Bahir Dar University

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering

Automotive Engineering program

Internship Report and project

Project title: Design of Car body painting machine

Hosting Company: Bishoftu Automotive engineering industry

Name ID No.

1. Leykun Tesfa...............................................................0904589

2.Tensae Ewunetie...........................................................0905230

Monitor: Mr. Tesfahun T.

Company Supervisor: Mr. Dawit

Submission date:
 Declaration

We declare that this project entitled with “design and analysis of car body painting
machine” is our own original work. To the best of our knowledge, the work presented
here has not been presented for a degree in any other Institution of Higher Learning or
Universities.

We also confirm that the project work and report is only prepared for our academic
requirement not for any other purpose.

Name of Students Signature Date

1. Leykun Tesfa…………………… ………… …………

2. Tensae Ewunetie……………… ………… …………

Date of submission: _________________________

This internship project has been submitted for examination with our approval as a
university advisor.

Internship advisor:

Name: signature date

Tesfahun Tiku ---------------------- -----------------------

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 Acknowledgments

First of all, we would like to thanks our Almighty GOD for all things happened. Then
we would like to thanks our university and hoisting company for giving this
opportunity for us to experience what we have learnt in theoretical and practical
lesson to develop our experience.

We would like to express our special thanks of gratitude to our university advisor Mr.
Tesfahun Tiku and our company advisor Mr. Dawit for their able guidance and
support in completing our project and internship report. We would also extend our
gratitude to our family's for providing us with financial requirements.

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 Acronym and abbreviation

ABS -Anti-Lock Brake System

AC -Air conditioner
APCs -Armored Personnel Carriers
BAEI -Bishoftu Automotive Engineering Industry
DC -Direct Current
DDG -Duty Director General
DDG-ACB -Duty Director General for Administration and Capacity Building
DDR-R -Duty Director General for Researches
DG -Director General
dh = Differentiation with respect to lift height
E = Modules of elasticity
ECAS -Electronic Control Air Suspension
ECU -Electronic Control Unit
FOS = Factor of safety
I = Moment of inertia
IR -Infrared Sensor
LE = Equivalent length
LED -Light Emitting Diode
M = Bending moment
Pcr = Critical load
T = Applied torque
U.D.L -Uniformly Distributed Load
U.V.L -Uniformly Varying Load
σw = Working stress
τall = Allowable shear stress
ө = Angle of link from the horizontal

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 Executive summary

This report is about our internship program with Bishoftu Automotive Engineering
Industry (BAEI).in this comprehensive report we have discussed about every aspect
of BAEI which is observed and perceived during our internship program.

In this report we will find the details about BAEI right from its incorporation to the
current position. Along with it, the organizational structure, work flow, mission and
vision of the company, its major suppliers and end users of the product and services
are discussed also in detail.

During our internship program we mainly worked in bus production factory and
power train production factory section of the industry. As the main purpose of the
internship is to learn about the working in practical environment and to apply the
knowledge acquired during the studies in a real-world scenario in order to tackle the
problem using the knowledge and skill learned during the academic process.

This report covers the benefits that we are gained during our internship period in
terms of improving our practical skill, team playing skill, leadership skill,
entrepreneurship skill, communication skill, upgrading theoretical knowledge and
understanding about work ethics issues. This paper includes the task that we have we
have been executed in the company Engineering methods, tools and techniques we
have been using while performing our work tasks. It also includes challenges and

. problems we have been facing and identifying while performing our work tasks and
the proposed solution that we have taken to tackle the problem.

In the end of the learning and experience section we have select the problem in the
company and done a project for the selected problem which is the painting process
which is very bulky. The problem statement and justification, objective of the project,
methodology, analysis, result and discussion, proposed solution, conclusion and
recommendation of the project also explained in this paper

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 Table of Contents
Chapter one .......................................................................................................................... 1

Industry Background ......................................................................................................... 1

1.1. History of Bishoftu Automotive Engineering Industry .............................................. 1

1.2. Vision...................................................................................................................... 1

1.3. mission ................................................................................................................... 1

1.4. Major products and services ................................................................................... 1

1.5. Customers and Suppliers of BAEI............................................................................. 4

1.5.1. Main customers ................................................................................................... 4

1.5.2. Main suppliers ..................................................................................................... 4

1.6. Organizational structure and work flow .................................................................. 4

Chapter two .......................................................................................................................... 7

Internship experience........................................................................................................ 7

