l19146 Xa02uen E1 Combined

MECHANICAL
DRIVES 1
HANDS-ON SKILLS FOR MODULE 2:
KEY FASTENERS
ITEMS NEEDED FOR HANDS-ON SKILLS
Amatrol Supplied
970-ME1 Mechanical Drives 1 Learning System
Amatrol or School Supplied

Micrometer, 0-1 inch Range
Dial Caliper
6-inch Rule
School Supplied
Bench Vise
Hacksaw
Files
Electrical Tape
FIRST EDITION, MODULE 2, REV. D

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol, Inc. All other brand and
product names are trademarks or registered trademarks of their respective companies.
Copyright © 2019, 2018 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic, optical, mechanical,
or magnetic, including but not limited to photographing, photocopying, recording or any information storage and retrieval system, without written permission
of the copyright owner.
Amatrol,Inc., 2400 Centennial Blvd., Jeffersonville, IN 47130 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com
L19146-XA02UEN-E1 REV. D KEY FASTENERS

Copyright © 2019 Amatrol, Inc.
SKILL 1 SELECT A KEY SIZE FOR A GIVEN APPLICATION
PROCEDURE OVERVIEW
In this procedure, you will be given various scenarios and challenged to select the size and type of key stock that
best fits the application. You will first be given an example. Then you will do it yourself.
1. Examine the following application information, and using the chart provided, select the type and size of key for the
application.
Given Information:
• Application: Shaft to coupling connection for a high force hydraulic system
• Shaft diameter: 0.500 inch
• Shaft keyseat length: 1.500 inch
• Hub keyway length: 1.000 inch
Find:
FEATURE SPECIFICATION
Key Type
Nominal Width
Nominal Height
Width Tolerance
Height Tolerance
Length
Key Material
NOMINAL SHAFT NOMINAL KEYSEAT

NOMINAL KEY SIZE
DIAMETER DEPTH
Height, H H/2
Over To (Incl.) Width, W
Square Rectangular Square Rectangular
5/16 7/16 3/32 3/32 .... 3/64 ....
7/16 9/16 1/8 1/8 3/32 1/16 3/64
9/16 7/8 3/16 3/16 1/8 3/32 1/16
7/8 1-1/4 1/4 1/4 3/16 1/8 3/32
1-1/4 1-3/4 5/16 5/16 1/4 5/32 1/8
1-3/8 2 3/8 3/8 1/4 3/16 1/8
1-3/4 2-1/4 1/2 1/2 3/8 3/16
2-1/4 2-3/4 5/8 5/8 7/16 5/16 7/32
2-3/4 3-1/4 3/4 3/4 1/2 3/8 1/4
3-1/4 3-3/4 7/8 7/8 5/8 7/16 5/16
3-3/4 4-1/2 1 1 3/4 1/2 3/8
4-1/2 5-1/2 1-1/4 1-1/4 7/8 5/8 7/16
5-1/2 6-1/2 1-11/2 1-1/2 1 3/4 1/2
6-1/2 7-1/2 3-3/4 1-3/4 1-1/2* 7/8 3/4
7-1/2 9 2 2 1-1/2 1 3/4
9 11 2-1/2 2-1/2 1-3/4 1-1/4 7/8
All dimensions are given in inches. For larger shaft sizes, see ANSI Standard.
Square keys preferred for shaft diameters above heavy line; rectangular keys, below.
* Some key standards show 1-1/4 inches; preferred height is 1-1/2 inches.
Figure 1-1. Key Size Versus Shaft Diameter
L19146-XA02UEN-E1-S01, REV. D KEY FASTENERS S01-1

KEY WIDTH SIDE FIT TOP AND BOTTOM FIT

Width Tolerance Depth Tolerance
To Key- Shaft Key- Hub Key-
Type of Key Over (Incl.) Key seat Fit Range* Key Seat Seat Fit Range*
Class I Fit for Parallel Keys
… 1/2 +0.000 +0.002 0.004 CL +0.000 +0.000 +0.010 0.032 CL
-0.002 -0.000 0.000 -0.002 -0.015 -0.000 0.005 CL
1/2 3/4 +0.000 +0.003 0.005 CL +0.000 +0.000 +0.010 0.032 CL
-0.002 -0.000 0.000 -0.002 -0.015 -0.000 0.005 CL
3/4 1 +0.000 +0.003 0.006 CL +0.000 +0.000 +0.010 0.033 CL
-0.003 -0.000 0.000 -0.003 -0.015 -0.000 0.005 CL
Square
1 1-1/2 +0.000 +0.004 0.007 CL +0.000 +0.000 +0.010 0.033 CL
-0.003 -0.000 0.000 -0.003 -0.015 -0.000 0.005 CL
1-1/2 2-1/2 +0.000 +0.004 0.008 CL +0.000 +0.000 +0.010 0.034 CL
-0.004 -0.000 0.000 -0.004 -0.0015 -0.000 0.005 CL
2-1/2 3-1/2 +0.000 +0.004 0.010 CL +0.000 +0.000 +0.010 0.036 CL
-0.006 -0.000 0.000 -0.006 -0.015 -0.000 0.005 CL
.... 1/2 +0.000 +0.002 0.005 CL +0.000 +0.000 +0.010 0.033 CL
-0.003 -0.000 0.000 -0.003 -0.015 -0.000 0.005 CL
1/2 3/4 +0.000 +0.003 0.006 CL +0.000 +0.000 +0.010 0.033 CL
-0.003 -0.000 0.000 -0.003 -0.015 -0.000 0.005 CL
3/4 1 +0.000 +0.003 0.007 CL +0.000 +0.000 +0.010 0.034 CL
-0.004 -0.000 0.000 -0.004 -0.015 -0.000 0.005 CL
1 1-1/2 +0.000 +0.004 0.008 CL +0.000 +0.000 +0.010 0.034 CL
-0.004 -0.000 0.000 -0.004 -0.015 -0.000 0.005 CL
Rectangular
1-1/2 3 +0.000 +0.004 0.009 CL +0.000 +0.000 +0.010 0.035 CL
-0.005 -0.000 0.000 -0.005 -0.015 -0.000 0.005 CL
3 4 +0.000 +0.004 0.010 CL +0.000 +0.000 +0.010 0.036 CL
-0.006 -0.000 0.000 -0.006 -0.015 -0.000 0.005 CL
4 6 +0.000 +0.004 0.012 CL +0.000 +0.000 +0.010 0.038 CL
-0.008 -0.000 0.000 -0.008 -0.015 -0.000 0.005 CL
6 7 +0.000 +0.004 0.017 CL +0.000 +0.000 +0.010 0.043 CL
-0.013 -0.000 0.000 -0.013 -0.015 -0.000 0.005 CL
All dimensions are given in inches.
* Limits of variation. CL = Clearance; INT = Interference
§ To (Incl.) 3-1/2 inch Square and 7-inch Rectangular key widths.
Figure 1-2. ANSI Standard Class 1 Fits for Parallel Keys
The solution is as follows:

