Design and Fabrication of A Pedal-Operat PDF

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 5, May 2016)
Design and Fabrication of A Pedal-Operated Floor Mopping

Machine
Ritvick Ghosh1, H R Vinay Kumar2, Dattatraya3, Pavan Kumar B. Hiremath4, Prof. Pradeep Kumar K.V.5
1,2,3,4
Students of Mechanical Engineering, M.S. Ramaiah Institute of Technology, Bangalore
5
Assistant Professor, Mechanical Engineering, M.S. Ramaiah Insitute of Technology, Bangalore
Abstract— This paper elaborates the design and fabrication Environmentally safe soaps can be used in conjunction
of a floor cleaner which runs purely on mechanical power and with a reduced water system.
also has the capability of being ridden at low speeds by the
user. The mechanism used to drive the cleaning mechanism
II. PROBLEM STATEMENT
would be similar to the one used in a spinning mop commonly
known as a ‘magic mop’. The mechanism works using a bevel Large commercial areas like airports, railway stations,
gear system wherein high speed multiplications can be shopping malls, restaurants, schools, colleges, industrial
obtained using the right gear specifications. The input to the factories etc. often make use of electric (walk-behind) floor
system would be in the form a foot-pedal accessible to the mopping machines to clean floor areas. While many
user. • For the convenience of the user, the cleaner would companies offer attractive deals and specifications, there
move on 3 wheels (an auto-rickshaw configuration) which
are several problems associated with the use of electric
would be driven with the help of pedals through a mechanical
drive train. Attempts would be made to make the turning moppers. One obvious disadvantage is the absolute
radius of the machine as small as possible so as to enable more dependence on electricity for the use of the machine. It is
efficient cleaning without missing any spots. There would also not possible to provide electric plug points every few
be a mechanism to remove the dirty water so that the mop can meters as that would increase the electrical wiring cost of
be cleaned and fresh water be applied to offer uninterrupted the building by a significant amount; more so, in industrial
floor cleaning. areas set up in rural areas where the capital invested is not
much. Moreover, in areas which experience high footfalls
Keywords—Mechanical floor cleaner, magic mop, spinning
like airports and railway stations, there is always a risk
mop, bevel gear, mechanical drive train
associated with people tripping over the wires that run all
over the place when electric floor moppers are used. There
I. INTRODUCTION
is also the problem associated with inconsistent electric
Automatic floor scrubbers, also known as auto power supply due to load-shedding in various parts of the
scrubbers, are a type of floor cleaning machine that are country. The aim is to find a solution to the above problems
used to scrub a floor clean of light debris, dust, oil, grease by designing and fabricating a floor mopper that makes
or floor marks. These machines have either rotary(disk) or absolutely no use of electricity. Being mechanical, the
cylindrical scrubbing head and an automated system for initial investment cost also would be reduced drastically
dispensing cleaning solution and then vacuuming it up. So, from about Rs. 89000 for a commercial electric floor
in one pass over the floor, a user can dispense cleaning, mopper to an approximate amount of Rs.15000 for a
scrub it into the floor, then vacuum it all up with an auto mechanical one. This would help establishments who have
scrubber squeegee attachment at the back of the machine. a limited amount of capital to invest.
Auto scrubbers have a separate dispensing (solution tank)
tank and a collection(recovery tank) tank to keep the clean III. DESIGN METHODOLOGY
water from the dirty water and can be categorized into one
The following procedure was referred to during the
of two main types: walk behind or riding. Floor Scrubbers
design and fabrication stage:
are a more hygienic alternative to traditional cleaning
methods such as a mop and bucket.
33
B. Frame Material Used
AISI 1010 Carbon Steel has been chosen for the
fabrication of frame. The following are the salient features
MS 1010-
1. AISI 1010 carbon steel is a plain carbon steel with
0.10% carbon content.
2. Easily available in form of tubes with variety of cross
section and gauges.
3. MS 1010 has yield strength of 305MPa and Elastic
Modulus of 210GPa.
4. Good Conditions of workability at hot and cold
working conditions.
5. Almost any welding methods can be used to weld MS
1010.
6. Cheap and Affordable.
Fig. 1: Design and Fabrication Procedure
Table 2:
1. Market Analysis to identify problems and Properties of Mild Steel
requirements
2. Selection of suitable fabrication materials.
3. Concept design of structure
4. Analysis of design and optimisation
5. Start of production and fabrication
6. Testing and evaluation of overall performance
7. Incorporating necessary modifications
8. Presentation and report formation.
A. List of Materials Used
The following table illustrates the various raw materials
used in the components of the machine along with their
mechanical properties:
Table 1:
List of materials used
USED IN YIELD YO UNG’S

