KYAMBOGO UNIVERSITY

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING

BACHELOR OF ENGINEERING IN INDUSTRIAL ENGINEERING AND

MANAGEMENT

DESIGN OF A MECHANISED PEDAL WASHING MACHINE FOR RURAL

HOSPITALS

CASE STUDY: KIWOKO REFERAL HOSPITAL

BY

MBAZIRA PEREZ

14/U/8543/IEE/PE

A PROJECT REPORT SUBMITTED TO KYAMBOGO UNIVERSITY INPARTIAL

FULFILMENT OF THE REQUIREMENTS FOR THE
AWARDOF A BACHELOR’S DEGREE OF ENGINEERING
IN INDUSTRIAL ENGINEERING AND
MANAGEMENT

JUNE 2018
 DECLARATION
I Mbazira Perez, declare that this REPORT forwarded to the Faculty of Engineering,
Kyambogo University, is our own and attained from our efforts with assure explanation, it
has never been presented elsewhere in any university, or any other institution of higher
learning for any academic award.

Signature ….................................................. Date……………………………………

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 APPROVAL
This research project has been submitted for examination with my approval as University
Supervisor

Signature …..................................... Date……………………………………

MISS ATIMA ROSE

(UNIVERSITY SUPERVISOR)

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 ACKNOWLEGMENT

First and foremost, I would like to thank the Almighty GOD for the protection, wisdom and
guidance granted to me throughout these years of struggle for education.

I wish to thank with gratitude my supervisor Ms. Atima Rose for the guidance, commitment
and inspiration accorded to me for successive completion of this project.

To my fellow colleagues in the struggle Semata Peter, Ssebaka David and others, thanks for
any assistance rendered to me.

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 TABLE OF CONTENT
DECLARATION.......................................................................................................................i
APPROVAL .............................................................................................................................ii
ACKNOWLEGMENT ...........................................................................................................iii
TABLE OF CONTENT..........................................................................................................iv
LIST OF FIGURES ................................................................................................................vi
LIST OF TABLES .................................................................................................................vii
ABSTRACT...........................................................................................................................viii
CHAPTER ONE: INTRODUCTION ....................................................................................1
1.1 Background of study .......................................................................................................1
1.2 Problem statement................................................................................................................2
1.3 Objectives of study...............................................................................................................2
1.3.1 General objective ..............................................................................................................2
1.3.2 Specific objectives ............................................................................................................2
1.3.3 Research questions ............................................................................................................2
1.4 Scope of the study ................................................................................................................3
1.4.1 Content scope ....................................................................................................................3
1.4.2 Geographical scope ...........................................................................................................3
1.4.3 Time scope ........................................................................................................................3
1.5 Justification ..........................................................................................................................3
1.6 Significance of the study ......................................................................................................3
CHAPTER TWO: LITERATURE REVIEW .......................................................................4
2.1 Literature Review of a pedal Driven Washing Machine......................................................4
2.1.1 The Early washing machine ..............................................................................................4
2.1.2 Top loading washing machine: .........................................................................................5
2.1.3 Front-loading Washing machine .......................................................................................7
2.1.4 Commercial use.................................................................................................................9
2.2 Design of a pedal driven washing machine........................................................................10
2.2.2 Components of the machine............................................................................................11
2.3 Theoretical frame work ......................................................................................................17
2.4 Construction and working principle...................................................................................18
CHAPTER THREE: METHODOLOGY............................................................................19
CHAPTER FOUR: RESULTS AND DISCUSSION ..........................................................20

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4.1 Study the existing types of washing machines on the basis of design, performance,
economy and applications ....................................................................................................20
4.1.1 Existing cloth washing methods......................................................................................20
4.1.2 Studying the existing laundry washing methods.............................................................20
4.1.3 Operating specifications of a convectional electric washing machine............................21
4.2 Determining the performance parameters ..........................................................................22
4.3 Select, size the material and develop a lay out...................................................................25
4.3.1 List of components ..........................................................................................................25
4.3.2 Design of sprockets and chain.........................................................................................26
4.3.3 Power transmission .........................................................................................................26
4.3.4 Sketch of the design ........................................................................................................27
4.3.5 Final lay out of the Pedal Driven washing machine .......................................................29
4.4 Cost analysis.......................................................................................................................30
4.4.1 The bill of materials ........................................................................................................30
4.4.2 Payback period ................................................................................................................30
CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS.................................32
5.1 Conclusion..........................................................................................................................32
5.2 Recommendations ..............................................................................................................32
REFERENCES.......................................................................................................................33
APPENDIX .............................................................................................................................34
Appendix i: Different components...........................................................................................34

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 LIST OF FIGURES
Figure 2.1: Early washing machine............................................................................................5
Figure 2.3: Top loading washing machine .................................................................................5
Figure 2.4: Front loading washing machine...............................................................................7
Figure 2.5: Commercial washing unit ........................................................................................9
Figure 2.6: Ball Bearing ...........................................................................................................11
Figure 2.7: Bicycle Seat ...........................................................................................................12
Figure 2.8: Spur gear................................................................................................................13
Figure 2.9: Helical gear............................................................................................................13
Figure 2.10: Worm gear ...........................................................................................................14
Figure 2.11: Bevel gear ............................................................................................................14
Figure 2.12: Plumber block......................................................................................................15
Figure 2.13: Assembly of chain, catcher and Sprocket............................................................16
Figure 2.14: Shaft.....................................................................................................................16
Figure 4.1: Pie chart showing the percentage of use of different Laundry washing methods in
rural hospitals ...........................................................................................................................21
Figure 4.2: A bar graph showing the energy consumption for Electric machine ...................22
Figure 4.3: A bar graph showing power output against pedaling rate ....................................23

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 LIST OF TABLES
Table 3.0: Methodology and Data Instruments for each Specific Objective ...........................19

Table 4.1: Comparison of existing washing methods ..............................................................20

