin 3 t   3   b44  K14  sin 4 t   4 
where the coefficients of form are defined as: by К11 and using (27) we get:
K 21 K 22 K 23 K 24 b21   A3  b31  A4  b41  A5   A2  A1  12
b21  b22  b23  b24 
K11 K12 K13 K14
b21  B3  B1  12  b31   B4  b41  B5  B2 (29)
K K K K
b31  31 b32  32 b33  33 b34  34 (27) b21  C3  b31  C4  C1  12  b41  C5  C2
K11 K12 K13 K14
K 41 K 42 K 43 K 44 from which the first three coefficients of form can be
b41  b42  b43  b44 
K11 K12 K13 K14 determined.
From the third equation follows:
So, based on (22) and [11] it follows:
C2  b31   C4  C3  12  C5
K11  A2  A1  12  K 21   A3  K 31  A4  K 41  A5  0 b21   b41  (30)
C3 C3
K11   B2  K 21  B3  B1    K 31   B4  K 41  B5  0
1
2
(28) inclusion of which in the first equation follows:

K11  C2  K 21  C3  K 31  C4  C1  12  K 41  C5  0
C5  A3  C3  A5 A3  C2  C3   A2  A1  12 
K11  D3  K 21   D4  K 31   D5  K 41  D2  D1  12  0 B31  b41  (31)
A4  C3  A3   C4  C3  12  A4  C3  A3   C4  C3  12 
By observing any three equations of the system (28), for
By substituting (30) and (31) into the second equation of
example the first three and dividing them
the system (29) and after rearranging we get [11]:
B2  C3  A4  C3  A3   C4  C3  12  
b41  
 B  B     C  A  C  A   C  C      B  B     C  B 
3 1 1
2
5 3 3 5 4 3 1
2
3 1
2
1 3 4
(32)
  B  B     A  C  C   A  A     C  C      B  B     C
3 1 1
2
2 2 3 2 1 1
2
4 3 1
2
3 1 1
2
3  B4

 C  B  C   B  B    A  C  A  C  C  
3 5 5 3 1 1
2
4 3 3 4 3 1
2
Other values of bk1 are obtained by substituting the by the coefficients ai and bi (i = 1,2,3,4) in the form:
corresponding values of ωi2 into the expressions for bk1:
A2  b1  A3  b2  A4  b3  A5  b4  0
(30), (31) and (32).
For determination of particular solutions of the system  B2  b1  B3  b2  B4  b3  B5  b4  0
(35)
(17), a substitution (18) is introduced and a new system C2  b1  C3  b2  C4  b3  C5  b4  0
is, according to [11], obtained in the form:
D3  b1  D4  b2  D3  b3  D2  b4  Q
A1  
x1p  A2  x1p  A3  x2p  A4  x3p  A5  x4p  A6  t The coefficients ai are obtained by an analogous
 B2  x  B1  
p
x  B3  x  B4  x  B5  x  B6  t
p p p p procedure for coefficients with terms with t:
1 2 2 3 4
(33)
C2  x1p  C3  x2p  C1  
x3p  C4  x3p  C5  x4p  C6  t A2  a1  A3  a2  A4  a3  A5  a4  A6
 B2  a1  B3  a2  B4  a3  B5  a4  B6
D3  x1p  D4  x2p  D5  x3p  D1  
x4p  D2  x4p  D6  Q (36)
C2  a1  C3  a2  C4  a3  C5  a4  C6
Particular solutions of the system (33) are assumed in the D3  a1  D4  a2  D3  a3  D4  a4  D6
form:
The coefficients are obtained from (35) in the form:
x  a1  t  b1
1
p
Dbi
bi  where:
x2p  a2  t  b2 Dsb
(34)
x3p  a3  t  b3 A2  A3 A4 A5
x4p  a4  t  b4  B2 B3  B4 B5
Dsb 
C2 C3 C4 C5
After including the expression (34) in the system (33) and
equalizing the coefficients in the terms containing t0 and t, D3  D4  D3 D2
we obtain systems with 2 x 4 algebraic equations and, for example, Db1:
50
0  A3 A4 A5 A6  A3 A4 A5
0 B3  B4 B5 B6 B3  B4 B5
Db1  Da1 
0 C 2 C4 C5 C6 C3 C4 C5
Q  D4  D3 D2 D6  D4  D3 D2
The appropriate procedure is also carried out for the where: Dsa=Dsb.
coefficients ai from where it follows:
D
ai  ai where for example Da1: From the above-mentioned considerations follows the
Dsa
forms for general solutions to a system (17):
x1  K11  sin 1 t  1   K12  sin 2 t   2   K13  sin 3 t   3   K14  sin 4 t   4   a1  t  b1
x2  K11  b21  sin 1 t  1   K12  b22  sin 2 t   2   K13  b23  sin 3 t   3   K12  b24  sin 4 t   4   a2  t  b2
x3  K11  b31  sin 1 t  1   K12  b32  sin 2 t   2   K13  b33  sin 3 t   3   K14  b34  sin 4 t   4   a3  t  b3 (37)
x4  K11  b41  sin 1 t  1   K12  b42  sin 2 t   2   K13  b43  sin 3 t   3   K14  b44  sin 4 t   4   a4  t  b4
The solutions of the system of equations (37) contain 8 where the values of ϕ0, u10 and u20 represent the deflection
unknown constants: K11, K12, K13, K14, α1, α2, α3 and α4 in the position of static equilibrium of the system, before
which can be determined from the initial conditions. the start of load lifting.
For the observed system, the initial conditions [11] for the Using the initial conditions (38) in the general solution
time moment t=0 are: (37), a system of 8 equations is obtained in the form:
x1  0     0   0 x3  0   u2  0   u20
x1  0     0   0 x3  0   u2  0   0
(38)
x2  0   u1  0   u10 x4  0   y  0   0
x2  0   u1  0   0 x4  0   y  0   0
0  K11  sin 1  K13  sin  2  K13  sin  3  K14  sin  4  b1

0  K11  1  cos 1  K12  2  cos  2  K13  3  cos  3  K14  4  cos  4  a1
u10  b21  K11  sin 1  b22  K12  sin  2  b23  K13  sin  3  b24  K14  sin  4  b2
0  b21  K11  1  cos 1  b22  K12  2  cos  2  b23  K13  3  cos  3  b24  K14  4  cos  4  a2
u20  b31  K11  sin 1  b32  K12  sin  2  b33  K13  sin  3  b34  K14  sin  4  b3 (39)
0  b41  K11  sin 1  b42  K12  sin  2  b43  K13  sin  3  b44  K14  sin  4  b4
By determining the values for the constants K11, K12, K13, importance not only from a theoretical, but also from a
K14, α1, α2, α3 and α4, the dynamic behavior of the load professional point of view because it requires at least a
with mass M, which is located in the middle of the span rough understanding of the behavior of such systems in
during lifting, is defined. their application in exploitation. The paper presents a
procedure for forming and solving a system of differential
4. CONCLUSION equations that describes the dynamic behavior of a rope
system during the process of load-lifting from the ground
As mentioned, cable cranes are unavoidable in the located in the middle of the crane span.
construction of dams, bridges, forestry and quarries, or in
some other branch of industry or constructions where it is
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konstruisanju, oblikovanju i dizajnu KOD 2006, 30- Russia pp. 300-304.
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52
DOI: 10.24867/MD.12.2020.3.53-60
Research paper
DESIGN OPTIMIZATION AND MANUFACTURING ISSUES OF BLISTERS OBTAINED BY