2.1. Sections we have worked........................................................................................ 7

2.2. Distribution of the product ..................................................................................... 7

2.3. Task executed by our self ...................................................................................... 13

2.4. Techniques, tools and engineering methods ......................................................... 14

2.4.1. Tools .................................................................................................................. 14

2.4.2. Engineering method........................................................................................... 15

2.4.3. Techniques applied in our work tasks ................................................................. 16

2.5. Problems and challenges faced during working ..................................................... 16

2.6. The measurements taken ..................................................................................... 16

2.7. Over all benefits gained from the internship ......................................................... 17

2.7.1. Improving our practical skill ............................................................................... 17

2.7.2. Upgrading theoretical knowledge ...................................................................... 17

2.7.3. Team playing skill ............................................................................................... 18

2.7.4. Improving our leadership skills ........................................................................... 18

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 2.7.5. Understanding about Related Work Ethics & Industrial Psychology .................... 19

2.7.6. Improving entrepreneurship skill ....................................................................... 19

2.7.7. Improving our interpersonal communication skills ............................................. 19

2.8. Conclusion and Recommendation in the internship .............................................. 20

2.8.1. Conclusion ......................................................................................................... 20

2.8.2. Recommendation .............................................................................................. 20

CHAPTER THREE .................................................................................................................. 22

Project ............................................................................................................................ 22

3.1. Background of the Project..................................................................................... 22

3.2. Problem statement and justification ..................................................................... 23

3.2.1 Problem statement ............................................................................................. 23

3.2.2. Justification........................................................................................................ 23

3.3. Objective .............................................................................................................. 24

3.3.1. General objective ............................................................................................... 24

3.3.2. Specific objective ............................................................................................... 24

3.4. Scope .................................................................................................................... 24

3.5. Literature review .................................................................................................. 24

3.5. Methodology and design procedure analysis ........................................................ 25

3.5.1. Data collection ................................................................................................... 25

3.5.2. Data analysis ...................................................................................................... 26

3.6. Component parts .................................................................................................. 26

3.7. Material selection ................................................................................................. 28

3.8. Design procedure and analysis .............................................................................. 29

3.8.1. Design of hydraulic scissor lift ............................................................................ 29

3.8.1. Design of link ..................................................................................................... 29

3.8.2. Design of Pin ...................................................................................................... 31

3.8.3. Design of Cylinder .............................................................................................. 32

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 3.8.4. Design of top plat form ...................................................................................... 34

3.8.5. Design of bottom plat form ................................................................................ 34

3. 9. Design of the base frame ..................................................................................... 34

3.10. Design of power transmitting shaft from DC motor to wheel .............................. 36

3.11. Results and Discussion ........................................................................................ 37

3.12. Conclusion and recommendation ........................................................................ 38

3.12.1. Conclusion ....................................................................................................... 38

3.12.2. Recommendations ........................................................................................... 39

3.12. Cost analysis ....................................................................................................... 39

References .......................................................................................................................... 42

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Table of figure

Figure 1.1: - double cabin pick up .......................................................................................... 2

figure 1.2: - heavy duty trucks ............................................................................................... 2

Figure 1.3: - Motor cycle and fork lifts ................................................................................... 3

Figure 1. 4: - tanks and armored vehicle ................................................................................ 3

Figure 1.5. working flow of the company ............................................................................... 6

Figure 2.1 New product of bus factory ................................................................................... 7

figure 2.2: - Anbesa bus ......................................................................................................... 7

figure 2.3 Axle assembly ........................................................................................................ 8

figure 2.4 engine assembly .................................................................................................. 10

Figure 2.5 frame alignment ................................................................................................. 11

Figure 2.6: - flow diagram in the painting room ................................................................... 12

Figure 2.7:- final work sop ................................................................................................... 13

Figure 2.8 hand tools ........................................................................................................... 15

Figure 2.9: - power tools ..................................................................................................... 15

Figure 3.1 solenoid valve circuit .......................................................................................... 27

Fig 3.2 Spray gun ................................................................................................................. 28

Figure3.2. link ..................................................................................................................... 29

Figure 3.3. U.V.L. on link ...................................................................................................... 30

Figure 3. 4. link Cross section .............................................................................................. 31

figure 3.5. Pin ...................................................................................................................... 32

Figure 3.6. Cylinder ............................................................................................................. 32

figure 3.7. scissor mechanism .............................................................................................. 33

Figure 3.8 top plat form ...................................................................................................... 34

Fig 3.9 bottom plat form ..................................................................................................... 34

Figure 3.10 free body diagram of U.D.L load ........................................................................ 35

Figure 3.11 base frame ........................................................................................................ 36

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Fig 3.12 Final result ............................................................................................................. 38

ix
 Chapter one

Industry Background

1.1. History of Bishoftu Automotive Engineering Industry

Project 40720/currently named Bishoftu Automotive Engineering Industry
established in 1984 to overhaul medium repair of armored and automotive parts,
communication equipment’s, maintain radar stations and anti-air craft guns.