Table 4.2: Shows the Operating specifications of a convectional electric washing machine..21

Table 4.3: Required torque and power for each of the 3 processes .........................................24

Table 4.4: Shows the list of components required ...................................................................25

Table 4.4: Shows the specifications for sprocket and chain ....................................................26

Table 4.5: Shows the Bill of materials .....................................................................................30

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 ABSTRACT
The pedal driven washing machine is designed at Kiwoko Hospital to aid rural hospitals in
Uganda in washing Hospital laundry. The national electrification rate in Uganda is estimated
at 14% with the rural population having even a lower rate of below 7%. Power shortage
remains one of the greatest obstacles in rural areas. (Web site: International Cooperation and
Development visited on 10/09/2017). This challenge makes use of an electric washing
machine impossible for the rural Hospitals. Hand washing the hospital laundry continues to
be a challenge as the labour requirement is very high; 20 people work for 9 hours every day,
these people are exposed to risk of infection from contaminated laundry. This project is
aimed at providing an alternative cloth washing method which can work in the absence of
electricity and relive hospitals from the high labour cost and reduce the risk of labour
infections from contaminated clothes. The methods used for the design was based on the
availability of material in the local market, interviews, desk research, literature reviews,
questionnaires and observations. The results obtained from the research showed that the
designed machine is time saving, can reduce the infection risk and save labour costs if
adopted by the rural Hospitals.

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 CHAPTER ONE
INTRODUCTION
1.1 Background of study
A washing machine is a machine that washes dirty clothes. It contains a barrel into which
the clothes are placed. This barrel is filled with water, and then rotated very quickly to make
the water remove dirt from the clothes. Most washing machines are made so that detergent
(liquids or powders) can be put into the machine which helps make the clothes cleaner. The
term is mostly applied to machines that use water as opposed to drying cleaning machines
(which use alternative fluids and is performed by specialist business).
Washing machine technology developed as a way to reduce the manual labour spent,
providing an open basin or sealed container with pedals to automatically agitate the clothing.
The earliest machines were hand operated and constructed from wood, while the later
machines made of metal permitted a fire to burn below the washtub, keeping the water warm
throughout the days washing (Wikipedia). Depending on the position of loading in clothes,
electric washing machines are of 2 types: top loading and front loading machine. The typical
electric washing machine on average will consume 500watts for 0.25hours of washing and as
such, one must have access to a reliable electricity source if he is to use this machine. The
national electrification rate in Uganda is estimated at 14% with the rural population having
even a lower rate of below 7%. Power shortage remains one of the greatest challenges in rural
areas, regardless of the government’s effort to electrify rural areas. (Web site: International
Cooperation and Development visited on 10/09/2017). An electric washing machine will
therefore be very expensive to operate and unreliable in most rural areas of Uganda.

Among those greatly affected by this condition are the Rural Health centers. These hospitals
are not in position to safely wash contaminated laundry using the electric washing machines,
which is the standard for performing such a task. Kiwoko referral Hospital for example,
found in Nakaseke District faces the same problem. This Hospital serves Luweero, Nakaseke
and Nakasongola district, attending to over 600 patients a day (Kiwoko Hospital Audit
Report 2016). Because of the large number of patients, the hospital employs 20 people
working who work for 9 hours daily to hand wash the hospital laundry. 80% of the workers
find this work undesirable because the operation exposes them to a high risk of infection
from the contaminated laundry. This work also involves a lot of effort and time. The Hospital
administration spends 8million every month on paying the workers which amounts to about
96 million a year, this is very expensive (Kiwoko Hospital Audit report 2016).

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The pedal driven washing machine does not need electricity to operate and as such, can be
used in rural areas with no electricity supply. This machine generates power through human
pedaling and with the drive mechanism, converts the pedaling motion into required rotary
motion of the drum. With the help of compound gear system, the machine achieves the
desired speed for different purposes like washing, rinsing and drying. Its innovation lies in its
simple design and use of inexpensive parts.

This project makes laundry washing safe by reducing workers’ contact with the contaminated
laundry which is apparently exposing them to a high risk of infection from the clothing,
reduce human effort and save time. The hospital can also save labor costs as this operation
only needs 4 people working 4 hours a day, instead of 20 people.

1.2 Problem statement

Because of Power shortage in rural areas of Uganda, Kiwoko Hospital found in Kiwoko
Village employs 20 people who work for 9 hours every day to hand wash Hospital laundry,
this is time consuming. Therefore in the absence of electricity, a mechanized Pedal washing
machine provides a faster alternative for performing this task which only needs 4 people
working 4 hours a day

1.3 Objectives of study

1.3.1 General objective

To design a driven washing machine

1.3.2 Specific objectives

i. To study the existing types of washing machines on the basis of design, performance,
economy and applications
ii. To determine the machine parameters
iii. To select, size the material and develop a lay out.
iv. To carry out a cost analysis of developing a unit of pedal powered washing machine

1.3.3 Research questions

i. What are the different types of existing washing machines?
ii. What are the machine parameters?
iii. Which materials are appropriate for the design and what are the component sizes?
iv. What is the cost of developing a unit of pedal powered washing machine?

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1.4 Scope of the study
1.4.1 Content scope
The study concentrated on studying existing laundry washing methods in rural Hospitals in
Uganda with their associated time, costs, risks and required man power, with the major
emphasis on developing a pedal driven washing machine which could be used by the rural
Hospitals to save time, cut labour costs, and reduce workers’ risk of infection due contact with
contaminated clothing.

1.4.2 Geographical scope

The study was carried out in Uganda at different Rural Hospitals and major at Kiwoko Referral
Hospital. The Hospital is located in Nakaseke District, Kiwoko Town Council.

1.4.3 Time scope

The study took a period of Seven months that is from November to May 2018.