PO ISSO N’S
SL NO . MATERIAL USED STRENGTH MO DULUS
CO MPO NENT (GPA) RATIO
(GPA)
FRAME,
1) MILD ST EEL WELDED 305 190 0.3 IV. 3D MODELLING
COMPONENT S
2) DELRIN WIPER 72 3.2 0.35

A. 3D Modelling of Sub-Assemblies
3) COT T ON YARN MOP FIBRE 225 7.9 0.35
The 3D modelling of the entire machine is divided into
SPROCKET
the following stages or sub-assemblies on Autodesk
AND Inventor:
4) CAST IRON 130 110 0.26
PLUMMER
BLOCK
FRESH WAT ER
5) POLYPROPELENE 43 2 0.42
T ANK
34
1. Modelling of frame
2. Modelling of bevel gear sub-assembly
3. Assembly of all sub-components incorporating
components such as pedals, wheels, chain-and-sprocket,
brakes,etc.
The Frame is modelled based on the dimensions taken
from a regular bicycle frame taking into account the forces
encountered by the frame when a person of an average
weight uses it. The Centre Of Gravity of the frame is
obtained on Autodesk Inventor from which the
Displacement and stress Analysis are carried out.
Optimisations are made in order to ensure that the stresses
encountered by the frame are within an acceptable level.
Fig. 3: Modelling of bevel gear sub-assembly
B. Stress-Analysis of Frame
Fig. 2: Modelling of frame
Next, the bevel gear assembly is modelled taking with

the help of specifications derived from the calculations that
will be found in subsequent sections. Pitch circle diameters
Fig. 4: Displacement analysis of frame
of the gear and pinion and the pressure angles are obtained
from standard gears which are readily available in the The displacement analysis is conducted after applying
market. The axial force on the gear is found to be 86N and the estimated loads and the maximum displacement is
the radial load on the gear is found to be 16N which found to be 0.2956mm.
resembles the results obtained from the design calculations
shown in the subsequent section.
35
Torque and Power Calculations:
No. of teeth on the pedal sprocket Z1= 24
teeth
No. of teeth on the wheel sprocket of
gear , Z2= 24 teeth
Gear ratio Z1/Z2= 1
Assuming 60 pedal rotations in 1 minute,
Wheel RPM N2= 60 rotations
Linear velocity at an RPM of 120
= (pi*wheel diameter*N2)/60
=(3.142*26*2.54*0.01*60)/60=2.07m/s
= 7.45kmph
Fig. 5: Stress Analysis of Frame
2
Assumed acceleration : 0.5 m/s
The Stress analysis is conducted after applying the
Force required to move the machine of
estimated loads and the maximum Von-Mises stress is
found to be 0.2826 Mpa. 30 kgs F = m*a = 30*0.5= 15 N
C. 3D Assembly of Entire Machine Wheel torque required = Force* radius

of wheel=15*26*2.54*0.01
=9.9Nm
To find pedal torque,
n1T1 = n2T2
60*T1 = 9.9*60
T1 = 9.9 Nm
Power required to be exerted on the

pedals = (2*pi*N*T)/60
= (2*3.142*60*9.9)/60
= 62.2 W
B. Speed of mop rotation:
Number of teeth on the pedal sprocket=48
Number of teeth on input bevel gear sprocket = 24
Assuming 60 rpm of the pedal, speed of the gear shaft
Fig. 6: 3D Model of Assembled Machine
n1= (48/24) * 60 = 120rpm
V. DESIGN CALCULATIONS Number of teeth on input bevel gear Z1 = 27
A. Specifications Number of teeth on output bevel gear (pinion) Z1 = 22
1) Length: 1.29m. Speed ratio i = Z1/Z2 = 27/22 = 1.227
2) Width: 0.55 m.
Therefore, for 60 rpm of the pedal shaft, the mop rotates
3) Height: 1.126 m.
(48/24)*1.227*60 times= 147.24 RPM
4) Kerb Weight: 30 kgs (approx.) Or for every rotation of the pedal, the mop rotates 2.45
times.
36
C. Bevel gear design calculations:
1) Pitch circle diameter of the gear D1 = 200mm
2) Pitch circle diameter of the pinion D2=163mm
3) Face width = 40mm
o
4) Pressure angle a = 20
Torque on the gear shaft Mt
1
= (60*106*N)/(2*pi*n1)
= (60*106*0.0622)/(2*3.142*120) Fig. 7: Mop Diameter
= 4949.71 N-mm VI. FABRICATION

