Interesting Machines-2 Orrery

What is an Orrery?

Simply put, an Orrery is a functional mechanical model of the solar system. But the definition is the only simple part of this beautiful mechanical system.

Image Source: Wiki

Antikythera Mechanism

Image Source: Wiki

Robert Brettell Bate, circa 1812. Now in Thinktank, Birmingham Science Museum.

Image Source: Wiki

A 1766 Benjamin Martin Orrery, used at Harvard

History

The Antikythera mechanism, which is dated to ca. 150 – 100 BCE, may be considered the first orrery that is still in existence. Discovered in the wreck of a ship in 1900 off the Greek island of Antikythera (hence the name), this device consisted of hand-driven mechanisms that represented the diurnal motions of the Sun, the Moon, and the then-known five known planets (Mercury, Venus, Earth, Mars, Jupiter).

During the 16th century, two astronomical clocks were built for the court of William IV, Langrave of Hesse-Kassel (in modern day Bavaria, Germany). These showed the motions of the Sun, Moon, Mercury, Venus, Mars, Jupiter and Saturn based on the Ptolemaic system.  These clocks are now on display at the Museum of Physics and Astronomy and the Royal Cabinet of Mathematical and Physical Instruments (in Kassel and Dresden, respectively).

Clock makers George Graham and Thomas Tompion built the first modern orrery around 1704 in England. Graham gave the first model, or its design, to the celebrated instrument maker John Rowley of London to make a copy for Prince Eugene of Savoy. Rowley was commissioned to make another copy for his patron Charles Boyle, 4th Earl of Orrery, from which the device took its name in English.

Design

As a functional model of the Solar system, the Orrery is designed to replicate the movements of the planets and their moons around the Sun. The rotational motion of the planets and their moons is controlled by gears. Each planet and its moon has its own gearing powered by a common hand crank, in most cases. The gear ratios are set according to the number of days it takes for the planets to move around their own axis and around the sun. 

There are different types of Orreries. A model that only includes the Earth, the Moon and the Sun is called a tellurion or tellurium, and one which only includes the Earth and the Moon is a lunarium. A jovilabe is a model of Jupiter and its moons.^[12]The below table gives the list of planets along with the time periods: Source: Wikipedia

Planet	Avg. Distance from Sun	Diameter	Mass	Density	No. of moons	Orbital period (years)	Inclination to ecliptic	Axial tilt	Rotational period (sidereal)
Mercury	0.39 AU	0.38 Earth diameter	0.05 Earth mass	5.5 g/cm³	0	0.24	7.0	0	59 days
Venus	0.72	0.95	0.82	5.3	0	0.62	3.4	177	-243 days
Earth	1.00	1.00	1.00	5.5	1	1.00	0	23	23.9 hours
Mars	1.52	0.53	0.11	3.9	2	1.88	1.9	25	24.5 hours
Jupiter	5.20	11.21	317.9	1.3	67	11.9	1.3	3	10 hours
Saturn	9.54	9.45	95.2	0.7	62	29.5	2.5	27	11 hours
Uranus	19.2	4.01	14.5	1.3	27	84	0.8	98	-17 hours
Neptune	30.1	3.88	17.1	1.6	14	165	1.8	28	16 hours
Pluto	39.4	0.18	0.002	2	5	248	17.1	122	-6.4 days

Given below is the gear train arrangement of the Ken Condal orrery

Construction and Craftsmanship

Calculating the time taken for planets and their satellites to move around the sun and their respective axes is not the tough part in making an orrery. As mentioned above an orrery depends on its gear train to move the planets around the sun. Getting the number of teeth and diameter right to ensure the correct variations in rpm for each planet is only the beginning of the complexity. The real complexity is in getting the gear train tolerances right and balancing the system for smooth movements of all planets, 

Fabrication of the gears to minimum backlash at the same time not too tight to increase manual effort when using the crank. Too much backlash increases rotation movement losses thereby increasing the inaccuracies in the orbit time. 

I don't deny there are more complex gear trains with better accuracies being manufactured. We still have to remember Orreries are made by individuals with very limited access to high end machining technologies and these are not mass manufactured gears but one-offs. It is a very demanding process to get the tolerancing right during design and to get the gears manufactured accordingly. 

Gears are usually made of whatever material the creator finds suitable, can be brass, steel, wood, etc. The Orrery has to look beautiful. Its probably one of the few machines in the world whose Form and Function are important in equal parts. Makes the machine all the more fascinating.A lot of respect to the people making these beautiful machines.

Sanderson Orrery: The Orrery of Professor Jules Verne.

One of my favorite machines and definitely one of the most beautiful machines in the world. Powered by a steam engine. The video is with the Mozart Clarinet is a wonderful tribute to this timeless beauty.

Interesting Machines-1 Linotype Typesetting machines

A machine which, I consider, to be a jewel in machine design. The printing process, in the pre-digital era, required these machines to "set the page". Typesetting is the composition of text by means of arranging physical types or the digital equivalents. 