1.5 Justification
There is a great need for designing a pedal driven washing machine for Rural Hospitals
because;
i. The present electric washing machines have a high power consumption, 500watts for
0.25 washing hours and yet there is electricity shortage in rural areas.
ii. The present hand washing method exposes the people involved to a high risk of infection
from contaminated laundry
iii. Hand washing is time wasting, 20 people work for 9 hours every day to finish the wash.
iv. The cost of purchasing a commercial electric washing machine is high, between $800 -
$2700 (Washing machine catalog 2017). Most rural hospitals cannot afford this.

1.6 Significance of the study

If this project is implemented, Rural Hospitals will;
i. Reduction in the labour requirement from 20 people to 4 people which lowers the labour
expenses from 36m to 10m a year.
ii. Make cloth washing safe by reducing workers’ contact with contaminated laundry which
reduces the risk of infection.
iii. Increased Hospital sanitation due to a constant supply of clean clothing brought about by
a faster rate of washing.
iv. Higher hospital capacity hence more patients can be handled. This is because the
machine has a higher efficiency than man.
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 CHAPTER TWO
LITERATURE REVIEW

2.1 Literature Review of a pedal Driven Washing Machine

A washing machine is a machine that washes dirty clothes. It contains a barrel into which
the clothes are placed. This barrel is filled with water, and then rotated very quickly to make
the water remove dirt from the clothes. Most washing machines are made so that detergent
(liquids or powders) can be put into the machines which help make the clothes cleaner. The
term is mostly applied to machines that use water as opposed to drying cleaning machines
(which use alternative fluids and is performed by specialist business).

2.1.1 The Early washing machine

Clothes washer technology developed as a way to reduce the manual labor spent, providing
an open basin or sealed container with paddles or fingers to automatically agitate the clothing.
The earliest machines were hand-operated and constructed from wood, while later machines
made of metal permitted a fire to burn below the washtub, keeping the water warm
throughout the day's washing.

The earliest special-purpose mechanical washing device was the washboard, invented in 1797
by Nathaniel Briggs of New Hampshire

By the mid-1850s steam-driven commercial laundry machinery were on sale in the UK and
US. Technological advances in machinery for commercial and institutional washers
proceeded faster than domestic washer design for several decades, especially in the UK. In
the United States there was more emphasis on developing machines for washing at home,
though machines for commercial laundry services were widely used in the late 19th and early
20th centuries. The rotary washing machine was patented by Hamilton Smith in 1858. As
electricity was not commonly available until at least 1930, some early washing machines
were operated by a low-speed, single-cylinder hit-and-miss gasoline engine.

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 Figure 2.1: Early washing machine

2.1.2 Top loading washing machine:

Figure 2.3: Top loading washing machine

In this washing machine the clothes are loaded from the top of the washing machine. There is
a cover at the top that helps loading and unloading of clothes in the round vessel that perform
the function of the washer as well as the rinser and drier in the fully automatic washing
machine. The top loading washing machine is preferred by the people who don’t want to
bend the body while loading the clothes in the machine. This washing machine is more
widely used than the front loading washing machine in many parts of the world.

During the wash cycle, the outer tub is filled with water sufficient to fully immerse and
suspend the clothing freely in the basket. The movement of the agitator pushes water outward
between the paddles towards the edge of the tub. The water then moves outward, up the sides
of the basket, towards the center, and then down towards the agitator to repeat the process, in
a circulation pattern similar to the shape of a torus. The agitator direction is periodically

5
reversed, because continuous motion in one direction would just lead to the water spinning
around the basket with the agitator rather than the water being pumped in the torus-shaped
motion. Some washers supplement the water-pumping action of the agitator with a large
rotating screw on the shaft above the agitator, to help move water downwards in the center of
the basket.

While a top-loading washing machine could use a universal motor or DC brushless motor, it
is conventional for top-loading washing machines to use more expensive, heavy, and more
electrically efficient and reliable induction motors. The action of a front-loading washing
machine is better suited to a motor capable of reversing direction with every reversal of the
wash basket; a universal motor is noisier, less efficient, doesn't last as long, but is better
suited to the task of reversing direction every few seconds.

Reversible motor
In most current top-loading washers, if the motor spins in one direction, the gearbox drives
the agitator; if the motor spins the other way, the gearbox locks the agitator and spins the
basket and agitator together. Similarly, if the pump motor rotates one way it recirculates the
sudsy water; in the other direction it pumps water from the machine during the spin cycle.
Mechanically, this system is very simple.

Mode-changing transmission
In some top loaders, the motor runs only in one direction. During agitation, the transmission
converts the rotation into the alternating motion driving the agitator. During the spin cycle,
the timer turns on a solenoid which engages a clutch locking the motor's rotation to the wash
basket, providing a spin cycle. General Electric's very popular line of Filter-Flo (seen to the
right) used a variant of this design where the motor reversed only to pump water out of the
machine. The same clutch which allows the heavy tub full of wet clothes to "slip" as it comes
up to the motor's speed, is also allowed to "slip" during agitation to engage a Gentle Cycle for
delicate clothes.

Reversible motor with mode-changing transmission

Some top-loaders, especially compact apartment-sized washers, use a hybrid mechanism. The
motor reverses direction every few seconds, often with a pause between direction changes, to
perform the agitation. Spin cycle is accomplished by engaging a clutch in the transmission. A
separate motorized pump is generally used to drain this style of machine. These machines
could easily be implemented with universal motors or more modern DC brushless motors, but

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older ones tend to use a capacitor-start induction motor with a pause between reversals of
agitation.

2.1.3 Front-loading Washing machine

Figure 2.4: Front loading washing machine

The front-loading or horizontal-axis clothes washer is the dominant design. In addition, most
commercial and industrial clothes washers around the world are of the horizontal-axis design.

This layout mounts the inner basket and outer tub horizontally, and loading is through a door
at the front of the machine. The door often but not always contains a transparent window.
Agitation is supplied by the back-and-forth rotation of the cylinder and by gravity. The
clothes are lifted up by paddles on the inside wall of the drum and then dropped. This motion
flexes the weave of the fabric and forces water and detergent solution through the clothes
load. Because the wash action does not require the clothing be freely suspended in water,
only enough water is needed to moisten the fabric. Because less water is required, front-
loaders typically use less soap, and the repeated dropping and folding action of the tumbling
can easily produce large amounts of foam or suds.