THE THERMOFORMING PROCESS
Aleksandar PETROVIĆ1, * - Aleksandar MILTENOVIĆ1 - Milan BANIĆ1
1 University of Niš, Faculty of Mechanical Engineering, Niš, Serbia
Abstract: This paper includes the overview, analysis, and proposals of solutions to certain techno-technological
challenges that occur during the whole cycle of development of plastic blister products obtained by a thermoforming
process. The paper gives a brief theoretical overview about the thermoforming process and how the process is carried
out, describes the types of molds involved in the process as well as certain influential factors. The main contribution of
the research relates to the optimization of an otherwise iterative process of design a blister pack for storage printed
circuit boards (PCB) and printed circuit boards assembly (PCBA) for electric motors which are primarily used in the
automotive industry.
Key words: Blister, Tray, Thermoforming, Design for Manufacturing (DFM), Printed Circuit Board Assembly (PCBA)
1. INTRODUCTION used Geometrical Element Analysis (GEA) and found that

results obtained with simulations do not precisely match
This paper describes the entire product development with results obtained with real analysis. They also found
pathway of blister packs, which finds its purpose both that Geometrical Element Analysis (GEA) gives better
internally (in production company), for the storage and results of the trend for thickness variation of the product
automated production of printed circuit boards, and through the mold as well as relatively precise prediction
externally, by transporting them to the other companies of max and min values of thickness. Regarding that
for assembling process or their further processing. These assertion, they found Geometrical Element Analysis
types of printed circuit boards are built in various types of (GEA) as a useful tool for thermoforming process in
electric motors and other moving subsystems in mass general even they didn’t find completely accurate results
production processes. with Geometrical Element Analysis in all aspects of their
Namely, after the process of production and assembling experiment.
of printed circuit boards, it is necessary to have a unified Wanderson de Oliveira L. et al. [2] in their paper
and strictly technically defined product that is capable of discussed the complexity of mathematical modeling of the
receiving a certain number of printed circuit boards, products obtained by the thermoforming process. They
which strength, load-bearing capacity and stacking concluded the complexity is mostly caused by the non-
capability are not in question. linearity in the effects of the processing parameters. Due
Beyond the design process, the paper describes the to this problem, they applied artificial neural networks
technological process of thermoforming, as well as the (ANN) to develop better prediction and optimization. In
materials, molds, and machines that participate in it. more details, they used processing parameters set as
As the thermoforming products and processes of network inputs and the deviations group as the outputs.
obtaining them are well known as well as its wide The processing parameters set was obtained as an
application in industry, authors from different fields have experimental test. Same as in previous paper which has
researched that area of engineering in recent years and discussed, Wanderson de Oliveira L. et al. used
decades. Some authors analyzed the problem from design Polystyrene for their research.
aspects, some of them did it in the area of production and Kouba K. et al. [3] paid significant importance to
automatization, using analytical methods, numerical thickness distribution as one of the main goals needed to
methods, different CAE or mathematical software. achieve during the thermoforming process. For their
Nowadays a number of authors made different predictions research, they used Finite Element Method (FEM) at the
using artificial intelligence algorithms and machine beginning of its application in computer simulations. In
learning. this way, they provide huge importance in the area of
Sencer S. et al. [1] in their paper dealt with wall thickness simulations of the thermoforming process with this
distribution during and after the thermoforming process. method. The objective of their computer simulation of
They conducted predetermined research, where they thermoforming was the accurate determination of
compared results of thickness distribution after the thickness distribution throughout the entire area of a final
thermoforming process obtained experimentally and product using triangular elements with adaptive mesh and
results obtained by numerical simulation. Material used in Newton-Raphson iteration algorithm. The genesis of their
this research was Polystyrene (PS) in form of sheets. They work was a comparison of the results obtained by Song
*Correspondence Author’s Address: University of Niš, Faculty of Mechanical Engineering, Aleksandra Medvedeva 14, 18106 Niš,
Serbia, aleksandarpetrovicmfn@yahoo.com (aleksandar.petrovic@masfak.ni.ac.rs)
Aleksandar Petrović, Aleksandar Miltenović, Milan Banić: Design Optimization and Manufacturing Issues of Blisters Obtained by the
Thermoforming Process; Machine Design, Vol.12(2020) No.3, ISSN 1821-1259; E-ISSN 2406-0666; pp. 53-60
W. et al. [4]. This is an analysis of thick sheet, which, 2.2. Design of Blisters for PCBA Storage
unlike previously published papers, is known by the
presented analysis, which was done with a finite The design of the blisters is done by first defining a list of
thickness. Previous publications have dealt with sheets of requirements. Requirements must be satisfied in order for
large aspect ratios and thus applied the membrane the design to be validated. There are three separate types
approximation. The wall thickness differences were up to of requirements that a design must meet in order to be
5% compared to the references. So they concluded that usable. The next chapter will discuss more about
the finite element method can be used to predict the wall requirements, sub-requirements and their fulfillment.
thickness distribution even for more complex geometric Throughout the process, there are a number of iterations
objects. that are usually caused by geometric constraints, new
ideas, but also an experiential insight into the technology
of the product itself.
2. BLISTER PACKAGES, DESIGN AND THE
Fig.1 shows the appearance of the blister after the first
OBTAINING PROCESS iteration.
The challenges that arose after the completion of this
Line character thermoforming is a highly productive phase of design mainly concerned the inability to
process in which in most cases participates: a specialized produce, more accurately, the formation of curved and
thermoforming machine, a unique mold which design is undulating surfaces after thermoforming. For this reason,
aligned with the product, as well as the production iteration continued.
material - plastic film wrapped like rolls.
2.1. Blister Packages for Printed Circuit Boards
Storage
Blisters, also known as trays or vacuums are packages
that are obtained by the thermoforming processes under
special conditions. Their purpose is to store, care of
various products for a range of uses ranging from
confectionery, food, and up-to-date precision electronic
products, as is the case with printed circuit boards.
As mentioned earlier in the paper, in addition to the
storage and transport role, blisters for the storage of
printed circuit boards also find their purpose as a kind of Fig.1. 3D view of the first iteration of blister
fixture for boards, which in their production and
assembling process are subject to certain automated type Once the design is agreed upon, the process of design and
processes. For this reason, it is necessary that the layout fabrication of the thermoforming mold follows. The shape
of the boards is strictly defined, and that the distance and type of the mold depend on the geometry of the
between the cores of the blisters is identical and with very blister itself.
narrows tolerances. According to the arrangement of the 2.3. Production Process
cores in which the boards are placed, programing codes
and paths are created by which automated machines are Thermoforming is a type of forming process that uses
guided so that the grippers can perform pick and place heat as a significant processing segment. Material is
operations with semi-finished board products during the heated to a temperature that allows forming without
production and assembling. Arrangement of the cores is altering the basic characteristics of the plastic mass.
the best read from the generated “.dxf” files. Generally, thermoforming can be defined as a technique
An additional specificity of blisters for the storage of of processing foils, which are heated to a high elastic state
printed circuit boards is the imperative of maximum and formed.
The manufacturing process begins by unwinding the rolls
security of the boards from the moment they are
of material. After the initial tightening of a certain length
positioned in their cores. That implies the supports on
of foil, corresponding to the length of the process step, the
which the boards lie must be close to the outer edges of
strip foil first comes to the heating zone. As the foil closer
the board, which is caused by the dense arrangement of approaches the molds, the temperature increases
electronic components on the surface of the board, their gradually, and the material becomes warmer, softer and
spread, which in some cases requires the complete more elastic. This allows the material to be more suitable
absence of any support in zones of such arrangement. for further shaping. As the process continues, the foil
The above-described requirement in the design and encounters molds that close, form the blister and open in
manufacture of blisters must not conflict with the the cycle, which is shown in Fig.2.
requirement that the board is in a stable equilibrium state, There are several variants of this process, such as:
both at the moment of insertion into the core of the blister  Drape forming;
and at the time of transport or any possible mechanical  Vacuum forming;
pressure from above. The presence of the least labile  Vacuum snap-back forming;
equilibrium is unacceptable and represents a new iteration  Billow vacuum forming.
leading to the final design, which is only adopted after the As well as variants with plug-assist system:
final production and testing of the blister in exploitation.  Plug-assist vacuum forming;
54
 Plug-assist pressure forming; path can be quite long when it comes to designing special-
 Pressure reverse draw with plug-assisted [6]. purpose blisters such as blisters for printed circuit boards.
While in [11] for design, authors used CATIA and
parametrical options, as well as control points in CATIA
in [12], here it was necessary to use feature-based
technology combined between Autodesk Inventor and
SolidWokrs in order to make a product which could be
produced. Also, the previous chapter stated that there are
three types of requirements that need to be met. The first
Fig.2. Process schematic [5]: Battenfield Gloenco Rollfed
type of requirement relates to overcoming the challenges
Sheet + Thermoforming Line. A: Rollfed Sheet Take-off
of good matching of printed circuit boards and blister as
Station; B: Pin Chain Engagement; C: Heater Zone; D:
well as relations between several of them. The list of
Forming Station; E: In-Line Separate Mechanical
requirements and ideas is made by the brainstorming
Toggle- Clamp Trim Station;
method by interested individuals who are thoroughly
aware of the whole issue. Listed below are sub-
The main segments of the variant systems are molds,
requirements and challenges including problems that
pressure and vacuum. By their combination and
occur on the formed products that need to be met and
orientation, these variants are applied. In the present case,
overcome in order for the first type of requirement to
different variants were used for different blisters. The
satisfy:
thermoforming variant and mold design were chosen
 This paper is based on a realistic blister design project
based on the blister geometry. Fig.3 presents the most
common variant of the process [6], which was also for a number of sub-projects (one sub-project represents
applied to some blisters that were designed, one blister design with unique PCBA. One of the basic
manufactured, and discussed in this paper. requirements, common to all types of requirements that
will be described below, is the design of identical frames
(edges) for all projects (Fig.4.).
Fig.3. Detailed process schematic [6]: 1 – Plastic sheet;