The Machine: From Wiki "The linotype machine is a "line casting" machine used in printing sold by the Mergenthaler Linotype Company and related companies. It was a hot metal typesetting system that cast blocks of metal typefor individual uses. Linotype became one of the mainstay methods to set type, especially small-size body text, for newspapers, magazines and posters from the late 19th century to the 1970s and 1980s, when it was largely replaced by phototypesetting, offset lithography printing and computer typesetting. The name of the machine comes from the fact that it produces an entire line of metal type at once, hence a line-o'-type, a significant improvement over the previous industry standard, i.e., manual, letter-by-letter typesetting using a composing stick and drawers of letters.

The linotype machine operator enters text on a 90-character keyboard. The machine assembles matrices, which are molds for the letter forms, in a line. The assembled line is then cast as a single piece, called a slug, of type metal in a process known as hot metal typesetting. The matrices are then returned to the type magazine from which they came, to be reused later. This allows much faster typesetting and composition than original hand composition in which operators place down one pre-cast glyph (metal letter, punctuation mark or space) at a time.

The machine revolutionized typesetting and with it especially newspaper publishing, making it possible for a relatively small number of operators to set type for many pages on a daily basis. Before Ottmar Mergenthaler's invention of the linotype in 1884, daily newspapers were limited to eight pages."

The Inventor: From Wiki "Ottmar Mergenthaler (May 11, 1854 – October 28, 1899) was a German-born inventor. In 1876 he was approached by James O. Clephane, who sought a quicker way of publishing legal briefs, via Charles T. Moore, who held a patent on a typewriter for newspapers which did not work and asked Mergenthaler to construct a better model. Mergenthaler recognized that Moore's design was faulty and two years later he assembled a machine that stamped letters and words on cardboard. While he was riding on a train, the idea came to him: why a separate machine for casting and another for stamping? Why not stamp the letters and immediately cast them in metal in the same machine? By 1884 the idea of assembling metallic letter molds, called matrices, and casting molten metal into them, all within a single machine, was applied.Mergenthaler reportedly got the idea for the brass matrices that would serve as molds for the letters from wooden molds used to make "Springerle," which are German Christmas cookies. His first attempt proved the idea feasible, and a new company was formed, then fights with shareholders and unions followed with the press even in Germany attacking him. Finally success came with many honors, including a trip to his old home town.

Another fifty patents were required before Mergenthaler could show a more or less usable model to the New York Tribune on July 3, 1886. "

Even though digital printing has taken over from these beautiful machines the design, in itself, is hardly obsolete. Various mechanisms found in this machine are still widely in use in present day automation machines and will continue to do so as long as there are mechanical machines in this world.

Loading/Unloading station--Rubber curing Hydraulic Press

A unique system designed and built for a rubber component manufacturing company. The company has a series of 4 2 mold rubber curing presses i.e. one mold on top of another. 8 operators were usednto load/unload molds and refill cured rubber with raw rubber. Challenge was to eliminate 7 operators and ensure a single operator can load/unload molds from all presses. This system would also ensure that the operator doesn't have to touch any mold thereby preventing injuries as the molds are at 200deg celcius. 

Designed a system using pneumatics and servo. SMC pneumatic cylinders were used to lock, pull, slide and open the molds from top and bottom tiers. Parker servo coupled with MGM Varvel gearbox was used to position the trolley at every press. The positioning accuracy achieved was +/-1mm. One of the most unique and challenging systems I've ever designed and built.

Automobile badge masking system.

Automobile manufacturer's badges in the steering wheels are ultrasonic welded. The badges have small protrusions at the back for insertion into holes in the steering wheels. These are then welded ultrasonically to the steering wheel. Only a certain length of the protrusion needs to be welded. If the weld is short then the badge becomes loose during hard braking or front end collisions and injures the driver. If the weld is more it creates the same problem. A maskant is used for ensuring the weld does not overshoot the required length. Accuracy required is+/-0.05mm. A simple wirecut fixture was used to hold the badge, fixture+badge slid on rails and was picked by a simple pneumatic pick and place system. The fixture with badge was placed over a pump+pipes+tank circuit. The fixture ensures the badge is coated only to the required level. Another pick and place system removes the fixture+badge and places a it on the output rails. A drying circuit pumps hot air over the maskant for drying. 

Rubber Tube post curing inflator

After rubber tubes are cured in their molds they need to be inflated into shaped rims so the tubes take the shape of the rims when they left in it for around 4-5 minutes. The rims are rotated slowly with tubes in them.

Automotive V belt "Improper profile" indication system

Designed and built for a V belt manufacturer. Contains 2 sets of changeable nylon pulleys with grooves machined to mate with correct profile V belt. A rodless pneumatic cylinder raises and lowers the bottom pulley set for facilitating belt removal. Rollers are placed above each groove. These rollers "roll" over the V belt surface as the top pulley is rotated by an induction motor. Each roller has a proximity sensor placed above it. A V belt with an improper profile will not sit in its groove but be raised a bit thereby moving the roller towards the proximity sensor. A simple alarm system indicates to the operator which belt has an improper profile.

Automotive V belt "Squeal" noise testing machine

Designed and built for a V belt manufacturer. Used for comparing squeal noise levels between the client's V belts and their competitor's ones.. Squeal noise is caused by misalignment in the pulleys. A simple threaded rod was used to create various degrees of misalignments between the pulleys. Decibel levels were measured by using noise level sensors (if that's what they are called).