-1 -1
Pitch angle of gear d1 = tan (1/i) = tan (1/1.227) Metal fabrication is a value added process that involves
o the construction of machines and structures from various
= 39.17
raw materials. The process of fabrication is started in the
Mean radius of gear rm1 = (D1/2 – b sind1/2) fabrication shop on the basis of engineering drawings
generated in the design process after assessing the
= (200/2 – 40 sin 39.17 /2)
capabilities of the shop with respect to metal cutting,
= 87.36mm foaming, welding and machining.
Metal fabrication jobs usually start with shop drawings
Tangential tooth force Ft = Mt1/rm1
including precise measurements then move to the
= 4949.71/87.36 fabrication stage and finally to the assembly to the project.
The following steps were followed in fabricating this
= 56.65 N project:
Axial force on gear and radial load on pinion Fa = Ft*tan • Stage 1: Cost Estimation
a *sin d1 = 87.36 mm • Stage 2: Procurement of raw materials
Radial load on gear and axial force on pinion Fr = Ft*tan • Stage 3: Fabrication of individual parts
a* cos d1 = 56.65*tan20*cos 39.17 • Stage 4: Final Assembly
= 15.98 N
D. Area swept by the mop:
At 7.45 kmph, the mopping machine moves at 2.07m/s
Thus, area swept by the mop/ pedal rotation
= 2.07*mop diameter
= 2.07*0.35
= 0.7245 m2
In one minute, the mop can sweep 0.7245*60 = 43.47 m2
Fig. 8: Second-hand bicycle frame
37
Fig. 9: Machine mounted on wheels with pedal and chain fixed Fig. 12: Machine in an assembled state
VII. RESULTS AND DISCUSSION

A. Comparison with electric floor moppers:
Table 3:
Comparison with electric floor mopping machines
MOP TANK
ROTATION COST WEIGHT
BRAND DIAMETER CAPACITY TYPE
(RPM) (Rs.) (cm.) (kgs) (lts.)
Project 147 15000 35 30 5 Rideable
Windsor
240 93226 51 95 53 Walk-behind
SCC20DI
Mastercraft
175 68445 53.34 69 54.9 Walk-behind
RA535
Cleanfreak
185 85227 45.72 74 30 Walk-behind
DURA18
Fig. 10: Bevel gear sub-Assembly for mop Global-
200 200000 50.8 92 49 Walk-behind
Industrial
A comparison was made with commercially available

electric floor moppers. From the table it can be inferred that
this project is not only significantly cheaper than its electric
counterparts but is also lighter in weight which makes it
more portable. The speed of the mop rotation is only a little
bit lower than electric moppers but can be increased using
the appropriate gear ration. The mop diameter too can be
increased during optimization or multiple mops can be
incorporated to ensure a more thorough cleaning process.
B. Scope for future work:
Here are a few suggestions/modifications which can be
Fig. 11: Mop mounted to the bevel gear sub -assembly incorporated into the existing machine which would make
it more user-friendly and also make it as marketable as
their electric counterparts:
38
1. Incorporate additional mops or a single mop of bigger REFERENCES
diameter to ensure 100% cleaning at corners. [1] http://nptel.ac.in/courses/IIT-
2. Incorporation of a vacuum pump for more efficient MADRAS/Machine_Design_II/pdf/2_13.pdf
removal of waste water. [2] http://science.howstuffworks.com/transport/engines-
3. Increasing the capacity of tanks to ensure cleaning for equipment/gear4.htm
a longer time. [3] http://www.techtree.com/content/features/9975/top-5-robotic-
automated-floor-cleaners-india.html
4. Retrofitting of an electric motor to reduce the
[4] H. Ligata, H. H. Zhang – ―Overview and Design of Near Net-
pedaling effort. Formed Spherical
5. Use of higher durability mop material which can be Involute Straight Bevel Gears‖, Paper 161, ENG 107, International
used for cleaning in outdoor areas including streets, Journal of Modern Engineering
footpaths etc. [5] J.B.K. Das, Dr. P.L. Srinivasa Murthy – ―Design of Machine
Elements – II‖ , Feb 2013 Edition
39

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International Journal of Emerging Technology and Advanced Engineering

Design and Fabrication of A Pedal-Operated Floor Mopping

USED IN YIELD YO UNG’S

2) DELRIN WIPER 72 3.2 0.35

Fig. 3: Modelling of bevel gear sub-assembly

Fig. 2: Modelling of frame

Next, the bevel gear assembly is modelled taking with

C. 3D Assembly of Entire Machine Wheel torque required = Force* radius

Power required to be exerted on the

= 4949.71 N-mm VI. FABRICATION

VII. RESULTS AND DISCUSSION

A comparison was made with commercially available

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