2 – Mold; 3 – Clamp; 4 – Seal; 5 – Vacuum;
The product takes the form of a mold or is shaped by its

Fig.4. 3D view of the final iteration of blisters frame
contours and surfaces by vacuum, air pressure (and) or
mechanical force.
 The orientation of the printed circuit boards inside the
In this case, a Polystyrene (PS) electrostatic discharge
(ESD) black plastic film with an initial material thickness core have two ways. In the case of projects which blister
of 1mm was used. The change in material thickness was has only a storage and transport role but not automation
discussed later in the paper, while material change was one, the following applies:
not possible. 1. SMT projects (printed circuit boards with no
Namely, precision electronics require an environment components on them), the boards usually lie on the
(material) that is exclusively electrostatic discharge (ESD) bottom of the blister and no special supports are
in order to reduce static electricity to protect electrostatic- required.
sensitive devices such as printed circuit boards. Process
2. SMT + TH projects (printed circuit boards with
temperature range for Polystyrene (PS) is 150 – 190 °C
additional capacitors, diodes, etc.) where the cores of
[5].
the blisters must have special supports on edges.
The manufacturing process ends with the separation of
blisters from the foil strip. Cutting tools are made of However, this assumption is not always satisfied. There
special knives. Usually, the cutting tool is separate from are examples of projects where SMT + TH boards stick to
the mold and forms a separate product station. the bottom of the blisters, with the orientation of their
Recycling as an aspect of global importance comes after components facing up. This is the case for all blisters
cutting edges. The whole process is intermittent and of subject to automation - the orientation of both the SMT
cellular type. The length of the step depends on the length and SMT + TH components must go up.
of the product or its mold cavity.  Poor board stability in core. If the supports are not
properly positioned and a slightly higher offset value is
3. DESIGN OPTIMIZATION PROPOSAL, left, the board may fall into the core of the blister, either
REDUCTION OF ITERATIONS, AND due to its own weight or Earth's Force, or due to
CREASE PREDICTION mechanical force from the outside. The last case
described can be very problematic if the blister is used on
The previous chapter describes the standard, conventional the line as is the case with the PCBA blisters.
path that the blister design process passes each time. That
55
Ways to overcome problems with intrusions are reflected

in making a prototype that fits in as closely as possible
with a future real blister. Core problems can be solved by
3D printing a software-cut core. During the printing, the
orientation of the core should be reversed in relation to
that in use. The reason for this is the minimal shrinkage of
the material in the initial layers (where the board fits in)
and the avoidance of later oscillations in dimensions as
the print moves along the vertical axis.
Once the print is complete, the functionality of the core
can be tested and, if satisfied, continue with the process.
With 3D printing, it is possible to simulate the geometry
of the blister and the characteristics of its design, up to the
point where it is not required and that the material
properties are appropriate with respect to the real blister.
Specifically, 3D printing tests and validates design in the
field of material rigidity.
Fig.5. First iteration of blisters core with tiny fixtures on
The following illustrates the process of testing the design
the edge
of a blister core for a project related to the projects of
blister design for printed circuit boards. After cutting out
one core in SolidWorks (Fig.8.), it is followed by
processing in ZORTRAX M200 software for processing
models (Z-Suite, Fig.9.).
Fig.6. 3D view of the final iteration of inside of blister for

first done project
 Too small offset relative to the outer contours and

shape of the board. The “offset” mentioned may be
caused by the choice of dimensions and tolerances by the
designer, but may also be due to shrinkage of the material
after cooling. If this problem occurs, it may be difficult Fig.8. Core cutting for 3D printing (133 mm x 120 mm)
for the boards to enter their cores, which can further cause
damage to the electronic components due to unwanted
friction, etc.
 Intrusion of certain components of the printed circuit
board into the blister above when blisters are in the stack.
This problem can usually be solved as early as design, by
creating a variety of cross sections. However, the fact that
blisters are not absolutely rigid bodies should not be
overlooked, and that under the influence of stacked
boards and other blisters positioned above them, the
blisters can be bent.
Fig.9. Parameter settings in software for 3D printing
Printing was done by LPD (Layer Plastic Deposition)

technology – depositing melted material layer by layer
onto the build platform [10].
High print quality with a dense pattern and a diameter of
nozzle - 0.4 mm was applied at 0.14 mm layer thickness.
The reason to cut just one core instead of printing the
entire blister is because of the size of the print plate (200
mm x 200 mm x 180 mm, [10]) that just fits the print of
one core. Figure 10 shows the printing time (9 h and 49
Fig.7. Cross-section of the first iteration of the PCBA min), the Z-PCABS material used, with 78 g being used
components intrudes into the blister above for printing. Figure 11 shows a prototype core that can be
tested.
56
 Blisters must be suitable for automation. All blisters

must be suitable for automation and stackable. That mean
blisters must be compatible with pallet handling systems.
Also blisters must not jam together. Especially the
lowermost blister must not be jammed or excessively bent
by the weight of the entire stack of parts.
Fig.10. Information for printing
Fig.12. Automation machine for production of PCBA
 Grip for handling. There must be enough undercuts on

the grip side of the blisters (typically the long side of the
blister).
Fig.11. 3D print of blisters core
The same principle applies to molding (prototypes) using

CNC technologies. While large-series blisters are made of
aluminum molds (certain types of steel molds are used for
processes with high-temperature, high-pressure) [7],
cheaper and softer materials can be used for small-series
or trial tools. A possible problem with the tool will also
Fig.13. Undercuts on the blister
cause the problem on a real blister. Iteration at this stage
is already getting very expensive. For this reason, molds
The geometry of undercuts must be dimensioned by the
of hardwood, industrial plasters, medium-density
provided guide where needed dimension for vertical
fiberboard or syntactic foam should be made and blisters
component should be at least 15 mm; while for horizontal
produced [7]. If the blisters thus obtained prove
dimension 10 mm. It wasn’t possible to reach 10 mm
satisfactory, the manufacture of steel molds can also be
because of inability to produce so deep undercut. More
started. However, if there is a problem, it is possible to go
words about that issue from technical side will be given in
back a few steps and make a change in the design of the
the following text (third type of requirements).
tool. It may very often happen that the design of the tool
geometrically exactly matches the desired blister design,
but only under ideal conditions. When mechanical
properties, chemical properties, material thickness,
heating time, cooling time, room air properties are
included in the whole problem, a thermoformed blister
can have unwanted creases, very thin surfaces subject to
splitting and other negative consequences.
In addition to the design requirements listed at the
beginning of this chapter, which mainly relate to the ratio
of board and blister (core), i.e. the best fit and stable Fig.14. Inside of the automation machine
balance possible, there are two other types of
requirements that must be met in order for the final design  The clearance around the edge between the workpiece to
to overcome problems that they may occur both at the be handled and the tray cavity must be 0.3 mm to 0.5 mm.
beginning of the blister use and during exploitation. The  Rotation prevention. A rotation prevention system
designer in this case has a large number of inputs that has
must be provided for trays in the stack. This means that
to incorporate to satisfy all 3 types of requirements with
additional sub-requirements that are imposed by them the Poka-Yoke system must be provided to prevent the
during the design process. blisters from being wrong placed when packaged and thus
The second type of requirement relates to the mistakenly stacked onto the automation line. After the
characteristics that the blister must satisfy in order for the initial iterations and designing the specific undercuts
packaging to be used in the PCBA line automation shown in Fig.15, there was a final version (Fig.16.) of the
process and are defined by the automation machine design with one sloping side opposite the remaining three
manufacturer. These include: rounded ones.
57
related to DFM, or simply iterates the design in the

process itself. The following pictures will show the final
design of the blister for two different sub-projects, which
are accompanied in most illustrations through the work.
The design given will be compared with real blisters after
the design process and a discussion will be provided.
Fig.15. First iteration of blisters Poka- Yoke system
Fig.18. 3D view of final blister design
Fig.16. Final iteration of blisters Poka- Yoke system
 For trays, inlays or workpieces that are not

symmetrical: There must be a feature on the tray so that
trays and any tray inlays that are used can be fed in the Fig.19. Stacked blisters filled with printed circuit boards
correct orientation without error.
As for the third type of requirements, these are the
requirements related to the so-called design for
manufacturing (DFM), that is, represent the requirements
of technology and are being worked to take all measures
to prevent the following challenges [6], classified as
follows:
 Sharp corners;
 Deep draws;
 Ribs;
 Undercut;
 Draft angles; Fig.20. 3D view of final blister design
 Thickness variation.
In the thermoforming process, similar to plastic injection
molding, angles play a significant role. A schematic
representation of the angles to be used and avoided during
the design is shown in the Fig.17.
Fig.21. Real blister with printed circuit boards