From 1991 up to 2008 the project works finalize and the industry started overhauling
tanks and Ural military Turks. In 2008 the industry reorganized under defense
industry sector named as Bishoftu Motorization Engineering Complex established in
1999. Later in 2010 it re- established and re-named as Bishoftu Automotive
Engineering Industry while it incorporated into the Metals and Engineering
Corporation. Located 45 km East of Addis Ababa, in the town of Bishoftu.

Today Bishoftu Automotive Engineering Industry is the single largest vehicle

manufacturer in Ethiopia, from light vehicle to heavy duty commercial trucks, buses,
special purpose vehicles, military trucks and APCS. In addition, the industry works
overhauling and upgrading of Tanks and APCS (Armor Personnel carrier). In addition
to producing and supplying automotive products it also working on the expansion of
modern automotive technology as well as related production facilities owned by
private enterprise.

1.2. Vision
To become a competitive automotive industry in the global market.

1.3. mission
Lead the industrial development of Ethiopia in the automotive sector.

1.4. Major products and services

Bishoftu Automotive Engineering Industry has eight factories and one VIP and referral
garage. Those are:

I. Light vehicle production factory for

➢ Pick up
➢ Station wag
➢ 2,3,5 tone mini trucks
1
 Figure 1.1: - double cabin pick up

II. Heavy duty truck production factory

➢ All types of trucks
➢ Cargo truck
➢ Dump truck
➢ Water and fuel truck
➢ Trailer truck
➢ Fire truck
➢ Cranes
➢ Vans

figure 1.2: - heavy duty trucks

III. Bus production factory
➢ City bus
➢ Intercity bus
➢ City mid bus
➢ School bus
➢ Cross country bus
IV. Power train production factory
➢ All types of engines, transmissions, differentials etc.
V. vehicle system production factory
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 ➢ Fork lifts
➢ Telescope handler
➢ Motor cycle assembly plant manufacturing
➢ Bicycle assembly plant manufacturing
➢ Electrical and Mechanical parts
➢ Hydraulic and pneumatic parts

Figure 1.3: - Motor cycle and fork lifts

VI. Body and frame production factory

➢ Tipper body
➢ Semi-trailer
➢ All bus frames
➢ Water and fuel tankers
➢ Truck cabin
➢ Cabin and cargo for pick up
VII. Tank and armored vehicle production factory
➢ Tanks
➢ APCS
➢ Armor vehicles

Figure 1. 4: - tanks and armored vehicle

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 VIII. Painting production factor
➢ All vehicles and parts

1.5. Customers and Suppliers of BAEI

1.5.1. Main customers

➢ Addis Ababa Anbesa city service enterprise
➢ Federal water work enterprise
➢ Regional water work enterprise
➢ Ethiopian road authority and dam project of government
➢ federal ground force
➢ Ethiopian Military aviation

1.5.2. Main suppliers

➢ FAW African Investment
➢ Sino truck import export co.ltd
➢ Yutong Hong Kong limited
➢ China North industry corporation
➢ Kunshan special purposes vehicle manufacturing
➢ Liaoning Huanghai Automotive IMP

1.6. Organizational structure and work flow

The governing body of the institute includes the Director General, the Deputy
Director Generals, research and support directorates, and research centers.
The Director General is the Chief Executive Officer, exercising all the powers vested
on him by the Establishment Proclamation of the Institute. Provides management
leadership to technical and supportive directors at the HQ and the center directors.
Center Directors are managed by the DG.
Deputy Director General for Research (DDG-R) assists the DG and takes care of
various aspects of the research, i.e., technology generation, multiplication, and
dissemination. Sector Directors are line managed by DDG-R.

The Deputy Director General for Administration and Capacity Building (DDG-ACB)
assists the DG and takes care of various aspects of administration and capacity
building.