The key type for most applications having a shaft diameter below 6-1/2 inches should be square.
Key Type: Square
The nominal key width and height can be determined by either checking the shaft keyseat width and depth or by
looking in the table of figure 1-1. Since the shaft keyseat size is not given, use the table. It shows that the width for
a key for a shaft size of between 7/16 and 9/16 inch should be 1/8 inch. It also shows that the height should be 1/8
inch as well. You know this because it is a square key.
Nominal Key Width: 1/8 inch
Nominal Key Height: 1/8 inch

The tolerance on the width and height can be determined from the table in figure 1-2. A key that has a width and
height of 1/8 inches has a width tolerance of +0.000, -0.002 inch and a height tolerance of +0.000, -0.002 inch.
Key Width Tolerance: +0.000, -0.002 inch
Key Height tolerance: +0.000,-0.002 inch

The length should be determined by the length of the keyseat in the shaft and the hub. The length of the key should
be at least as long as the length of the keyseat in the hub and slightly shorter than the keyseat in the shaft. Taking
the average of the shaft and hub keyseat length can determine an acceptable length. Therefore, a length of 1-1/4
inches is an acceptable length.
Length: 1-1/4 inches
The key material is determined from the application of the system. Because this key will be used to connect a shaft
and hub for a hydraulic system, high forces can be assumed. Therefore, a high-carbon steel key should be used.
Key Material: High-Carbon Steel
2. Use the chart from question 1 to select the size and type of key given the following information.
Given Information:
• Application:
Shaft to coupling connection for an ore crusher used in mining.
• Shaftdiameter: 8.5 inches
• Shaft keyseat length: 2.500 inches
• Hub keyway length: 2.250 inches
Find:
Key Type
Nominal Width
Nominal Height
Width Tolerance
Height Tolerance
Length
Key Material

In this case, the shaft size is above 6-1/2 inches, so you should use a rectangular key.
Key Type: Rectangular
The nominal key width and height can be determined by either checking the shaft keyseat width and depth or by
looking in the table of figure 1-1. Since the shaft keyseat size is not given, use the table. It shows that the width for
a key for a shaft size of between 7-1/2 and 9 inches should be 2 inches. It also shows that the height should be 1.5
inches.
Nominal Key Width: 2 inch
Nominal Key Height: 1.5 inch
The width and height tolerance are obtained from the table in figure 1-2. The width tolerance for a rectangular key
having a width between 1.5 and 3 inch is +0.000, -0.005 inch. The tolerance for the height (depth) is +0.000, -0.005
inch.
Width Tolerance: +0.000, -0.005 inch
Height Tolerance: +0.000, -0.005 inch
The length of the key should be longer than the length of the keyseat in the hub and shorter than the keyseat in the
shaft. Therefore, a length of 2.375 inches is selected.
Key Length: 2.375 inches
The material for the key should be high-carbon steel because this is a heavy duty application.
Key Material: High-Carbon Steel

Given Information:
• Application:
Shaft to gear connection (heavy duty)
• Shaftdiameter: 3.0 inch
• Shaft keyseat length: 2.125 inch
• Hub keyway length: 2.0 inch
Find:
Key Type
Nominal Width
Nominal Height
Width Tolerance
Height Tolerance
Length
Key Material

The key should be 3/4 inch square, having a width tolerance of +0.000, -0.002 inch, a height tolerance of +0.000,
-0.002 inch, and a length of about 2.0 inch. The key should be made from high-carbon steel.
Given Information:
• Application:
Shaft connected to a belt drive to operate an exhaust fan (light duty).
• Shaftdiameter: 5/8 inch
• Shaft keyseat length: 1.25 inches
• Hub keyway length: 1.0 inches
Find:
Key Type
Nominal Width
Nominal Height
Width Tolerance
Height Tolerance
Length
Key Material

The key should be 3/16 inch square, having a width tolerance of +0.000, -0.002 inch, a height tolerance of +0.000,
-0.002 inch, and a length of 1-1/8 inches. The key should be made from cold-rolled steel.