Fig.17. Angles for thermoforming [6]
One of the problems that occur during the production was
It can often be the case that certain requirements overlap, in relation with undercuts on the blister sides which is
but sometimes requirements can be mutually exclusive. In mention above in the text. Namely, the required
that case, the priority requirement is usually that one dimension of depth of undercut was 10 mm. Fig.22.
58
showed an optimal solution that met both requirements in

the most optimal way.
Fig.22. Draft angles
The aforementioned image shows the appearance of the

blister as it looks when formed around the mold. So this
problem should be seen from the perspective of the draft Fig.24. View of undesirable creases obtained after
angle. The slope of all lateral edges with respect to the exploitation
vertical is 3 degrees, while the slope of the inner edges
with respect to the vertical is 5 and even 10 degrees (95 According to Engelmann S. [8] thermoforming
degrees and 100 degrees with respect to the horizontal), obtained parts tend to two types of shrinkage: free and
which is also a recommendation from Figure 17. mold shrinkage. Even during the heating phase, the semi-
At the moment of the separation of the mold and the finished parts can also create problems for the production
blister formed after thermoforming, the arrangement of of formed parts because of their free shrinking behavior.
the draft angles is such that problems can occur, Total shrinkage is equal to processing shrinkage + post
according to Fig.22. only in the area marked by the red shrinkage, where for PS (which is used in this paper) is
arrow. This problem becomes even more significant if we
0.4 − 0.7% [8]. Also compared with metal, plastic parts
consider the original desired dimension (10 mm) instead
have a thermal expansion that is 10 to 20 times higher [8].
of the current one (3.7 mm).
The tolerances of dimensions that are not specified are
Namely, if they were in the area of absolutely rigid
bodies, it would be physically impossible that formed ISO 2768-1 Class c. As many details are on the blister of
blister leave the mold. However, it should be borne in small dimensions, this tolerance is still quite narrow, and
mind that at the moment after formation, the blister is still when designing the tool, all shrinkage and expansion
in a warm state (but not as at the time of the last stage of coefficients should be calculated. Although most blisters
heating), sufficient to withstand the deformation of the applied the positive principle of formation, so this
protruding part of the mold and to return to its original affected as accurately as possible the dimensions of the
form. Thanks to this feature it was possible to provide an cores relative to the nominal dimensions and the smallest
undercut depth of about 4 (3.7 mm). expansion of the material.
The next challenge to overcome was the appearance of Another problem that arises here is the unequal
cracks and creases on the formed blister. Few of them distributed thickness after the process. This problem has
were visible immediately after the production process also been discussed by Kuttner R. et al. [9] which
(Fig.23.), while most cracks and creases appeared from emphasize the importance of controlling the thickness
the very beginning of exploitation (Fig.24.). variations in the vacuum forming process. This parameter
should be controlled from the purpose to meet the
functional requirements of the part. Illustration is given in
the Fig.25.

Fig.23. Cracks created on the real blister after Fig.25. Theoretical critical points after thermoforming
production process [6]
59
It should be noted that the process started with an initial [2] Leite, W.; Campos, C., Cabrera, F., Carrasco, A. &
material thickness of 1 mm. The wall thickness Hanafi, I. (2018). Vacuum Thermoforming Process:
distribution of the material after process varied from 0.4 An Approach to Modeling and Optimization Using
to 1.3 mm as determined by measurement. So in the Artificial Neural Networks. Polymers, Vol., 10.,
critical zones shown in the Fig.25 is exactly the thinnest Issue 2., (February 2018), ISSN 2073-4360
material formed in the narrow corners. An additional [3] Kouba, K.; Bartos, O. & Vlachopoulos, J. (1992).
difficulty is that these zones represent the places where Computer Simulation of Thermoforming in Complex
printed circuit boards rely on, and are in fact the most Shapes. Polymer engineering and science, Vol., 32.,
stressed places in the whole design. To overcome this Issue 10., (May 1992), 699-704
problem, thicker foils were applied, with an initial [4] Song, W.; Mirza, F. & Vlachopoulos, J. (1990).
thickness of 1.2 mm, 1.5 mm, and 1.7 mm. This partially Thermoforming of Thermoplastics, Third Eur. Rheol.
solved the problem. The thickness of the foil could not go Conf. and Golden Jubilee Meeting of the British Soci.
above 1.7 mm due to undercuts. Namely, the undercuts of Rheol., ISBN-13: 978-94-010-6838-3, Edinburgh,
were further reduced due to the thickness of the foil in UK, 462-464 ELSEVIER SCIENCE PUBLISHERS
terms of depth. However, in this case, the blister and the LTD, 94-97 Crown House, Linton Road, Barking
mold could not be separated without significant damage [5] Throne, J.L. (1996). Advances in Thermoforming,
to the sides of the blister. The second part of the solution iSmithers Rapra Publishing, Shawbury, UK, 15
was to upgrade the cooling system at the upper part of the [6] *** (2015)
mold. Molds usually contain, in addition to vacuum http://web.mit.edu/2.810/www/files/lectures/2015_le
system, cooling system, without the thermoforming ctures/lec8-thermoforming-2015.pdf - Gutowski T.
process would not succeed, or at least its product would Thermoforming of Thermoplastic Sheets. MIT
not reach satisfactory quality. The blister actually begins Lectures, Accessed on: 2020-04-27
its cooling upon contact with the mold. Following these [7] Throne, J.L. (2008). Understanding Thermoforming
improvements, the production of blisters continued to (2nd ed.), Hanser, ISBN 978-1-56990-428-2,
meet the requirements described in this chapter. Munich, Germany, 85
[8] Engelmann, S. (2012). Advanced Thermoforming,
4. CONCLUSION John Wiley & Sons., ISBN 978-0-470-49920-7,
Hoboken, New Jersey, 10
This paper belongs to a group of papers dealing with [9] Kuttner, R.; Karjust, K., Pohlak, M. (2007). The
design optimization, in terms of customizing the design so Design and Production Technology of Large
that it can be manufactured as well as reducing the Composite Plastic Products. Proc. Estonian Acad.
number of iterations, and ensuring that the final product is Sci. Eng., 2007, 13 (2), 117-128
as reliable as possible. The aim of this paper is to make [10] https://support.zortrax.com/m200-plus-specification/,
engineering suggestions, based on experience in the Accessed on: 2020-04-27
design of blisters. Once the designer has ensured that the [11] Aboulissane, B.; Bakkali, L. E.; Bahaoui, J., E.
future design will be the most optimally produced by the (2020). Workspace Analysis and Optimization of the
thermoforming, the gathering of the requirements that the Parallel Robots Based on Computer-Aided Design
design needs to satisfy begins. In the case of blisters for Approach. Facta Univesitatis Series Mechanical
the printed circuit boards, the requirements are divided Engineering, Vol., 18., Issue 1., (2020), 79-89, ISSN
into three categories. In order to reduce the number of 0354-2025
iterations, prototypes obtained by 3D printing have been [12] Husain, K.; Rashid, M.; Vitković, N.; Mitić, J.;
introduced. The third type of requirements (design for Milovanović, M.; Stojković, M. (2018). Geometrical
manufacturing) is the type with the highest priority so the Models of Mandible Fracture and Plate Implant.
first and second types of requirements adapt to it. Also, Facta Univesitatis Series Mechanical Engineering,
design for manufacturing (DFM) principles concluded in Vol., 16., Issue 3., (2018), 369-379, ISSN 0354-2025
the third chapter can be applied to the design of other
products obtained by the thermoforming in order to
achieve less number of iterations as well as high quality
finished product possible.
REFERENCES
[1] Karabeyoglu, S.; Ekşi, O. & Erdoğan, S. (2017). An

Experimental Study on Wall Thickness Distribution
in Thermoforming. Advances in Science and
Technology, Vol., 11., Issue 3., (September 2017)
139–142, ISSN 2299-8624
60
DOI: 10.24867/MD.12.2020.3.61-66
Research paper
TOOTH CONTACT ANALYSIS OF ARCHIMEDEAN WORM GEAR DRIVES FOR THE

MODIFICATION OF THE NUMBER OF THREADS ON THE WORM HELICAL SURFACE
Sándor BODZÁS *
University of Debrecen, Faculty of Engineering, Debrecen, Hungary
Abstract: The aim of this study is the analysis of the normal stress and normal deformation results on the connecting
tooth surfaces of worm wheels based on the modification of the number of threads on the worm helical surface.
Designing of six gear drives having different number of threads is needed for the mechanical analysis. Knowing of the
calculated geometric parameters of the elements the CAD models could be designed. After that the TCA could be done
which is necessary before the correct production of the connecting elements. Static analysis will be done by a given
load torque. The received results will be represented on charts in the function of the number of threads. The
consequences will also be determined.
Key words: worm, worm-wheel, torque, TCA, CAD
1. INTRODUCTION 2. THE GEOMETRIC DESIGNING OF THE