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Research Directorates are answerable to the DDG-R, and guide, coordinate and
oversee research in their respective directorates.
Research Center Directors are answerable to the DDG-R, and guide, coordinate,
and oversee research in their respective research centers.
Support Directorates are answerable to DG and DDGs. Carry out duties to better
support EIAR in discharging its duties and responsibilities effectively.
Research Directorates
Research directorates are answerable to the DDG-R guide, coordinate and oversee
research in their respective directorates.
➢ Crops Research Directorate
➢ Livestock Research Directorate
➢ Natural Resources Management Research Directorate
➢ Crop Protection Research Directorate
➢ Agricultural Engineering Research Directorate
➢ Agricultural Economics Research Directorate
➢ Agricultural Biotechnology Research Directorate
➢ Food Science and Nutrition Research Laboratories Directorate
➢ Technology Multiplication and Seed Research Directorate
➢ Climate, Geospatial and Biometrics Research Directorate
➢ Pastoral, Agro-pastoral and Special Support Regions Research and
Capacity Building Directorate
➢ Agricultural Extension and Communication Research Direct
Bishoftu Automotive Engineering Industry is growing and becoming broader from
time to time. It is opening new assembly and maintenance factories and as a result it is
becoming more complex and the number of workers is also increasing from time to
time.

Currently the company has 3500 workers including military, contract, and permanent.
The specific number of the sub-groups with their education status is listed below.

Permanent: - civil workers with degree, military workers with degree, and workers
with diploma.

5
Contract: - workers with degree and workers with diploma, and the rest workers are
master degree holders.

This profit-making industry different types of operational job flow cycles with the
main ones as purchase repulsion, market research for repulsion, and service repulsion.

The work flow and linkage between the various sections and authorities under the
company is shown in diagrammatic format below

repulsion Purchase

Factories Head of Market Logistic Purchase

marketing research and administration department
and sales advertisement

Market research repulsion for purchase

Operation Customer
head relations
Customer General
Manager
Market and Factories
sale head

Service repulsion

Factories Operational Logistics Purchasing

head administratio department
n

Figure 1.5. working flow of the company

6
 Chapter two

Internship experience

2.1. Sections we have worked

During our internship period we mainly worked on the bus and power train
production factory. Because in the bus production shops a modern and more electrical
city bus is assembled from the chassis up to the final finishing.
So, in order to see and know:

➢ The assembling procedure each component

➢ Electrical harness installation
➢ The braking line installation
➢ The function of each component

2.2. Distribution of the product

This factory produces city bus, mid-bus and cross-country bus. The factory solves the
problem of some Ethiopian town by the direction of public transport. All activities of
this factory are 100% assembly of vehicle part.

Figure 2.1 New product of bus factory

In the fourth month only the You tong (anbesa) bus is produced.

figure 2.2: - Anbesa bus

The job of public transport vehicle production factory is done under four shops.

➢ Chassis and engine assembly shop

7
 ➢ Body welding
➢ Color painting shop
➢ Finishing workshop
1, Chassis and engine assembly shop

The task of chassis and engine assemblies are done in seven stations. Activities in
each station are described below.

Station one: material supply to chassis line

➢ Supply of front &rear axle and chassis

➢ Supply of air reservoir and valves
➢ Supply of steering oil pipe system
➢ Supply of radiator and inter cooler
➢ Supply of air filter system
➢ Supply of engine and gear box
➢ Supply of harness
➢ Supply of pipe
➢ Supply of steering system
➢ Supply of AC compressor
➢ Supply of drive shaft
➢ Supply of fuel system

Station two: Axle assembly

➢ Front and rear axle assembly

➢ air bug assembly
➢ shock absorber
assembly
➢ stabilizer
assembly

figure 2.3 Axle assembly

8
Station three: - Small parts assembly

➢ All valves installed firmly

➢ Installation of adapters
➢ Air storage cylinder and stripe installation
➢ Mounting of four-way valve
➢ Mounting of ABS valve
➢ All installation brackets
Station four: - AC and steering system assembly

➢ Installation steering oil Pump

➢ Automatic air drier assembly
➢ Coolant line assembly
➢ Assembly of pitman arm and small & long tie rod
➢ steering angle installation
➢ Assembly of steering gearbox
➢ Ac belt tension, turning radius and toy in toy out measurement
➢ Steering oil tanker assembly
➢ Pulley assembly
➢ Steering column assembly
Station five: - installation of pipes
➢ Installation of galvanized pipe
➢ Installation of fuel line pipe
➢ Mounting of cooler system with pipe
➢ Installation of front and rear flexible hose
Station six: - Engine assembly

➢ Gear box with engine pre assembly

➢ Mounting and tighten of engine on the chassis
➢ Air cleaner assembly
➢ Engine front and rear bracket installation
9
 ➢ Assembly of exhaust system
➢ Installation of intake system
➢ Tighten of different types of both exhaust and intake hose with clamp
➢ Connection of upper and lower radiator hose

figure 2.4 engine assembly

Station seven: - Installation of chassis harness

➢ Chassis wiring harness installation

➢ generator harness assembly
➢ ECU harness
➢ ABS harness
➢ ECAS harness
➢ Gearbox harness
Station Eight: -Drive shaft and retarder assembly

➢ Pre assembly of cooler and radiator

➢ Assembly of cooler and radiator on chassis
➢ Mounting of pulley and fan
➢ Assembly of propeller shaft
➢ Fuel tanker
➢ Assembly of expansion tanker
After all this above-mentioned activity completed it delivered to Body welding shop.