Given Information:
• Application:
Shaft coupled to a pump used to supply cooling fluid to a CNC Milling Machine (light duty).
• Shaftdiameter: 3/8 inch
• Shaft keyseat length: 1 inch
• Hub keyway length: 3/4 inch
Find:
Key Type
Nominal Width
Nominal Height
Width Tolerance
Height Tolerance
Length
Key Material

The key should be 3/32 square, having a width tolerance of +0.000, -0.002 inch, a height tolerance of +0.000, -0.002
inch, and a length of 7/8 inch. The key should be made from cold-rolled steel.

SKILL 2 MEASURE THE ACTUAL SIZE OF A KEY AND KEYSEAT GIVEN A SAMPLE
PROCEDURE OVERVIEW
In this procedure, you will measure the size of a key and keyseat. You will then compare your measurements to the
specifications for the key and keyseat to determine if they are in tolerance.
1. Obtain the following items from the tool crib.

• Drum Brake Hub
• Motor
• Dial Caliper
• 6-inch Rule
2. Perform the following substeps to measure the width, depth, and length of the keyseat on the motor shaft.
A. Use the inside jaws of the dial caliper to measure the width of the keyseat in the shaft, as shown in figure 2-1.
Shaft Keyseat Width: ___________________________________________________________________ (inch)

The width of the keyseat should be approximately 3/16-inch (0.187 inch).
WIDTH
Figure 2-1. Measuring the Width of the Keyseat in the Shaft

B. Use the depth gauge of the dial caliper to measure the depth of the shaft keyseat, as shown in figure 2-2.
The distance that the depth gauge of the caliper extends into the keyseat is the same as the opening of the jaws.
This is also shown in figure 2-2.
Shaft Keyseat Depth: ___________________________________________________________________ (inch)

The depth of the keyseat should be approximately 3/32-inch (0.094 inch).
OPENING=TO
DEPTH GAUGE
EXTENSION
DEPTH
GAUGE
DEPTH=TO
JAW OPENING
Figure 2-2. Measuring the Depth of the Keyseat in the Shaft
C. Use a 6-inch rule to measure the usable length of the keyseat in the shaft, as shown in figure 2-3.
NOTE
Keyseats often have an arc on the back end. This arc is created by the tool that is used to cut the keyseat into the
shaft. The arc is not considered part of the usable length. The measurement should be made up to the point where
the arc begins.
START ARC
OF ARC
6
USABLE
5
LENGTH
4
3
2
1
in.
Figure 2-3. The Usable Length of the Keyseat
Shaft Keyseat Length: ________________________________________________________________ (inches)

The length of the keyseat should be approximately 2-1/8-inches.

3. Perform the following substeps to determine the width, depth, and length of the keyway in the brake drum hub.
A. Use the inside jaws of the dial caliper to measure the width of the keyway in the brake drum hub, as shown in figure
2-4.
Brake Drum Hub Keyway Width: __________________________________________________________ (inch)

The width of the keyway should be approximately 3/16-inch (0.187 inch).
BRAKE DRUM HUB
KEYWAY WIDTH
Figure 2-4. Measurement of Keyway Width

B. Use the dial caliper to measure the thickness of the hub wall, as shown in figure 2-5.
Hub Wall Thickness: ____________________________________________________________________ (inch)
BRAKE DRUM HUB
HUB WALL THICKNESS
Figure 2-5. Measurement of Hub Wall Thickness

C. Use the dial caliper to measure the thickness from the outside of the hub wall to the bottom of the keyway, as
shown in figure 2-6.
Hub Wall to Keyway: _________________________________________________________________ (inches)
BOTTOM
OF KEYWAY
THICKNESS
TO MEASURE
Figure 2-6. Measurement from the Outside of the Hub Wall to the Bottom of the Keyway
D. Calculate the depth of the hub’s keyway by subtracting the Hub Wall to Keyway measurement from the Hub Wall
Thickness measurement.
Hub Keyway Depth = ___________________________________________________________________ (inch)

The depth of the keyway should be 3/32-inch (0.094 inch).
E. Use a 6-inch rule to measure the length of the keyway in the hub.
Shaft Keyway Length: ________________________________________________________________ (inches)

The length of the keyway is approximately 1-1/2 inches.

4. Perform the following substeps to select the nominal size for a key.
A. Select the nominal width of the key.
The width should be the same width as the keyway width in the motor shaft and brake drum hub. keyway
Key Width: ___________________________________________________________________________ (inch)

The key width is 3/16-inch.
B. Select the nominal height of the key.
The height of the key is determined by adding the depth of the shaft keyway to the depth of the hub keyway.
Key Height: ___________________________________________________________________________ (inch)

This is a 3/16-inch square key. Therefore, the height is 3/16-inch.
C. Determine the length of the key.
The length of the key should be at least as long as the keyway in the hub and slightly shorter than the length of the
keyway in the shaft.
Key Length: ________________________________________________________________________ (inches)

The key length should be at least 1-1/2 inches.