Front-loaders control water usage through the surface tension of water, and the capillary
wicking action this creates in the fabric weave. A front-loader washer always fills to the same
low water level, but a large pile of dry clothing standing in water will soak up the moisture,
causing the water level to drop. The washer then refills to maintain the original water level.
Because it takes time for this water absorption to occur with a motionless pile of fabric,

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nearly all front-loaders begin the washing process by slowly tumbling the clothing under the
stream of water entering and filling the drum, to rapidly saturate the clothes with water.

Wash cycles
Over time machines have become more and more automated, first with very complex
electromechanical controllers, then fully electronic controllers; users put clothes into the
machine, select a suitable program via a switch, start the machine, and come back to remove
clean and slightly damp clothes at the end of the cycle. The controller starts and stops many
different processes including pumps and valves to fill and empty the drum with water,
heating, and rotating at different speeds, with different combinations of settings for different
fabrics.

Washing
Many front loading machines have internal electrical heating elements to heat the wash water,
to near boiling if desired. The rate of chemical cleaning action of the detergent and other
laundry chemicals increases greatly with temperature, in accordance with the Arrhenius
equation. Washing machines with internal heaters can use special detergents formulated to
release different chemical ingredients at different temperatures, allowing different type of
stains and soils to be cleaned from the clothes as the wash water is heated up by the electrical
heater.

However, higher-temperature washing uses more energy, and many fabrics and elastics are
damaged at higher temperatures. Temperatures exceeding 40 °C (104 °F) have the
undesirable effect of inactivating the enzymes when using biological detergent

Front loaders need to use low-sudsing detergents because the tumbling action of the drum
folds air into the clothes load that can cause over-sudsing and overflows. However, due to
efficient use of water and detergent, the sudsing issue with front-loaders can be controlled by
simply using less detergent, without lessening cleaning action.

Rinsing
Washing machines perform several rinses after the main wash to remove most of the
detergent. Modern washing machines use less water due to environmental concerns; however,
this has led to the problem of poor rinsing on many washing machines on the market,[95]
which can be a problem to people who are sensitive to detergents. The Allergy UK website
suggests re-running the rinse cycle, or rerunning the entire wash cycle without detergent. [96]

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In response to complaints, many washing machines allow the user to select additional rinse
cycles, at the expense of higher water usage and longer cycle time.

Spinning
Higher spin speeds, along with larger tub diameters, remove more water, leading to faster
drying. If a heated clothes-dryer is used after the wash and spin, energy use is reduced if
more water has been removed from clothes. However, faster spinning can crease clothes
more. Also, mechanical wear on bearings increases rapidly with rotational speed, reducing
life. Early machines would spin at only 300 rpm and, because of lack of any mechanical
suspension, would often shake and vibrate.

2.1.4 Commercial use

Figure 2.5: Commercial washing unit

A commercial washing machine is intended for more frequent use than a consumer washing
machine. Durability and functionality is more important than style; most commercial washers
are bulky and heavy, often with more expensive stainless steel construction to minimize
corrosion in a constantly moist environment. They are built with large easy-to-open service
covers, and washers are designed not to require access to the underside for service. Often
commercial washers are installed in long rows with a wide access passageway behind all the
machines to allow maintenance without moving the heavy machines.

Environmental impact
Due to the increasing cost of repairs relative to the price of a washing machine, there has
been a major increase in the number of defective washing machines being discarded, to the

9
detriment of the environment. The cost of repair and the expected life of the machine may
make the purchase of a new machine seem like the better option.

Different washing machine models vary widely in their use of water, detergent, and energy.
The energy required for heating is large compared to that used by lighting, electric motors,
and electronic devices. Because of their use of hot water, washing machines are among the
largest consumers of energy in a typical modern home.

2.2 Design of a pedal driven washing machine

Pedal driven washing machine involves the transfer of energy from a human source through
the use of a foot pedal and Gear system. This technology is most commonly used for
transportation and has been used to propel bicycles for over a hundred years. Some third
world development projects currently transform used bicycles into pedal powered tools for
sustainable development. This Washing Machine will generate power through human
pedaling and with the drive mechanism, converts the pedaling motion into required rotary
motion of the drum for washing. With the help of compound gear system, the machine will
achieve the desired speed for different purposes like washing, rinsing and drying. Its
innovation will lie in its simple design and use of inexpensive parts.

2.2.1 Need

The national electrification rate in Uganda is estimated at 14% with the rural population
having even a lower rate of below 7%. Power shortage remains one of the greatest obstacles
in rural areas. (Web site: International Cooperation and Development. Visited on
10/09/2017). This challenge makes use of an electric washing machine impossible for the
rural Hospitals. Hand washing the hospital laundry continues to be a challenge as the labour
requirement is very high; 50 people work for 9 hours every day, these people are exposed to
risk of infection from contaminated laundry.

The cost of procuring a new electric laundry machine remains high – Between $1500 to
$2600 which is expensive for local hospitals and health centers annual budgets. A pedal
driven machine would only cost approximately $450 after fabrication, which can fit in the
health centers budgets.

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2.2.2 Components of the machine
Bearing
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. It achieves this by using at least two races to contain the balls
and transmit the loads through the balls. In most applications, one race is stationary and the
other is attached to the rotating assembly. As one of the bearing races rotates it causes the
balls to rotate as well. Because the balls are rolling they have a much lower coefficient of
friction than if two flat surfaces were sliding against each other.

Figure 2.6: Ball Bearing

Ball bearings tend to have lower load capacity for their size than other kinds of rolling-
element bearings due to the smaller contact area between the balls and races. However, they
can tolerate some misalignment of the inner and outer race. The ball bearings used in our
project is shown in Figure 5.