GEAR PAIRS
The main property of the Archimedean worm gear drives
is the tooth profile which is linear in axial section [1, 3, 5, Knowing of designing experience of the
6, 7, 8]. The axes of the elements are bypass in the space. recommendations of the references [1, 2, 3, 5, 6, 8] six
This gear pair could be used where high transmission different types of gear pairs were designed. All of the
ratio, bypass and perpendicular axes position are required. input geometric parameters were the same only the
Many engineering constructions use these gear pairs number of threads was modified (Figure 1).
having different geometries. For example, they are used in The geometry of the worm wheel is also different from
the field of steering wheel system in case of the vehicle each other. The α angle of the worm wheel teeth is
industry, helicopter assembly, etc. continuously being changed in the function of the
The main input parameters of the designing process are modification of the number threads (Figure 2).
the number of threads of the worm, the number of teeth of The calculated geometric parameters could be seen in
the worm gear, the axial module and the transmission Table 1 for all of the gear drives.
ratio. Because of the facilitation of the designing process
the gear pairs were designed by the help of GearTeq and
the SolidWorks software. The geometric designing is
happened by the GearTeq where the user can set the input
parameters and the designing method knowing of the
reference’s recommendations [1, 3, 5, 6, 8]. After the
correct designing the connected gear pairs could be
visualized by SolidWorks where the inspection of the
appropriate tooth connection could also be done.
The Tooth Contact Analysis (TCA) [2, 4, 7, 9, 10, 11] is a) z1=1 b) z1=2
necessary for the analysis of the mechanical parameters
on the contact zone by different loads (torque, force, etc.)
or other environmental conditions. Based on the result the
geometric parameters, the material type or the loads could
be modified before the concrete production. The main
advantage of this analysis is the pre-estimated mechanical
parameters before the real assembly and application. This
analysis could be done by Ansys finite element software
[4]. c) z1=3 d) z1=4
*Correspondence Author’s Address: University of Debrecen, Faculty of Engineering, Debrecen, Hungary

bodzassandor@eng.unideb.hu
Sándor Bodzás: Tooth Contact Analysis of Archimedean Worm Gear Drives for the Modification of the Number of Threads
on the Worm Helical Surface; Machine Design, Vol.12(2020) No.3, ISSN 1821-1259; E-ISSN 2406-0666; pp. 61-66
c) z1=3, α=15.69° d) z1=4, α=20.62°
e) z1=3 f) z1=4
Fig.1. The geometric establishments of the designed

worm gear drives
e) z1=5, α=24.96° f) z1=6, α=29.13°
Fig.2. The angle of worm wheel teeth (α) in the function

of the number of threads
a) z1=1, α=5.26° b) z1=2, α=10.66°
Table 1. The geometric parameters of the designed gear pairs
The parameters of the worm gear drive

a) b) c) d) e) f)
(based on Figure 1)
Number of threads, z1 1 2 3 4 5 6
Number of teeth of the worm-wheel, z2 30
Diametral pitch, pd [mm] 5.08
Normal diametral pitch, pdn [mm] 5.099 5.158 5.254 5.386 5.55 5.745
Axial module, max [mm] 5
Normal module, mn [mm] 4.98 4.924 4.834 4.715 4.575 4.42
Worm lead of thread, px [mm] 15.7 31.4 47.1 62.8 78.5 94.2
Circular pitch of the worm-wheel, t0 [mm] 15.7
Lead angle, γm [°] 5 10 14.8 19.4 23.8 27.9
Addendum coefficient, f’ 1
Fillet coefficient, r’ 0.3
Clearance coefficient, js’ 0.2
Direction of the wheel right hand
Pitch diameter of the worm, d01 [mm] 56.8
Pitch diameter of the worm-wheel, d02 [mm] 150
Outside diameter of the worm, da1 [mm] 66.8
Outside diameter of the worm-wheel, da2 [mm] 161.8
Center distance, a [mm] 103.4
Face width of the worm-wheel, b2 [mm] 25.4
Worm length, L [mm] 100
Pressure angle, αax [mm] 20.1 20.3 20.6 21.1 21.7 22.4
Normal pressure angle, αn [mm] 20
Addendum of the worm, ha1 [mm] 5
Addendum of the worm-wheel, ha2 [mm] 5
Dedendum of the worm, hf1 [mm] 5.8
Dedendum of the worm-wheel, hf2 [mm] 5.8
Tooth thickness of the worm, Sax1 [mm] 7.9
Tooth thickness of the worm-wheel, Sax2 [mm] 6.9
Fillet radius, r [mm] 1.5
Transmission ratio, i 1/30 2/30 3/30 4/30 5/30 6/30
Diameter ratio, q 12
Designing standard DIN 867
62
3. TOOTH CONTACT ANALYSIS BY

LOAD TORQUE
The first step of the TCA is the definition of the

necessary coordinate system where the mechanical
parameters could be interpreted [9, 10]. Eight systems
were needed:
 the coordinate system of the worm which is situated
on the rotation center of the worm,
 the coordinate system of the worm wheel, which is
situated on the rotation center of worm-wheel, a) 1st tooth
 six coordinate systems are needed on the tooth
connection zone form which 2 coordinate systems
are needed for each worm-wheel tooth. We have
three connecting teeth.
The applied friction coefficient on the contact zone was
µ=0.01. The size of the element was 0.6 mm on the
contact zone. Automatic meshing was used on the
outside areas.
b) 2nd tooth
Fig.3. The FEM meshing and the nomination of the

worm wheel teeth
c) 3rd tooth
The selected material was structural steel (Table 2) for
the elements. Fig.4. The normal stress distribution perpendicularly
for the tooth surface (z1=3)
Table 2. The parameters of the selected material
Material Quality Structural steel
Density 7850 kg/m3
Yield stress 250 MPa
Tensile strength 460 MPa
Poisson factor 0,3
Young modulus 200 GPa
Temperature 22 °C
The worm was loaded by M=100 Nm torque. The

received normal stresses and deformations
perpendicularly for the tooth surfaces, the ‘x’ axial and
the ‘z’ radial normal deformation components were
analyzed for each connected worm-wheel tooth (Figure Fig.5. The correlation between the number of stress
3). and the normal stress
3.1. The normal stress analysis The lowest normal stress results are on the 3rd tooth in
absolute value. These values are continuously
Based on Figure 4 the received normal stress results on fluctuated. This fluctuation could be observed on the
the worm-wheel teeth could be seen in case of z1=3 1st tooth. Despite of them the normal stress is
number of threads. continuously being decreased in the function of the
number of threads on the 2nd tooth. Based on this
63
diagram the lowest stresses are on the z1=6 number of helical surface the normal deformation distribution will
threads for each tooth. Consequently, increasing of the be lower and smoother on each tooth (Figure 7).
number of threads the normal stress distribution will be
less on each connecting worm wheel tooth (Figure 5).
3.2. The normal deformation analysis

The normal deformation was analyzed into three
directions (perpendicular, axial and radial). The normal
deformation distribution on the worm wheel teeth
could be seen on Figure 5 in case of z1=6 number of
threads which is interpreted perpendicularly for the
tooth surface.
Fig.7. The correlation between the number of threads

and the normal deformation
The ‘x’ axial normal deformation distribution on the

worm wheel teeth could be seen on Figure 8 in case of
z1=3 number of threads which is interpreted into axial
direction of the worm wheel.
a) 1st tooth
a) 1st tooth
b) 2nd tooth
b) 2nd tooth
c) 3rd tooth
Fig.6. The normal deformation’s distribution

perpendicularly for the tooth surface (z1=3)
Based on Figure 7 the normal deformations are

approximately being decreased in the function of the
number of threads.
The lowest results are on the 3rd tooth in absolute
value. The highest results are on the 1st tooth in
absolute value. It is valid for all of the worm gear c) 3rd tooth
drives. Summing the lowest deformation distributions
are in case of z1=6 number of threads. Consequently, Fig.8. The ‘x’ axial normal deformation’s distribution
increasing of the number of threads on the worm (z1=3)
64
The highest deformations are on the 3rd tooth. The

lowest deformations are approximately on the 1st
tooth. These result are fluctuated. The lowest
deformation results are in case of z1=6 number of
threads on both teeth. The highest results are in case of
z1=5 number of threads (Figure 9).
Fig.11. The correlation between the number of threads

and the ‘z’ radial normal deformation
The lowest results are on the 3rd tooth in absolute