SKILL 3 CUT AND FILE KEY STOCK TO FIT A KEYSEAT
PROCEDURE OVERVIEW
In this procedure, you will learn how to cut key stock to the correct length and then use a file to prepare the key for
assembly into a keyseat.
1. You will need the following items:

• 3/16-inch square key stock
• Hacksaw
• Flat File- Single Cut, Smooth
• Bench Vise with Soft Jaw Caps
• 0-1 inch Micrometer
• 6-inch Rule
2. Using the micrometer, measure the width and thickness of the square key stock to verify that it is 3/16-inch key stock.
Key Stock Width: _________________________________________________________________________ (inch)
Key Stock Height: ________________________________________________________________________ (inch)

3. Use the 6-inch rule to measure 1 inch of the key stock, as shown in figure 3-1. Use a pencil to mark this measurement.
Figure 3-1. Measuring 1 Inch of Key Stock

4. Perform the following substeps to cut the key stock to the required length.
A. Place the key stock in the bench vise, as shown in figure 3-2.
NOTE
Make sure that the soft jaw caps are in place to avoid marring the surface of the key stock.
KEY STOCK
BENCH
VISE
SOFT JAW CAPS
Figure 3-2. Key Stock Placed in the Bench Vise
B. Use the hacksaw to cut off the 1-1/2 inches of required key stock.
C. Remove the keystock from the bench vise and return it to stock.
D. Retain the 1-1/2-inch piece for the next step.
5. Perform the following substeps to prepare the key for use.
A. Place the 1-1/2-inch key in the vise, as shown in figure 3-3.
KEY
BENCH
VISE
Figure 3-3. Key Placed in the Bench vise
B. Use the flat file to deburr the area where the cut was made.

C. Use the flat file to lightly chamfer the edges of the key, as shown in figure 3-4.
You will need to turn the key over to chamfer both sides of the key. The key is ready for assembly at this time.
WARNING
Chamfering means to only remove the sharp corners from the key. Do not round off the edges of the key. This will
reduce the holding power of the key and create a potential hazard.
SHARP CORNER CHAMFERED EDGE

(4 PLACES) (4 PLACES)
KEY KEY
Figure 3-4. Chamfering the Edges of the Key
6. Return all tools to the tool crib. The key you made will be used in the next skill.

SKILL 4 ASSEMBLE A HUB TO A SHAFT USING A KEY FASTENER
PROCEDURE OVERVIEW
In this procedure, you will assemble a hub called a prony brake drum onto the motor shaft, which the prony brake
uses to load the motor. This will teach you the basic steps of assembling a key fastener. You will apply this process
later by assembling other types of hubs, including those used in couplings.
1. Perform the following dress and PPE safety check to prepare for working with industrial equipment. Make sure that
you are able to answer yes to each item before proceeding.
YES/NO SAFETY CHECKOUT

Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put in a cap or under shirt
Wearing short sleeves or long sleeves are rolled up
Gloves are not being worn
Floor is not wet
Wearing heavy duty shoes (Instructor Option)
Wearing hearing protection (Instructor Option)
2. Perform a lockout/tagout on the Motor Control Console’s Main Power switch, if not already in place.
3. Perform the following substeps to mount and level the motor.
A. Locate the motor and place it on the work surface.
B. Select four aluminum motor risers (1-1/2-inch diameter by 1-1/4-inch long) from the 970-ME1 molded trays. The
aluminum motor risers are shown in figure 4-1.
Figure 4-1. Aluminum Motor Risers

C. Make sure that the motor base, risers, and mounting area of the work surface shown in figure 4-2 are free of dirt,
rust, and burrs.
D. Position the motor over the set of holes on the 970-ME1 work surface, as shown in figure 4-2.
The outlines of the other components to be mounted are also shown.
MOTOR
RISERS
PRONY (4 TYP)
BRAKE
DRUM
MOTOR
Figure 4-2. Location of Components on 970-ME1 Work Surface (Cord Not Shown for Clarity)
E. Place one motor riser under each of the motor feet.

F. Locate four bolts with the specifications 5/16 - 18 UNC - 2A × 2-3/4 hex head, along with compatible flat washers,
lock washers, and nuts.
G. Fasten the motor and risers to the work surface by assembling bolts, washers, and nuts.
Use a crisscross pattern to tighten the bolts.

H. Place the motor power cord through the hole in the mounting surface, as shown in figure 4-3.
MOTOR
MOTOR
WORK POWER
SURFACE CORD
HOLE
Figure 4-3. Motor Cord
I. Check the shaft for run-out. Record below the amount of run-out.
Run-Out: _____________________________________________________________________________ (inch)
The run-out should be less than 0.002 inch.
J. Check for motor shaft end float.
End Float ____________________________________________________________________________ (inch)

It should be less than 0.002 inch.
K. Check the level of the motor shaft. Shim the motor feet as needed.
Feeler Gauge Leaf Thickness _____________________________________________________________ (inch)
Effective Level Length _________________________________________________________________ (inches)
Mounting Bolt Distance ________________________________________________________________ (inches)
Shim Ratio _______________________________________________________________________________
Shim Thickness ________________________________________________________________________ (inch)

4. Locate the components for the prony brake in the 970-ME1 molded trays, as shown in figure 4-4.
This unit consists of a brake drum, tensioner belt, prony brake tensioner with a clevis and a cotter pin, and a small
retaining pin. Also locate the water bottle that is in the storage box. The bottle is used to spray water into the drum to
keep it cool while the unit is loaded. The brake drum attaches to the shaft of the motor in this skill.
NOTE
Only the brake drum is assembled in this skill. The other prony brake components shown in the figure will be
assembled in the next skill. The next skill will include detailed instructions on how to complete the prony brake
assembly.
BRAKE
DRUM
WATER
TENSIONER BOTTLE
BELT
PRONY BRAKE
TENSIONER RETAINING PIN
Figure 4-4. Components of Amatrol’s Prony Brake

5. Perform the following substeps to assemble the prony brake drum to the shaft of the motor using a key fastener.
WARNING
Your instructor must be present for the completion of this skill. This is because you will be using the key you made
in an earlier skill. The instructor must be satisfied that the key fits correctly into this application before the motor
can be started.
A. Locate the cap screws that hold together the two halves of the brake drum hub, as shown in figure 4-5.
Note that these are not setscrews. These screws clamp the two sections of the brake drum together against the
key fastener on the shaft to hold the drum hub in place.
CAP SCREWS
Figure 4-5. Cap Screws on Hub
B. Use a hex key wrench to back out the cap screws so the two halves of the drum hub can be separated enough for
the hub assembly to slide over the motor shaft and key.
C. Clean the shaft keyseat and the hub keyway with a wire brush to make sure that no dirt or burrs are in them.
D. Obtain the 3/16 square key you made in the last skill.