Bearing Life Cycle

Every bearing has a certain service life potential. However, research has shown that, for
various reasons, not every bearing achieves it. Important stages which have a major impact
on a bearing service life can be recognized during the bearing’s lifecycle. These stages are
mounting, lubrication, alignment, basic condition monitoring and dismounting.

Mounting
Mounting is one of the critical stages of the bearing’s lifecycle. If the bearing is not mounted
properly using the correct method and tools, the bearing’s service lifetime will be reduced.
Individual applications may require mechanical, heat or hydraulic mounting methods for
correct and efficient bearing mounting. Selecting the correct mounting technique for your

11
application will be helpful extend your bearing’s service life and reduce costs resulting from
premature bearing failure, as well as potential damage to the application.

Lubrication

Correct bearing lubrication is an essential step in reaching the bearing’s service lifetime. It is
important to select grease suitable for the bearing’s application, and to apply the correct
quantity before commissioning the bearing. During operation, the bearing will require
periodic re-lubrication. The right quantity of the right grease applied at the right intervals is
essential to achieving optimum bearing performance and maximum service life.

Alignment

After the bearing has been mounted to the shaft, the shaft should be aligned. If the shaft is not
properly aligned, the misalignment can cause the bearing to suffer additional load, friction
and vibration. These can accelerate fatigue and reduce the bearings, as well as other machine
components, service life. Furthermore, increased vibration and friction can significantly
increase energy consumption and the risk of premature failures.

Seat

A seat is place to sit. Seat is an arrangement in any bicycle on which a person can sit
comfortably. In designing a Seat arrangement, the right size and height should be considered
to prevent straining the operators back. Seat may be made of plastic, rubber, metal, etc
material.

Figure 2.7: Bicycle Seat

Pedal arrangement
A bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the
bicycle. It provides the connection between the cyclist's foot or shoe and the crank allowing
the leg to turn the bottom bracket spindle and propel the bicycle's wheels. Pedals usually

12
consist of a spindle that threads into the end of the crank and a body, on which the foot rests
or is attached, that is free to rotate on bearings with respect to the spindle.
Gear
Types of Gears
Spur gear
Gears having cylindrical pitch surfaces are called cylindrical gears. Spur gears belong to the
parallel shaft gear group and are cylindrical gears with a tooth line which is straight and
parallel to the shaft. Spur gears are the most widely used gears that can achieve high accuracy
with relatively easy production processes. They have the characteristic of having no load in
the axial direction (thrust load). The larger of the meshing pair is called the gear and smaller
is called the pinion.

Figure 2.8: Spur gear

Helical gear
Helical gears are used with parallel shafts similar to spur gears and are cylindrical gears with
winding tooth lines. They have better teeth meshing than spur gears and have superior
quietness and can transmit higher loads, making them suitable for high speed applications.
When using helical gears, they create thrust force in the axial direction, necessitating the use
of thrust bearings. Helical gears come with right hand and left hand twist requiring opposite
hand gears for a meshing pair

Figure 2.9: Helical gear

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Worm gear
A screw shape cut on a shaft is the worm, the mating gear is the worm wheel, and together on
non-intersecting shafts is called a worm gear. Worms and worm wheels are not limited to
cylindrical shapes. There is the hour-glass type which can increase the contact ratio, but
production becomes more difficult. Due to the sliding contact of the gear surfaces, it is
necessary to reduce friction. For this reason, generally a hard material is used for the worm,
and a soft material is used for worm wheel. Even though the efficiency is low due to the
sliding contact, the rotation is smooth and quiet. When the lead angle of the worm is small, it
creates a self-locking feature.

Figure 2.10: Worm gear

Bevel Gear
Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of
the gears themselves are conically shaped. Bevel gears are most often mounted on shafts that
are 90 degrees apart, but can be designed to work at other angles as well. One gear is rigidly
mounted on the shaft and another gear is fixed with the bottom of the washing machine.
Because of the position of the washing chamber, top loading, the bevel gear is the most
appropriate gear to give the necessary speeds with ease.

Figure 2.11: Bevel gear

14
Advantages of bevel gear

 This gear makes it possible to change the operating angle.

 Differing of the number of teeth (effectively diameter) on each wheel allows
mechanical advantage to be changed. By increasing or decreasing the ratio of teeth
between the drive and driven wheels one may change the ratio of rotations between
the two, meaning that the rotational drive and torque of the second wheel can be
changed in relation to the first, with speed increasing and torque decreasing, or speed
decreasing and torque increasing.

Plummer Block
A Plummer block is a pedestal used to provide support for a rotating shaft with the help of
compatible bearings & various accessories. Housing material for a pillow block is typically
made of cast iron or cast steel.
The fundamental application of both types is the same which is to mount bearings safely
enabling their outer ring to be stationary while allowing rotation of the inner ring. Housing is
bolted to a foundation through the holes in the base. Various seals are provided to prevent
dust and other contaminants from entering the housing. Thus the housing provides a clean
environment for the expensive bearings to freely rotate, hence increasing their performance
and duty cycle.

Figure 2.12: Plumber block

Power Transmission Chain and Sprocket

Sprocket-wheel is a profiled wheel with teeth, cogs, or even sprockets that mesh with a chain,
track or other perforated or indented material. The name 'sprocket' applies generally to any
wheel upon which radial projections engage a chain passing over it and is shown in Figure 2.
A chain is made up of a series of links with the links held together with steel pins. This
arranges makes a chain a strong, long lasting way of transmitting rotary motion from one gear
wheel to another.

15
When creating your own human powered vehicles, a chain drive will likely be your chosen
power transfer system, as it is an inexpensive, easy-to-install and highly efficient drive
mechanism. Bicycle chains are fairly simple, requiring only one inexpensive tool to remove
and attach links. Since a recumbent cycle will often require a chain that is one and a half to 3
times the length of a regular upright bicycle chain, some basics should be known, as you will
probably need to create the chain for your vehicle.
Catcher is a part of rickshaw on which sprocket could be mount. On it threaded design is
made by using it sprocket could be tighten.