value. The highest results are on the 1st tooth in
absolute value. The radial normal deformations
Fig.9. The correlation between the number of threads approximately are continuously being decreased in the
and the ‘x’ axial normal deformation function of the number of threads. It is valid for each
tooth. The lowest distribution results are in case of
The ‘z’ radial normal deformation distribution on the z1=6 number threads (Figure 11) in absolute value.
teeth of the worm wheels could be seen on Figure 10 in
case of z1=3 number of threads which is interpreted 4. CONCLUSION
into radial direction of the worm wheel.
The aim of this study is correlation analysis between
the number of threads and normal stress or normal
deformation. This is necessary to design six different-
type Archimedean worm gear drive where the different
is only the number of threads on the worm. These gear
drives were designed by the GearTeq software. After
that the assembly tasks and the good connection setting
could be done by SolidWorks software. TCA was done
by loaded torque on the worm. The connection zone
was analysis where three worm-wheel teeth are
connected with the worm surface directly at the same
a) 1st tooth time. The average normal stresses and normal
deformations (perpendicular for the tooth surface, axial
and radial components in comparison with the worm
wheel) were determined for each connecting tooth.
Based on the charts the consequences could be defined.
The most favorable mechanical parameters were
received in case of z1=6 number of threads. The
disadvantage of the more number of threads is the
much computed machine time during the
manufacturing process mainly because of the
complicate grinding of the helical surface.
Consequently, the application of more number of
b) 2nd tooth thread on the worm has to be balanced.
ACKNOWLEDGEMENT
This research was supported by the János Bolyai

Research Scholarship of the Hungarian Academy of
Sciences.
REFERENCES
[1] Dudás, I., (2000), The Theory and Practice of

c) 3rd tooth
Worm Gear Drives, Penton Press, London, ISBN
Fig.10. The ‘z’ radial normal deformation distribution 1877180295
(z1=3)
65
[2] Dudás, L., (2013), Modelling and simulation of a Miskolci Egyetem Innovációs és Technológia
new worm gear drive having point-like contact, Transzfer Centrum, pp. 29-34
Engineering with Computers, Engineering with [8] Litvin, F. L., (1998), Development of Gear
Computers: Volume 29, Issue 3, pp. 251-272, Technology and Theory of Gearing, NASA
ISSN 0177-0667 Reference Publication 1406, Chicago
[3] Litvin, F. L., Fuentes, A., (2004), Gear Geometry [9] Nieszporek T., Gołębski R., Soos L., (2017),
and Applied Theory, Cambridge University Press, Analysis of the worm-wheel toothing accuracy,
ISBN 978 0 521 81517 8 Technical Gazette, 24(4), 993-1000.,
[4] Moaveni S., (2015), Finite Element Analysis, https://doi.org/10.17559/TV-20160422094400
Theory and Application with ANSYS, Pearson [10] Liang, D., Luo, T., Tan, R., (2018), Generation
Education Limited, ISBN 10: 0-273-77430-1, p. and Meshing Analysis of a New Type of Double
928 Helical Gear Transmission, Hindawi,
[5] Terplán, Z., (1975), Gépelemek IV., Kézirat, Mathematical Problems in Engineering, pp. 1-10,
Tankönyvkiadó, Budapest, 1975., p. 220. https://doi.org/10.1155/2018/1539849
[6] Radzevich, S. P., Dudley’s Handbook of Practical [11] Kuzmanović, S., Rackov, M., Knežević, I., Vereš,
Gear Design and Manufacture, Third edition, M., (2017), Different Selection Procedures of
CRC Press, p. 656, ISBN 9781498753104 Universal Worm Gear Drives, Machine Design,
[7] Bodzás, S., Dudás, I., (2011), Production Vol. 9, No.2, University of Novi Sad, Faculty of
geometry and finite element method analisys of Technical Sciences / ADEKO, Novi Sad, 2017;
archimedean worm gear drive, microCAD 2011, ISSN 1821-1259; E-ISSN 2406-0666; str. 51-56;
XXV. International Scientific Conference, DOI: 10.24867/MD.9.2017.2.51-56
66
DOI: 10.24867/MD.12.2020.3.67-70
Research paper
SPECIALIZED ELEVATORS FOR PEOPLE WITH DISABILITIES

Dragan ŽIVANIĆ1, * - Nikola ILANKOVIĆ1 – Atila ZELIĆ1 – Kristina JAKIMOVSKA2 – Anita VASILEVA2
1 University of Novi Sad, Faculty of Technical Sciences, Novi Sad, Republic of Serbia
2 University of “Ss. Cyril and Methodius” Skopje, Faculty of Mechanical Engineering, Skopje, Republic of North Macedonia
Abstract: Access to higher floors of buildings for people with disabilities is a problem that every society faces and
needs special attention. Buildings with staircases represent an architectural barrier and prevent access to the facility
for persons with disabilities. In this paper, elevator solutions for people with disabilities will be shown.
Key words: elevators, people with disabilities, special devices
1. INTRODUCTION elevator will stop automatically and will not start until the
door is closed. The ceiling cover opens and closes
Most buildings and other structures have a staircase that automatically when the elevator moves.
represents an architectural barrier and completely denies
access to the facility for people with disabilities,
especially those who are wheelchair users.
This problem should be approached in such a way as to
enable the person using the wheelchair to be able to move
independently with the help of the technical solution
offered. Before deciding which solution is optimal in a
particular case, it is necessary to analyze the following
[2]:
 whether the disabled person will sit, stand or be in a
wheelchair during transportation, Fig.1. Vertical elevators without shafts (a) and with shafts
 whether the standard seat will fit in size and the user (b)
will need a special child seat,
 if a person with a disability can get worse over time, a Vertical shaft elevators are widely used: in households,
solution should be chosen that will be functional even residential buildings, as well as office buildings, fig. 1b.
after the eventual deterioration, They must be closed and require larger work during
 it is necessary to know whether the device will be assembly.
handled by a disabled person, trained person or both, For vertical elevators of this type, the shaft is made of
 it is necessary to define whether or not movement glass or metal, and their advantage is that they provide the
controls or controls are accessible to the user, ability to transport more than one person. They must have
 when installing into an existing building, it is
an additional ramp to assist the exit and entry into the
necessary to make an analysis of whether it is
elevator, whereby the user himself raises and lowers the
necessary to adjust the interior, ie whether a new
ramp [3].
arrangement of doors, radiators is needed.
It is necessary to ensure that, after the installation of the 2.2. Staircase elevators
device, a regular staircase can be used.
Staircase elevators are mounted on a rail that accompanies
2. OVERVIEW AND ANALYSIS OF the staircase, and can be installed on either side of the
EXISTING SOLUTIONS staircase. They can have straight and curved tracks.
Staircase elevators can be installed and removed very
2.1. Vertical elevators for people with disabilities quickly.
Vertical elevators with platforms used for wheelchairs There are seated, standing, staircase elevators with
provide the greatest independence in movement. reclining and staircase elevators with platforms.
However, these lifts take up more space and require more The sitting staircase elevator is equipped with a swivel
work to be done during installation. chair and handrails that make it easier to sit and get up
Vertical elevators without shafts are mainly applied in from the chair, fig. 2. The swivel seat is electrically or
homes, fig. 1a. Transport of people is accomplished with manually operated. The control can be done by the user
the help of a rail fixed to the wall. The door closing on the himself, but with the help of adequate control equipment,
elevator is checked electronically. If the door is open, the a trained person can assist in transportation [3].
*Correspondence Author’s Address: University of Novi Sad, Faculty of Technical Sciences, Trg Dositeja Obradovića 6,
21000 Novi Sad, Serbia, zivanic@uns.ac.rs
Dragan Živanić, Nikola Ilanković, Atila Zelić, Kristina Jakimovska, Anita Vasileva: Specialized Elevators for People with Disabilities;
Machine Design, Vol.12(2020) No.3, ISSN 1821-1259; E-ISSN 2406-0666; pp. 67-70
a straight staircase elevator is in the concept of the drive.