E. Slide the key into the keyway of the prony brake hub.
The key should fit into the keyway without forcing it. If it is too tight, take it out and measure it to see which part is
out of tolerance. Select a correct sized key from the toolbox and continue.
If an appropriately sized key is not available, repeat Skill 3 to prepare a properly sized key.
F. Check the key for play when it is in the keyseat by wiggling it.
There should be no play. If there is play, replace the key.
G. Remove the key from the prony brake hub keyway and insert it into the motor shaft keyseat. Line it up flush with
the end of the shaft, as shown in figure 4-6.
It also should slide in without forcing it and have no play.
KEY
Figure 4-6. Key Positioned on Motor Shaft
H. Pick up the brake drum in your hand and line it up in front of the shaft so that the drum’s keyway is in line with the
key on the shaft.

I. Slide the drum onto the shaft, as shown in figure 4-7.

The drum should slide on without using tools. If it doesn’t, pull it off and check the dimensions.
NOTE
You may have to hold the key in place as you do this to prevent it from sliding out of the motor shaft keyseat.
GAP BETWEEN SECTIONS OF

PRONY BRAKE DRUM
Figure 4-7. Drum Installed on Shaft
J. Tighten the cap screws with the hex head wrench evenly so that the key is compressed between the drum hub and
the motor shaft.
K. Verify that the gap between the two sections of the prony brake drum, as shown in figure 4-7, appears equal on
both sides of the drum hub.
If the gap is not even, loosen the cap screws on the side with the smaller gap and tighten the cap screws on the
other side.
7. Pull on the drum to see if the drum is securely fastened to the shaft.
If it is not securely fastened, repeat substeps 6I through 6K.
8. Leave the motor and hub set up. In the next skill, you will use this setup.

SKILL 5 USE A PRONY BRAKE TO MEASURE SHAFT TORQUE
PROCEDURE OVERVIEW
In this procedure, you will attach the prony brake to the electric motor and use it to load the motor. This will allow
you to measure the speed of the motor as its load is increased.
This prony brake will be used in other skills to demonstrate that the torque output changes as the power transmits
through various types of mechanical drives. Also, it will allow you to show the power efficiency of mechanical drives.
This is simply an exercise to reinforce your ability to measure motor speed. However, you will also learn how AC
motors react to load changes.

Floor is not wet
2. Perform a lockout/tagout on the Motor Control Console’s Main Power switch, if not already in place.
3. If you are continuing from the previous skill, proceed directly to step 4. If not, repeat all steps in Skill 4 to set up the
motor, level the work surface and the motor, and attach the brake drum to the motor using the square key. When
complete, your setup should appear as shown in figure 5-1.
Figure 5-1. Setup from Skill 4

4. Perform the following substeps to mount the prony brake to the work surface and to connect it to the motor.
The work surface has a slot on one side of the motor through which the small eye of the tensioner belt is fed. The other
side has holes to install the tensioner.
A. Locate the prony brake tensioner belt and retaining pin in the molded tray.
B. Slide the tensioner belt’s small eye into the slot of the work surface.
C. On the underside of the work surface, slide the 1/8" small retainer pin through the belt’s eye, as shown in figure
5-2.
This will hold the belt on one side.
1/8"
SLOT RETAINER
PIN
IN
IDE
SL
BELT’S
SMALL
EYE
Figure 5-2. Small Retainer Pin Through Belts Eye (Viewed from Underside of Work
Surface)

D. Pull the belt up into the counter bore.

E. Pull the belt tight.
F. Drape the belt over the prony brake drum.
G. Feed the brake drum belt tensioner up through the matching holes in the work surface, as shown in figure 5-3.
H. Line up the holes in the eyes of the belt with the holes in the belt tensioner.
I. Insert the clevis pin through the eye of the belt to hold the belt in place.
J. Place the cotter pin through the hole in the clevis pin to secure the clevis pin. The prony brake tensioner setup
should now look like figure 5-3.
COTTER
PIN
CLEVIS
PIN
HOLES FOR BELT

TENSIONER
Figure 5-3. Connecting Belt to Belt Tensioner

K. Loosen the adjustment knob on bottom of the prony brake tensioner by turning it clockwise. This is the zero force
setting for the tensioner. Continue loosening until it stops.
CW CCW
(LOOSEN) (TIGHTEN)
Figure 5-4. Adjustment Knob on Prony Brake (Viewed from Side of Work Surface)
L. Verify that the prony brake and motor assembly are positioned on the work surface, as shown in figure 5-5.
PRONY
BRAKE
DRUM
MOTOR
Figure 5-5. Location of Prony Brake and Motor

M. Make sure that the tensioner belt rests on top of the drum, as shown in figure 5-6.
Figure 5-6. Tensioner Belt Positioned on Top of Brake Hub
N. Make sure the prony brake tensioner belt wraps evenly around the brake drum.
If the prony brake tensioner belt is not wrapped evenly around the brake drum, loosen the fasteners of the motor
mount. Adjust the position of the motor until the prony brake belt runs parallel with the edge of the brake drum hub,
as figure 5-7 shows.
BELT PARALLEL MOTOR MOUNTING

WITH EDGE OF FASTENERS
BRAKE DRUM
Figure 5-7. Brake Belt Parallel with Edge of Brake Drum Hub
O. Retighten the motor mounting bolts.