Figure 2.13: Assembly of chain, catcher and Sprocket

Shaft
Shaft is a mechanical component for transmitting torque and rotation, usually used to connect
other components of a drive train that cannot be connected directly because of distance or the
need to allow for relative movement between them. Drive shafts are carriers of torque: they
are subject to torsion and shear stress, equivalent to the difference between the input torque
and the load. They must therefore be strong enough to bear the stress, whilst avoiding too
much additional weight as that would in turn increase their inertia. To allow for variations in
the alignment and distance between the driving and driven components, drive shafts
frequently incorporate one or more universal joints, jaw couplings, or rag joints, and
sometimes a splined joint or prismatic joint.

Figure 2.14: Shaft.

16
Drum as a Washing Chamber
It is just a chamber in which water is filled with detergent further cloth is put inside it for
rinse. In this type of machine, there are two drum are used: inner & outer. Inner drum: This
drum consists of clothes & it is less in diameter as compared to outer drum. Inner drum is
blanked throughout its body. It rotates with the help of compound gear & chain arrangement
in the desired speed with respect to the purpose. Outer drum: Outer drum is used to store
water used for washing the clothes.

2.3 Theoretical frame work

Pedal power washing machine is the transfer of energy from a human source through the use
of a foot pedal and Gear system. This technology is most commonly used for transportation
and has been used to propel bicycles for over a hundred years. Some third world development
projects currently transform used bicycles into pedal powered tools for sustainable
development.
An individual can generate four times more power (1/4 HP) by pedaling than by hand-
cranking. At the rate of ¼ HP, continuous pedaling can be served for only short periods,
approximately 10 minutes. However, pedaling at half this power (1/8 HP) can be sustained
for close to 60 minutes but power capability can depend upon age. As a consequence of the
brainstorming exercise, it was apparent that the primary function of pedal power one specific
product was particularly useful the bicycle.

A pedal-powered washing machine would allow women to wash clothes faster and with less
strain. In developing countries, rural women are among the least privileged. Women are both
essential to the family unit and integral to the economy. Usually, new technology improves
people’s efficiency, but women benefit less from new technology for several reasons. First,
women’s duties are neglected by technological improvement efforts because domestic chores
are often seen as cultural obligations for women so little effort is expended to diminish them.
Second, foreign aid in the form of appropriate technologies is unevenly distributed because
women are often considered less technically competent than men. Factors like these tend to
prevent the development of improved technology for women’s uncompensated, time-
consuming, and laborious
It is an affordable, environmentally-friendly alternative to devices powered by electricity or
fossil fuels. Since it is based on bicycle components, the machines can be manufactured
locally and repair parts are affordable and readily available. We are hoping that designed to

17
be produced and maintained in any culture where bicycle technology exists, will help to bring
appropriate technology and opportunities to women in developing nations across the world
and pave the way for other pedal-powered or appropriate technologies that would help
women.

2.4 Construction and working principle

A scrap bicycle is used as frame and power transmission mechanism. The wheels are
removed and the cycle is welded to a pre-fabricated assembly as shown in Figure 5. A shaft is
welded perpendicular to the rear sprocket of the bicycle. The shaft is supported by ball
bearings in order to restrict the bending of shaft during loading. A bicycle chain connects the
gear at the drum to a set of pedals mounted on the frame. A bevel gear (Pinion) is fixed to the
free end of the shaft. A bevel gear (Gear) is fixed to the main driving shaft of the washing
drum. The inner drum which holds the clothes is currently constructed by modifying a plastic
utility tub. Tubs like this are widely available at the scrapper or in Kisenyi where they sell
used chemical drums. The inner drum is perforated, so that the spinning of the drum will
extract water from the clothes. There are also three triangular fins inside the inner drum that
agitate the clothes during the wash. Rotational force turns the drum via a drive gear attached
to the opposite side of the pedal shaft to bring about the washing.
The operator loads and unloads clothing from the inner drum through a cut out on the side of
the outer barrel. The operator drains the soapy water and rinse water by opening a drain value
at the bottom of the barrel.

According to Shigley (1986), the power delivered by a shaft is given by

P=F×V
Where P = power (Nm/s), F = force of threshing, and V = velocity.

18
 CHAPTER THREE
METHODOLOGY

Table 3.0: Methodology and Data Instruments for each Specific Objective
S/N SPECIFIC METHOD DESCRIPTION OF METHOD EXPECTED OUTCOME
OBJECTIVE USED

1 To study the Observation 5 urban Hospitals and 6 washing Time taken, power
existing types of machine Stores were visited which consumption, cost and
washing machines enabled the research to observe 20
Performance parameters
on the basis of machines.
were determined.
design,
performance, Desk search The internet and washing machine Time taken
economy and journals were used and the related
Power consumption
applications technology. The researcher also
consulted literature review of Safety of the machines
different articles relating to
washing machines

2 To determine the Desk search The internet and the library books Suitable design parameters
machine were used determine parameters were determined
parameters
Interviews 3 technicians were interviewed at Permissible tolerances were
IHK and 1 technician from LG determined
Kampala

3 To select, size the Desk search Using books and the internet, Length, Surface area and
material and different formulae was used in diameters of components.
develop a lay out determining the component sizes

4 To carry out a cost Desk search Material price catalogs were used Prices of different
analysis of to determine material prices and components and Economic
developing a unit different formulae were used to viability of the design, Cost
of pedal washing compute for cost analysis of the of machine determined
machine project.