It is applicable for lifting heights up to two floors [3].
Fig.2. Sitting staircase elevators
Persons who use crutches can use the elevator where they
have space to accommodate aids when walking. The chair
is positioned eccentrically to get as close as possible to
the edge of the upper staircase when rotated about an axis, Fig.4. Platform elevator on a straight route staircase (a)
making it much easier to get up and sit. and on a curved route staircase (b)
Standing staircase elevators are used for persons who can
stand on the elevator during transport or for persons who 2.3. Stair climbers
cannot stretch their leg (rigid leg), fig. 3a. These elevators
take up less space in the staircase compared to the sitting All of the previous solutions, however simple they may
one. seem, require careful analysis and consideration of the
These elevators typically have 1 or 2 handrails on which a location and method of installation, to ensure the safety of
person can hold, which increases safety when the persons using them. The shown devices solve
transporting. There is an option of sitting elevators where problems on a single staircase, so in buildings with
the chair folds down. multiple staircases more elevators need to be installed.
Staircase elevators with leaning are very similar to Because of this, stair climbers have been created that are
standing ones, with the exception that they provide simple and much cheaper than elevators. These are
additional support below thighs, fig. 3b. And these lifts mobile devices adaptable to all types of staircases with
have handrails. different inclination.
Fig.3. Standing staircase elevators (a) and staircase

elevators with leaning (b)
Fig.5. Universal stair climber (a) and standard stair
Staircase elevators with a platform allow people with climber (b)
disabilities, along with a wheelchair, to be transported
from floor to floor. Although the platform can be folded Mostly these devices are used in residential buildings,
against a wall, it takes up a lot of space. Platform where there is less need for the transportation of people
elevators are done on a straight and curved staircase. The with disabilities, and less can be found in public
platform elevator on a straight staircase can be used for all buildings. All this comes from the relatively long
types of stairways and slope angles, fig. 4a. preparation of the person being transported by the escort.
The features of this elevator are easy to use, easy control In the end, there is a fundamental difference between
(one touch), maximum user safety. There is a wide range elevators and stair climbers, which is a companion. A
of places for the installation of such a platform lift, stair climber is a device that grasps a wheelchair and
namely schools, office buildings, churches, theaters, moves using tracks over stairs.
residential quarters, stadiums, etc. The universal stair climber seen in fig. 5a provides
There are two stops: on the ground floor and at the top of accessibility to all places where stairs appear as an
the stairs. No between stopping is foreseen. obstacle. The uniquely designed platform adapts to all
In fig. 4b, the layout of the platform elevator for the types of wheelchairs, including self-propelled, children's
curved staircase can be seen. The elevator is used for and sports. Although robust, it is easy to operate and
stairs that have a curved route. The basic difference from offers a high level of security.
68
The standard stair climber showin in fig. 5b is safe, Staircase elevators can be installed outside with controls
reliable and easy to use. It is designed to snap under at the bottom and top of the staircase, in stainless steel
standard wheelchairs. It also allows weaker people to cabinets that are kept locked up [5].
push the device without problems up and down the stairs
at a maximum angle of 35° [3]. 4. PROBLEMS WITH STAIRS AND
2.4. Evacuation chair STAIRCASES IN FACILITIES IN THE
CITY OF NOVI SAD
A chair of this type is an evacuation device used to
transport people with disabilities down the stairs during On the basis of the previously processed technical
an emergency. It has a patented speed controller and solutions, an analysis was made of the institutions in Novi
braking system, so that a person with less physical Sad from the aspect of accessibility to people in
strength is able to easily evacuate a larger (heavier) wheelchairs, as well as technical solutions within
person as shown in fig.6 [5]. buildings.
The simplest solution is a wheelchair ramp. According to
new standards, the permitted angle of inclination of the
wheelchair ramp is 6%. [1]
Fig. 8 shows the approach to the Serbian National Theater
in Novi Sad where the situation is specific as it consists of
multiple stair partitions. Therefore, it is impossible to
think of a single stair elevator, so the possible solution is
a mobile stair climber.
Fig.6. Evacuation chair
3. COMMON PROBLEMS WITH

OPERATIONS OF SPECIALIZED
ELEVATORS FOR PEOPLE WITH
DISABILITIES
3.1. Door opening problems Fig.8. Ramp of big length at the Serbian National Theater
in Novi Sad and the usage of a stair climber
One of the biggest problem that occurs when installing
special elevators for people with disabilities is the
The problem at the Faculty of Technical Sciences in Novi
problem of doors. The point is that the rail, ie the elevator
guide must be installed along the entire route so that in Sad is not reflected in the entrance to the building, but
some parts it may pass by the door, which would interfere there is a problem in the Faculty corridor as well as in the
with entry and exit of the room. This problem is solved by teaching block.
sectioning the rail at the door area so that the part of the
rail can be lifted. This lifting and lowering is
accomplished manually or by remote control [4].
3.2. Controls and power supply
Controls and managing devices for elevators for people
with disabilities can be standard, mounted at the end of
handrails, or other devices such as a joystick may be used,
fig 7. These lifts can be operated by the user from his / her
position, or a trained person may be in charge of the
management process, who will do this with remote
controls.
Most elevators are supplied from the grid, with straight-
line elevators having battery power in the event of a
power failure. Elevators with curved routes have the
ability to be powered by rechargeable batteries, which are
charged at the beginning and end of the staircase.
Fig.9. Wide staircase in the Faculty of Technical Sciences
corridor
Fig. 9 shows very wide staircase located in the corridor,

where the platform would not cause any particular
problems to other staircase users. Considering the
staircase extension, it is possible to install a curved route
staircase elevator at this location, fig.10.
Fig.7. Control options
69
5. CONCLUSION
The paper deals with several devices that are used to

transport people with disabilities across stairs and
staircases. Classic vertical elevators can also be installed
for big height differences, but require larger construction
work, especially if they are subsequently installed in the
facility.
The disadvantage is the price. Staircase elevators are less
expensive and require less space during installation. They
can be sitting, standing or with a platform. Even cheaper
devices for the transportation of people with disabilities
are stair climbers that can be adapted for all types of stairs
Fig.10. Possible solution with the curved route staircase and staircases. The disadvantage of these devices is that
elevator people with disabilities are not independent, but need a
companion. It should be noted that all these devices can
On the other hand, due to sufficient space available, be used outside when approaching the building, but the
ramps were installed at the entrance to the Faculty of most economical solution, unless it is a large height
Technical Sciences main building, fig. 11, as well as at difference, is a ramp.
the entrance to the Mechanical Engineering Institute Designing elevators is a very demanding and responsible
building, fig. 12. job. Each elevator is designed according to general
principles and requirements. Very often, small changes
can significantly advance common practice. If the issues
of persons with disabilities are taken into account in the
planning phase, and if they are involved in the process of
defining a particular program, the costs of possible
adaptation would be avoided. At the same time, this
provides conditions for the implementation of the social
model of disability.
ACKNOWLEDGMENT
This paper has been supported by the Ministry of

Education, Science and Technological Development
through the project no. 451-03-68/2020-14/200156:
“Innovative scientific and artistic research from the FTS
(activity) domain”.
Fig.11. Ramp at the entrance to the Faculty of Technical
Sciences main building
REFERENCES
[1] Ernst N. (2000). Architectural design, Građevinska

knjiga, Beograd
[2] Kalaba B. (2003). Systematization and analysis of
elevators for people with disabilities, bachelor thesis,
FTN, Novi Sad
[3] Živanić D. (2019). Continuous and automated
transport, workbook, FTN, Novi Sad
[4] Šelendić B. (1982). Vertical, angled and horizontal
transport, Beograd
[5] Šostakov R. (1995). Transport devices, FTN, Novi
Sad
Fig.12. Ramp at the entrance to the Mechanical

Engineering Institute building
70
IN MEMORIAM: Prof. Dr. Eng. Kiril ARNAUDOV (1930 – 2020); Machine Design, Vol.12(2020) No.3, ISSN 1821-1259; E-ISSN 2406-0666
IN MEMORIAM Romania, Russia, Ukraine, and USA) and two expressly