5. Fill the brake drum with water using the water bottle so that the water level is about 1/4-inch from the lip, as shown in
figure 5-8.
6. Attach a piece of black electrical tape on the side of the brake drum, as is also shown in figure 5-8. Attach a small
piece of reflective tape on top of the black electrical tape.
PUT TAPE
HERE
1/4-inch MOTOR
WATER LEVEL SHAFT
Figure 5-8. Brake Drum Water Level and Reflective Tape Location (Belt Not Shown for Clarity)
7. Perform the following substeps to install the mechanical system’s guards.
WARNING
Do not operate the mechanical drive system without the guards in place. Also, do not attempt to open or bypass
the guard at any time during operation. Performing any of these actions will create a hazardous situation.
A. Locate both halves of the guard, shown in figure 5-9. Notice the location of the interlock switch tongue on each half.
INTERLOCK SWITCH
TONGUE
INTERLOCK SWITCH
TONGUE
Figure 5-9. Mechanical System’s Guard

B. Place each guard half on the work surface so that the pins fit into the notches along the edge of the surface, as
shown in figure 5-10.
MECHANICAL GUARD HALVES
WORK SURFACE PINS IN NOTCHES ON WORK SURFACE

WORK SURFACE EDGE
Figure 5-10. Guard Halves on Work Surface

C. Slide the guard halves together so that the pins enter the slots on the bottom side of the work surface, as shown
in figure 5-11.
MECHANICAL GUARD HALVES
WORK SURFACE PINS INSIDE WORK WORK SURFACE

SURFACE SLOTS
Figure 5-11. Guard Halves Slid Together
D. Verify the interlock tongues slide into the safety switch heads, as shown in figure 5-12.
INTERLOCK TONGUE SAFETY SWITCH HEAD
Figure 5-12. Interlock Tongue Into Safety Switch Head
E. With both guards in place, the circuit can now be operated.

8. Perform the following substeps to start the motor.

A. Clear all tools and loose components from the work area and put them in their proper storage location.
B. Connect the motor’s power cord to the Motor connector on the back of the 970-ME1 Control Console. Use the
metal retainer clip to secure the cord.
C. Verify the guard interlock cord is connected to the Guard Interlock connector on the back of the 970-ME1 Control
Console. Verify the fastener is screwed fully CW to secure the cord.
D. Make sure that the 970-ME1’s power cord is plugged into the AC IN connector.
E. Plug the other end of the 970-ME1’s power cord into the wall outlet.
F. Make sure the Constant Speed/Variable Speed switch is in the Variable Speed position.
G. Verify that the guard is in place.
WARNING
Do not attempt to operate the mechanical drive system without the guard in place. Also, do not attempt to open or
bypass the guard at any time during operation. Performing any of these actions will create a hazardous situation.
H. Remove the lockout/tagout.

I. Turn on the Main Power switch.
The Main Power Indicator on the 970-ME1 should illuminate.
J. Make sure that no one is near the motor.
K. Turn on the motor power by pressing the Power On pushbutton.
The Power On pushbutton should illuminate.
L. Verify that the VFD’s adjustment knob is set to zero (fully CCW).
M. Press the green Start pushbutton.
N. Slowly rotate the adjustment knob to 50% (30 Hz).
A setting of 50% should cause the motor to operate at 50% of its nameplate rating, which is 1650 rpm.

9. Perform the following substeps to measure the motor speed at various load settings.
A. Observe the reading on the prony brake scale, shown in figure 5-13.
ZERO FORCE
READING
Figure 5-13. Zero Reading on the Prony Brake Scale
It should be zero. If not, turn the prony brake’s adjustment knob fully clockwise until it stops.
B. Measure the speed of the motor using the tachometer. Record your reading in column 2, row 1. This is the unloaded
speed of the motor. It should be approximately 825 rpm.
SCALE READING SPEED TORQUE

(pounds) (rpm) (inch - pounds)
0
1
2
3
4
5
C. While the motor is running, increase the load on the prony brake to 2 pounds by turning the adjustment knob
counterclockwise until the scale reads 2 pounds.
D. Measure the speed of the motor at this load setting. Record it in column 2, row 2 of the table.
E. Repeat substeps C and D for each of the other load settings in the table.
As you increase the load on the motor, you should notice that the motor slows down a bit. The VFD will remove
power to the motor when the current gets too high.
F. Reduce the load on the motor to zero by turning the adjustment knob on the prony brake clockwise until the scale
reads zero.
G. Turn the speed adjustment knob on the VFD fully CCW to 0%.
The motor should slow to a stop.
10. Press the red STOP pushbutton to turn off the power to the motor.
11. Turn off the Main Power switch and perform a lockout/tagout.
12. Calculate the torque (in units of in-lb) delivered by the motor for each load setting in the table of step 9. Torque is
calculated by multiplying the force applied by the radius (T = f × r).
The radius of the prony brake is approximately 1.5-inches. Multiply the force by the radius to determine torque. Record
your calculations in column 3 of the table.
You should notice that as speed decreases, torque increases.
13. Leave the setup in place. You will use this setup in the last skill of this Module.