19
 CHAPTER FOUR
RESULTS AND DISCUSSION

4.1 Study the existing types of washing machines on the basis of design, performance,
economy and applications

4.1.1 Existing cloth washing methods

 Use of Hand
Here, clothes are washed by use of hand by majorly women. This is a very slow, time
consuming and tiresome process which involves soaking, beating, scrubbing and rinsing dirty
textiles. It costs Kiwoko Hospital Shs5million every month to employ 20 women to hand
wash the hospital laundry. They work 9 hours every day under exposure to a risk of infection
from the contaminated patient’s laundry and contact with the detergent thus danger is posed
to Women’s skin. This process often occupies the entire day of hard work, not to mention the
drying and the ironing.

 Use of an Electric Washing Machine

This is a conventional washing machine used in modern hospitals in developed countries and
some parts of Uganda urban hospitals with access to stable supply of electricity.

4.1.2 Studying the existing laundry washing methods.

Considering a load of 100pairs of Bed sheets and comparing the existing washing methods
used by the different rural Hospitals,

Table 4.1: Comparison of existing washing methods

Method Time taken No. of Water

Persons Requirement
(Liters)

Hand washing 8 hours 1 400

Electric machine 1 hour 1 100

Hand Cranked Washing 5 hours 1 300

machine

20
 Percentage of use of different Laundry washing methods in
Rural Hospitals

[PERCENTAGE]
[VALUE]%

[PERCENTAGE]

Hand wash Electric Machine Hand Cranked

Figure 4.1: Pie chart showing the percentage of use of different Laundry washing
methods in rural hospitals

4.1.3 Operating specifications of a convectional electric washing machine

Table 4.2: Shows the Operating specifications of a convectional electric washing

machine
Process Time Taken RPM Torque Generated by motor
(mins) required

Washing 30 20rpm 60.2Nm

Rinsing 5 500rpm 3.5Nm

Drying 15 1000rpm 2.0Nm

4.1.4 Energy Consumption

Motor is the main energy consuming device. Motor is not operating at all the cycle. It is idle
during water fill and drain cycle, at that time motor does not consume energy. The motor
operates during wash, rinse and spin process. The motor consumes more power during wash

21
process when compared to rinse and spin process. The below figures show the energy and
time split up for different water levels and various load condition.

Energy Consumption Chat for Electric Machine

145

140
Energy Consumption in (Wh)

135

130

125

120

115
2 3 4 5
Weight of Dry Clothes in Kg

Figure 4.2: A bar graph showing the energy consumption for Electric machine

4.2 Determining the performance parameters

4.2.1 Pedaling Rate
Human beings are very adaptable and can produce power over a wide range of pedaling
speeds. However, people can produce more power for a much longer time if they pedal at a
certain rate. This rate varies from person to person and depends on their physical condition,
but for every person there is a pedaling speed in between straining and fatigue that is the most
comfortable, and that has the most efficient power production. Generally most people
engaged in delivering power continuously for 1 hour or more will be most efficient when
pedaling in the range of 50 to 70 rpm. For simplicity's sake, 60 rpm is used, as an easy
reference value for estimates of the gear ratios required to drive a given load. The washing
machine has 3 different processes which require different pedaling rates. The processes are:
washing, rinsing and drying.

22
 POWER OUTPUT AGAINST PEDALING RATE
350 100
50
2

300
POWER OUT PUT (WATTS)

250

200 300

150
200
100 125

50 100

0
20 40 60 80 100

PEDALING RATE (RPM)

Figure 4.3: A bar graph showing power output against pedaling rate
It can be seen from table 1 that the total time required for the entire process is 50 minutes. For
a more comfortable and efficient power production through pedaling the pedaling rate is
taken as 60 rpm. From Figure 5, it can be seen that under optimal conditions, when pedaling
at 60 rpm a healthy person produces 125 Watts of power. The total by a healthy man is
around 200 Watts. Thus, pedaling at 60 rpm and developing a power of 125 Watts provides
considerable factor of safety for the person pedaling. Now, keeping the input power constant
at 125 W and using different speeds as required for different processes, we can calculate
torque for the three different processes.

Power, P=2𝜋NT/60,

Torque available at the tub for washing, T=60𝑥125/2𝜋X20=59.68𝑁

Now calculating the actual power available for washing, P=2𝜋𝑥 20 𝑥 59.68/60=2.5𝑊

Torque available at the tub for rinsing, T=60𝑥125/2𝜋𝑥 500=2.38𝑁

Now calculating the actual power available for rinsing, P=2𝜋𝑥 20𝑥59.68 𝑥 60=62.5𝑊

Torque available at the tub for drying, T=60𝑥125/2𝜋1000=1.19𝑁

Now calculating the actual power available for drying, P=2𝜋𝑥 20𝑥59.68/60=125𝑊

23
The minimum torque is the deciding factor for determining the capacity of washing machine
as the same load of clothes remains during all the three processes. Therefore the capacity of
the washing machine is calculated to be around 1.2 kg.

Table 4.3: Required torque and power for each of the 3 processes
Process RPM Required Torque Available Power Required

1. Washing 20 rpm 59.68Nm 2.5W

2. Rinsing 500 rpm 2.38Nm 62.5W

3. Drying 1000 rpm 1.19Nm 125W

24
4.3 Select, size the material and develop a lay out

4.3.1 List of components

Table 4.4: Shows the list of components required

S/N Component Part Details Dimension Suitable Reason
Engineering
Material

1 Drums Outer Drum Diameter 100cm Plastic High Corrosion

Resistance, cost
Inner Drum Total 200litres
Volume

Outer Drum Diameter 130cm Perforated Mild Availability and

Steel cost effectiveness
Outer Drum Total 240litres
Volume

2 Shaft Diameter 30mm Mild steel High strength

Distance between the 70cm

Shaft and the cycle

3 Seat Height of the Seat 80cm Polymer and sponge Comfort

4 Bearing Height of the Handle 62/22 Sealed for Life High corrosion
where d = Stainless Steel resistance in
22mm presence of
water. Radial and
Axial loading