translated works in the USSR, one of which is in his
dissertation (Express information "Details Machine” No.
42, 1973), cited over 20 times, as well as one translation in
India. There are also several patents in Bulgaria and one in
Germany.
Initiator, founder and first president (2001 - 2003) of the
Balkan Association of Power Transmissions, whose
honorary president he was elected in 2012. In addition to
several national meetings, he is the principal organizer of
7 scientific events - 1 national conference, 3 conferences
with international participation, 2 international
conferences and 1 international congress. He has been a
member of multiple programs (scientific) committees of
conferences abroad (Germany, the Balkan countries,
Russia, Ukraine), including many times as Vice-Chairman
of those conferences (Ukraine).
He is a representative of Bulgaria in the Gears Committees
of the international organizations ISO and IFToMM since
1987. He has represented Bulgaria at the Council for Mutual
Economic Assistance’s meetings on gears for 20 years. He
was involved as a foreign expert at the German Standards
Institute in the preparation of the German DIN standards. He
Prof. Dr. Eng. Kiril ARNAUDOV
is a member of the editorial board of the international journal
1930 - 2020
"Gearing and Transmissions", the Bulgarian journal
Prof. Dr. Eng. Kiril Arnaudov was born on May 25, 1930 "Mechanical Engineering" and Serbian journal "Machine
in Sofia, Bulgaria. Design". He has been invited to lecture in Germany,
He graduated from Mechanical and Electrical Engineering Technical University - Magdeburg (specialized course in
Institute - Sofia in 1953 as a mechanical engineer. He planetary gear trains) and in Ukraine, OPU - Odessa. In
received his PhD in Engineering from Dresden University recent years he has been sought by TU - Munich to solve
of Technology in 1968. He has a scientific background in specific scientific problems, incl. for the preparation of
gears and drive technology. patent litigation expertise and as a dissertation reviewer.
He began work as a technologist at the Plant 16 (1953- He has been the chairman of National Scientific and
1954), specializes then in Germany, working as a designer Technical Society "Gears and Power Transmissions" since
in Getriebewerke - Leipzig (1959) and ABUS - Dessau its inception in 1971. He is awarded the silver and gold
(1960, 1961). He was an Assistant and Associate professor badge of the Scientific Engineering Unions, the gold badge
(since 1969) at Higher Mechanical and Electrical "Prof. Assen Zlatarov", the award "Academician Angel
Engineering Institute - Sofia, finally an Associate Balevski", he is an honorary member of the Scientific
Professor and Professor (1992) at the Institute of Engineering Unions. He has participated in the Higher
Mechanics and Biomechanics of Bulgarian Academy of Attestation Committee and in a number of scientific,
Sciences, where he was head of a laboratory. technical and expert councils at the Technical University -
He has co-authored a textbook and a guide to Machine Sofia, Ministry of Mechanical Engineering, Council of
Elements, as well as six books on gears, including Ministers of the Republic of Bulgaria. For active
„Planetary gear trains“ (edition of BAS), translated and cooperation with our mechanical engineering sector
published in the USA (CRC Press, 2019); (participation in developments with a number of research
He is the author of BDS 17108-89 standard for the load organizations and factories) and the assistance provided, he
capacity calculation of gears, as well as the other basic was awarded the title of “Excellence of the Ministry of
standards for gears. He has presented papers at scientific Mechanical Engineering” in 1982. Nominated as
conferences and congresses in the following countries: Corresponding Member of Bulgarian Academy of
Australia, Bosnia and Herzegovina, China, Czech Sciences (2008).
Republic, France, Germany, Greece, Hungary, Japan, However, first of all, he was an excellent teacher and friend
Kazakhstan, Montenegro, North Macedonia, Poland, who was always able to advise willingly his colleagues and
Romania, Russia (USSR), Serbia, Ukraine, United students not only in the field of science.
Kingdom, and USA. He has over 100 citations to his works Prof. Kiril Arnaudov passed away peacefully on
abroad (Austria, China, Croatia, Germany, Hungary, 11.11.2020. He will be truly missed.

machine design, Vol.XX(20XX) No.X, ISSN 1821-1259 pp. XX-xx
DOI: 10.24867/MD.1X.20XX.X.XX-XX
xxxxx xxxxx
INSTRUCTIONS FOR THE PREPARATION OF THE FULL PAPER FOR THE JOURNAL
”MACHINE DESIGN”
Petar PETROVIC1, * - Szabo MIKLOS2 - Anna KRENCZYK3
1 University of Novi sad, Faculty of Technical Sciences, Novi Sad, Serbia
2 University of Miskolc, Faculty of Mechanical Engineering, Miskolc, Hungary
3 Silesian University of Technology, Dept. of Engineering Processes Automation and Integrated Manuf. Systems, Gliwice, Poland
Received (dd.mm.yyyy); Revised (dd.mm.yyyy); Accepted (dd.mm.yyyy)
Abstract: Instruction for the preparation of the camera ready papers for the journal MACHINE DESIGN is presented.
These pages provide You with an example of the layout and style, which we wish You to adopt during the preparation of
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*Correspondence Author’s Address: University of Novi Sad, Faculty of Technical Sciences, Trg Dositeja Obradovica 6, 21000 Novi
Sad, Serbia, ppetrovic@tu.ac.rs
Petar Petrovic, Szabo Miklos, Anna Krenczyk: Instructions for the Preparation of the Full Paper for the Journal ”Machine Design”;
Machine Design, Vol.XX(20XX) No.X, ISSN 1821-1259, E-ISSN 2406-0666; pp. XX-XX
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REFERENCES
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[1] Spotts, J., Blitzer, W. & Gingrich, T. (2007). Name of
clearly displayed by leaving single line of spacing above
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of-site Accessed: YYYY-MM-DD
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[3] Cohen, B., Milbank, A. & Romney, J. (2009). Title of
paper as JPEG or TIFF format (resolution at least 300
conference paper, Proceedings of xxx xxx, conference
dpi).
data, location, ISSN, ISBN, Randolph, B. (Ed.), pp.
11-19, Publisher, City
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edition) page numbers (first-last), ISSN
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In: Name of Book in Italics, Name(s) of Editor(s),
(Ed.), page numbers (first-last), Publisher, ISBN,
Place of publication
M2 [6] *** (2009) http://www.nastit.hu - The National
Statistics Institute, Statistics Year Book, Accessed
on: 2010-05-18
[7] *** (2005) TFOD machine & transmission trends
ISEP Redding Publishing Company Assembly, pg.68,
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UNIVERSITY OF NOVI SAD

FACULTY OF TECHNICAL SCIENCES

novi sad, 2020

technical preparation and cover design

Electronic version of journal available on

machine design is covered by the following indexes

CIP – Каталогизација у публикацији

MACHINE Design / editors Siniša Kuzmanović, Milan Rackov. - 2009- .-

Siniša Kuzmanović & Milan Rackov

2. Design Optimization and Manufacturing Issues of Blisters Obtained by the Thermoforming

4. Specialized Elevators for People with Disabilities

FORMING OF A SYSTEM OF EQUATIONS WHICH DESCRIBES THE DYNAMIC

Received (02.09.2020); Revised (10.11.2020); Accepted (12.11.2020)

1. INTRODUCTION material and large loads within inaccessible terrain i.e. to

Fig.1. Dynamic model of cable crane

2. EQUATIONS OF MOTION FORMING supporting rope on roller supports or equations of motion

2.2. Equations of motion of a supporting rope

System of partial differential equations can be solved if  2 w 

where, according to [11]:

t  t0 and F0  Q (13) Using Lagrange's equations of the second kind, the

Fig.5. Cable crane supporting structure model for the

Roller supports are, in addition to the forces Hd, also

The kinetic energy of the load amounts: B1  M 1 B2  k s1  0,5  c3 B3  kc1  0, 25  c3

The system of differential equations (17) describes the

x4h  K 41  sin 1 t  1   K 42  sin 2 t   2   K 43  sin 3 t   3   K 44  sin 4 t   4 

(28) inclusion of which in the first equation follows:

0  K11  sin 1  K13  sin  2  K13  sin  3  K14  sin  4  b1

DESIGN OPTIMIZATION AND MANUFACTURING ISSUES OF BLISTERS OBTAINED BY

Received (14.08.2020); Revised (20.10.2020); Accepted (22.10.2020)

1. INTRODUCTION used Geometrical Element Analysis (GEA) and found that

Fig.3. Detailed process schematic [6]: 1 – Plastic sheet;

The product takes the form of a mold or is shaped by its

Ways to overcome problems with intrusions are reflected

Fig.6. 3D view of the final iteration of inside of blister for

 Too small offset relative to the outer contours and

Printing was done by LPD (Layer Plastic Deposition)

 Blisters must be suitable for automation. All blisters

Fig.10. Information for printing

Fig.12. Automation machine for production of PCBA

 Grip for handling. There must be enough undercuts on

Fig.11. 3D print of blisters core

The same principle applies to molding (prototypes) using

related to DFM, or simply iterates the design in the

Fig.15. First iteration of blisters Poka- Yoke system

Fig.18. 3D view of final blister design

Fig.16. Final iteration of blisters Poka- Yoke system

 For trays, inlays or workpieces that are not

Fig.21. Real blister with printed circuit boards

showed an optimal solution that met both requirements in

Fig.22. Draft angles

The aforementioned image shows the appearance of the

[1] Karabeyoglu, S.; Ekşi, O. & Erdoğan, S. (2017). An

TOOTH CONTACT ANALYSIS OF ARCHIMEDEAN WORM GEAR DRIVES FOR THE

Received (20.07.2020); Revised (23.09.2020); Accepted (25.09.2020)

Key words: worm, worm-wheel, torque, TCA, CAD

1. INTRODUCTION 2. THE GEOMETRIC DESIGNING OF THE

*Correspondence Author’s Address: University of Debrecen, Faculty of Engineering, Debrecen, Hungary

c) z1=3, α=15.69° d) z1=4, α=20.62°

Fig.1. The geometric establishments of the designed

e) z1=5, α=24.96° f) z1=6, α=29.13°

Fig.2. The angle of worm wheel teeth (α) in the function

a) z1=1, α=5.26° b) z1=2, α=10.66°

Table 1. The geometric parameters of the designed gear pairs

The parameters of the worm gear drive