SKILL 6 CALCULATE ROTARY MECHANICAL POWER
PROCEDURE OVERVIEW
In this procedure, you will calculate the power output of various power transmissions based on given information.
1. Calculate the power delivered by a belt drive system shown in figure 6-1.
The formula for rotary power in Hp (Pout) is Driven Torque (T)  Driven Speed divided by 5252.
Pout = ___________________________________________________________________________________ (Hp)
TORQUE = 50 ft - lbs
SPEED = 1200 rpm
TORQUE = 25 ft - lbs
SPEED = 2400 rpm
DRIVER
DRIVEN
Figure 6-1. Belt Drive System
T ×S
Pout =
5252
50 × 1200
Pout =
5252
60000
Pout =
5252
Pout = 11.42 Hp

2. Calculate the power delivered by the gear drive system shown in figure 6-2.
Pout = ___________________________________________________________________________________ (Hp)
INPUT
GEAR
TORQUE OUT = 22 ft - lbs

SPEED OUT = 550 rpm
Figure 6-2. Gear Drive System
It should be approximately 2.30 Hp.

3. Calculate the power delivered by the motor given the information shown in figure 6-3.
Pout = ___________________________________________________________________________________ (Hp)

It should be approximately 9.52 Hp.
SPEED OUT = 150 rpm
SPEED IN = 400 rpm
R1 R2
WHEEL F = 1000 lbs.

R1 = 1.5 in
R 2 = 4 in INPUT OUTPUT
GEAR GEAR
Figure 6-3. Gear Drive System

4. Calculate the power in Hp at a gear shaft given the following information.

You will first need to calculate the torque.
Force = 0.84 lb
Radius Distance = 3.94 ft
Speed = 1200 rpm
Pout = ___________________________________________________________________________________ (Hp)
The solution is 0.76 Hp.

5. Calculate the maximum torque that can be generated by a motor given the following information. Show all calculations
on the data sheet. Round off to the nearest 0.1 ft-lb.
Speed = 1140 rpm

Pout = 0.33 Hp
Maximum Torque = _______________________________________________________________________ (ft-lb)
The solution is 1.5 ft-lb.

6. Calculate the maximum speed of a motor based on the following information. Show all calculations on the data sheet.
Round off to the nearest rpm.
Maximum Torque = 425 ft-lb.

Pout = 100 Hp
Maximum Speed = ________________________________________________________________________ (rpm)
The solution is 1236 rpm.

7. Solve the following design problem:
Select the best small DC motor from the table based on the following information. Choose the rating closest to your
calculated value. However, be careful not to undersize your selection.
Torque required = 0.92 ft-lb
Speed required = 1200 rpm
STANDARD POWER RATINGS FOR SMALL DC MOTORS

Hp 1/20 1/12 1/8 1/6 1/4 1/3 1/2 3/4 1
Calculated Power = ________________________________________________________________________ (Hp)
Selected Motor’s Power = ___________________________________________________________________ (Hp)
The solution is 0.21 Hp, 0.25 Hp.

SKILL 7 CALCULATE MECHANICAL EFFICIENCY
PROCEDURE OVERVIEW
In this procedure, you will calculate the mechanical efficiency of a number of power transmissions.
1. Calculate the efficiency of the gear train shown in figure 7-1 given the following information.
Horsepower of Motor = 20 Hp
Horsepower of Gearbox Output shaft = 17 Hp
Efficiency = ______________________________________________________________________________ (%)
Figure 7-1. Efficiency of a Gearbox Connected to a Motor Shaft
The solution is 85%.

SKILL 7 CALCULATE MECHANICAL EFFICIENCY
2. Calculate the efficiency of the belt drive system shown in figure 7-2 given the following information.
Motor Power = 4 Hp
Output Shaft Speed = 3500 rpm
Output Shaft Torque = 54 in-lb
Efficiency = ______________________________________________________________________________ (%)
Figure 7-2. Efficiency of a Pulley System Connected to a Motor Shaft

3. Calculate the efficiency of the chain drive shown in figure 7-3 given the following information.
Motor Shaft Speed = 1750 rpm Motor Shaft Torque = 12 in-lb

Output Shaft Speed = 875 rpm Output Shaft Torque = 18 in-lb
Efficiency = ______________________________________________________________________________ (%)
Figure 7-3. Efficiency of a Chain Drive Connected to a Motor Shaft

SKILL 8 MEASURE ELECTRIC MOTOR CURRENT
PROCEDURE OVERVIEW
In this procedure, you will use the current display of the VFD to measure the current to the motor as load is applied
using the prony brake.
1. Verify that the motor and prony brake are set up as they were in Skill 5.
If the setup has been disassembled, return to Skill 5 to reassemble the setup.

Floor is not wet
3. Add water to the brake drum if necessary.

The water level should be about 1/4-inch below the lip of the drum opening. Do not let the drum run dry.
WARNING
Do not operate the mechanical drive system without the guard in place. Also, do not attempt to open or bypass the
guard at any time during operation. Performing any of these actions will create a hazardous situation.
4. Reinstall the guard.

5. Remove the lockout/tagout.
6. Perform the following substeps to start the motor.
A. Observe the reading on the prony brake.
It should be zero. If not, turn the prony brake’s load nut clockwise until the scale reads zero.
B. Press the Power On pushbutton.
C. Verify the mode switch is switched to Variable Speed and press the green START pushbutton to turn on the motor.
D. Rotate the VFD’s adjustment knob fully CW.