5 Chain Length 700mm Mild steel Cost, High

Strength

6 Frame Bicycle Frame Normal Mild Steel Good service life

Bicycle
frame

7 Base Area 10000m2 angle iron Cost, Availability

on market

25
4.3.2 Design of sprockets and chain

Figure 4.4: the design of Sprocket and chain

Table 4.4: Shows the specifications for sprocket and chain

Specifications Design

Chain Pitch (p) 15.87mm

Number of Countershaft Sprocket Teeth (N) 44

Number of Rear Sprocket Teeth (n) 12

Center to Center of both sprockets (c) 60mm

Number chain of Links 46

Chain Length 716mm

4.3.3 Power transmission

Sprocket
The normal person’s crank speed is 60 rpm at normal conditions. If we assume that the
countershaft sprocket has gotten 60 rpm
S1 = 60 rpm, T1 = 44 teeth,

S2 = ??, T2 = 12

Using the relationship of gears,

S1.T1 = S2.T2

S2 = 60𝑥 44/12 = 220rpm

26
Bevel Gears
Since the rear sprocket and the driver gear are shearing the same shaft, which means that the
driver gear has the same speed as the rear sprocket.

Speed of the driver = S3 = 220, N3 = 100teeth

We know that the maximum Speed is the dryinng speed = 1000rpm.

Therefore, S4 = 1000rpm and N4 = ??

Using the formula S1.N1 = S2N2

N4 = 220𝑥 100/1000 = 22teeth

Therefore the driven gear = 22teeth

4.3.4 Sketch of the design

Volume = 240litres I Volume = 200 liters

Outer diameter = 130 cm Outer Diameter = 100cm

Outer drum Inner drum

27
 Shaft Diameter = 30mm Inner Diameter = 30.5mm
Outer Diameter = 65mm

Shaft Bearing

Bevel Gear
No of teeth of Driver = 100teeth, d = 50mm
No. of teeth of Driven = 22teeth, d = 30mm

28
 4.3.5 Final lay out of the Pedal Driven washing machine

Handle

Washing
chamber
Bicycle Frame

Bevel gear

Pedal
Bearing, rear sprocket
Bicycle Seat
and Plummer block
Chain

Base

29
4.4 Cost analysis

4.4.1 The bill of materials

Table 4.5: Shows the Bill of materials

S/n Name of the component Qty Cost (Ugx)

1 Chain and Pedal Crank 1 each 30,000

2 Sprockets 2 32,000

3 Bevel Gear 2 200,000

4 Shaft & Nuts 70,000

5 Bicycle Frame and Seat 1 each 55,000

6 Bearing and Plummer Block 1 each 170,000

7 Drums 2 160,000

8 Hollow sections & Aluminium Plate 60,000

9 Labour 300,000

TOTAL 1,167,000

4.4.2 Payback period

Initial cost of performing Task = 150,000*20 = 3,000,000

Apparent cost of performing the Task = 150,000*4 = 600,000

Monthly maintenance cost = 30,000

Hospital therefore saves (3,000,000-630,000) = 2,370,000

Initial Sales Price of new machine = 2,000,000

Considering the amount the hospital saves as the cash inflow

30
Pay back = Total cost of project / cash inflows

= 2,000,000 / 2,370,000

= 10 months

It can be concluded that the pedal powered washing machine is an economical solution to the
washing problems faced by hospitals in the rural areas as it is affordable and easier to
implement.

Pedal washing machine is an environmentally friendly solution. It is the best solution for the
environment since some parts use recycled material and since it also saves water. The
solution does not require electric power or power from internal combustion engines thus
saving energy.

31
 CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion
1. The existing cloth washing methods were successfully reviewed which was achieved
with the help of library search, internet and local information, it was ascertained that
the dominant methods for this task are Electric Washing machine and hand washing.
2. The different components were selected, designed and the pedal washing machine
designed has a maximum power requirement of 125W and equivalent of a person
pedaling a distance of 1km.
3. At least any given local hospital can afford to buy this machine. The use of
inexpensive parts makes the final cost low, enabling rural hospitals to afford it.
4. The cost analysis for the project was carried out and the payback period. The project
has shorter payback period will attract potential investors from experimentation
therefore, it can be concluded that the system is practically feasible.

5.2 Recommendations
1. The design should be adopted by rural Hospitals areas without electricity to increase
their efficiency and their capacity. This design can also be adopted in homes to
reduce on their power costs.
2. The construction of the machine should be based on the design parameters presented
in this report.
3. A proper maintenance schedule should be adhered to so as to get the best output of the
machine. Necessary repairs need be done in time such that the machine is available all
the time.
4. Testing of the machine for its performance should be done at 60rpm to compare the
expected results and the achievable outcome

32
 REFERENCES
1. Bruzzone, M. &Wieler, A. (2010) “Reflecting on an Intercultural Design-Build Project in
the Kathmandu Valley” Final Draft, February 5, 2010.
2. By Human Power Flywheel Motor.”-A past review, Proceedings of the 1st International
and 16th National.
3. Conference on Machines and Mechanisms IIT Roorkee, India, Dec 18-20 2013
4. http://en.wikipedia.org/wiki/Washing machine.
5. http://home.howstuffworks.com/washer1.htm
6. http://www.apparelsearch.com/definitions/miscellaneous/washing_machine.htm
7. http://www.ideafinder.com/history/inventions/washmachine.htm
8. Prof. Nitinchandra R. Patel, Mohammed A. Vasanwala, Balkrushna B. Jani, Miteshkumar
D. Rathwa& Ravi A. Thakkar “Material selection and testing of hacksaw blade based on
mechanical properties’ international journal of innovative research in science, engineering
and technologyvol. 2, issue 6, June 2013
9. R.S.Khurmi “Design of Machine Elements”, Eurasnia publishing house 3 Pvt Ltd, 14th
revised edition.
10. S.M.Moghe&K.S.Zakiuddin (2013) “Design and Development of Turmeric Polishing
Machine Energized.

33
 APPENDIX

Appendix i: Different components

34