7. With the motor running at zero load, press and release the DISPL button repeatedly until the reading has units of
Amperes. An “A” appears on the VFD display, as shown in figure 8-1, when current is displayed. Record the current
reading on the VFD Display in row 1 of the table below. Use the tachometer to measure and record the motor speed.
SCALE READING CURRENT SPEED

(pounds) (Amps) (rpm)
0
2
4
6
8
10
12
VFD DISPLAY
AMPERE
CURRENT
READING
DISPL
BUTTON
Figure 8-1. Sample Current Reading on VFD Display

8. Rotate the knob on the prony brake tensioner to set the load on the prony brake to 2 pounds.
CAUTION
Remember to check the water in the brake drum frequently and add water as needed.
The VFD display’s ammeter should display the current in amps being drawn by the motor.
Record the current reading and speed in row 2 of the table of Step 7.
9. Measure and record the current drawn by the motor and speed for each of the other loads specified in the table.
10. Does the current increase as the load on the motor is increased?
Current Increase: ______________________________________________________________________ (Yes/No)
You should observe that current increases. This proves that current input can be used as a monitor of motor load. In
later skills, you will use this ability to monitor the effects of your adjustments.
11. Release all load on the motor by turning the prony brake’s adjustment knob fully clockwise.
12. Turn the speed adjustment knob on the VFD fully CCW to 0% and press the red STOP pushbutton to stop the motor.
WARNING
The heavy loads and high speeds applied to the brake drum cause it to get very hot. Avoid touching any part of the
motor and brake drum assembly until they have had ample time to cool off.
13. Turn off the Main Power switch.

14. Perform a lockout/tagout.
15. Remove the guard.
16. Disconnect the motor cable from the Motor Control Console.
17. Disassemble the components and store them.
18. Replace the guard.
19. Remove the lockout/tagout.


l19146 Xa02uen E1 Combined

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

l19146 Xa02uen E1 Combined

Uploaded by

Copyright:

Available Formats

MECHANICAL

ITEMS NEEDED FOR HANDS-ON SKILLS

Amatrol or School Supplied

FIRST EDITION, MODULE 2, REV. D

L19146-XA02UEN-E1 REV. D KEY FASTENERS

NOMINAL SHAFT NOMINAL KEYSEAT

L19146-XA02UEN-E1-S01, REV. D KEY FASTENERS S01-1

KEY WIDTH SIDE FIT TOP AND BOTTOM FIT

Figure 1-2. ANSI Standard Class 1 Fits for Parallel Keys

The solution is as follows:

Nominal Key Width: 1/8 inch

Nominal Key Height: 1/8 inch

L19146-XA02UEN-E1-S01, REV. D KEY FASTENERS S01-2

The solution is as follows:

L19146-XA02UEN-E1-S01, REV. D KEY FASTENERS S01-3

The solution is as follows:

The solution is as follows:

L19146-XA02UEN-E1-S01, REV. D KEY FASTENERS S01-4

The solution is as follows:

L19146-XA02UEN-E1-S01, REV. D KEY FASTENERS S01-5

1. Obtain the following items from the tool crib.

Shaft Keyseat Width: ___________________________________________________________________ (inch)

Figure 2-1. Measuring the Width of the Keyseat in the Shaft

L19146-XA02UEN-E1-S02, REV. D KEY FASTENERS S02-1

Shaft Keyseat Depth: ___________________________________________________________________ (inch)

Figure 2-2. Measuring the Depth of the Keyseat in the Shaft

Figure 2-3. The Usable Length of the Keyseat

Shaft Keyseat Length: ________________________________________________________________ (inches)

L19146-XA02UEN-E1-S02, REV. D KEY FASTENERS S02-2

Brake Drum Hub Keyway Width: __________________________________________________________ (inch)

BRAKE DRUM HUB

Figure 2-4. Measurement of Keyway Width

L19146-XA02UEN-E1-S02, REV. D KEY FASTENERS S02-3

Hub Wall Thickness: ____________________________________________________________________ (inch)

BRAKE DRUM HUB

HUB WALL THICKNESS

Figure 2-5. Measurement of Hub Wall Thickness

L19146-XA02UEN-E1-S02, REV. D KEY FASTENERS S02-4

Hub Wall to Keyway: _________________________________________________________________ (inches)

Hub Keyway Depth = ___________________________________________________________________ (inch)

Shaft Keyway Length: ________________________________________________________________ (inches)

L19146-XA02UEN-E1-S02, REV. D KEY FASTENERS S02-5

Key Width: ___________________________________________________________________________ (inch)

Key Height: ___________________________________________________________________________ (inch)

Key Length: ________________________________________________________________________ (inches)

L19146-XA02UEN-E1-S02, REV. D KEY FASTENERS S02-6

1. You will need the following items:

Key Stock Width: _________________________________________________________________________ (inch)

Key Stock Height: ________________________________________________________________________ (inch)

Figure 3-1. Measuring 1 Inch of Key Stock

L19146-XA02UEN-E1-S03, REV. D KEY FASTENERS S03-1

SOFT JAW CAPS

Figure 3-2. Key Stock Placed in the Bench Vise

Figure 3-3. Key Placed in the Bench vise

L19146-XA02UEN-E1-S03, REV. D KEY FASTENERS S03-2

SHARP CORNER CHAMFERED EDGE

Figure 3-4. Chamfering the Edges of the Key

L19146-XA02UEN-E1-S03, REV. D KEY FASTENERS S03-3

YES/NO SAFETY CHECKOUT

Figure 4-1. Aluminum Motor Risers

L19146-XA02UEN-E1-S04, REV. D KEY FASTENERS S04-1

E. Place one motor riser under each of the motor feet.