2, Body welding shop

Station one: - frame Alignment

➢ Left and right side align

10
 ➢ Engine cover align
➢ Read and front align
➢ Upper floor aligns

Figure 2.5 frame alignment

Station two: - frame welding

Station three: - Roof welding and air duct transmission opening

Station four: -

➢ Floor partition welding

➢ Expansion tanker support
➢ Air cleaner and rear engine start button support
➢ Air duct cover

Station five: - upper and lower sealed boarded welding

Station six: - fender and step-down weld

➢ Wheel cover
➢ Door stand cover
➢ Radiator cavity welding
Station seven: - Driver compartment and passenger door welding

Station eight: - Front and rear cup cover welding and engine and AC compartment
door welding.

3, Painting work shop

Under this shop we have seen how paint is mixed and the procedure of painting to all
type of vehicles. The operation is performed as shown in the chart below.

11
Primary Primary Putty Polishing
painting room drying drying room
room room

Final and Final and mid

middle drying coating room
room
Figure 2.6: - flow diagram in the painting room
4, Finishing work shop

Station one: -

➢ Air conditioner assembly

➢ Battery assembly
➢ All external LED displays
➢ AC fuse board assembly
➢ Water pump installation
Station two: -
➢ Sky light assembly
➢ Door emergency valve hose assemble
➢ Roof sponge
➢ Play wood
Station three: -
➢ Roof harness
➢ Gage harness
➢ Roof lamp installation and assembly
➢ Speakers
➢ AC and sky light inner cover
Station four: - Mirror assembly
➢ Side window and glass
➢ Rear glass Assembly
➢ Floor mat and edge frame
➢ Brake pedal and acceleration pedal
Station five: -
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 ➢ Side decoration
➢ Dash board assembly
➢ Hand brake assembly
➢ Driver compartment assembly
➢ Fuse box assembly
Station six: -
➢ Door assembly
➢ Multi instrumental and dash board switch assembly
➢ Steering column cover
➢ Deforester assembly
Station seven: -
➢ Front grille
➢ Rear viewer mirror
➢ Handrail assembly
Station eight: -
➢ Passenger sits
➢ Driver sits
➢ Front wind screen chuck

Figure 2.7:- final work sop

2.3. Task executed by our self

During our internship period we have executed the following tasks

In bus production factory

➢ Torque rear and front axle

➢ Assembly of air suspension and shock absorber

13
 ➢ Mounting of ABS valve
➢ Installation of electrical harnesses
➢ Installation of galvanizing pipe
➢ Installation of intake and exhaust system
➢ Mounting of engine and transmission to chassis
➢ Cooling system assembly
➢ Frame welding
➢ Left and right-side alignment welding
➢ Battery assembly
➢ Side window and glass assembly
➢ Dash board assembly and etc.

In power train production factory

➢ We disassemble commercial engine

➢ Washing each part with benzene
➢ Inspection, measuring and servicing
➢ Re assemble the engine
➢ Gear box disassembly and inspection

2.4. Techniques, tools and engineering methods

2.4.1. Tools
We mainly use two division of tools based on the source of energy applied on the
tools. These are;

1. Hand tools which we apply our force to operate with them and

2. Power tools which operate by electric, compressed air or hydraulic pressure

Hand tools: socket wrench, internal snap ring remover, Hammer, Adjustable wrench
box wrench, dial gauge, Vernier caliper, filer gauge.

14
 Figure 2.8 hand tools
Power tools

➢ Air power wrench

➢ Mobile crane
➢ Hydraulic lift scissor jack
➢ Grinder
➢ Welding machine
➢ Drilling machine
➢ Fork lift

Figure 2.9: - power tools

2.4.2. Engineering method

The mechanical engineering methods that we have been experienced during our intern
time are:

➢ Welding
15
 ➢ grinding
➢ hammering
➢ cutting
➢ drilling
➢ boring

2.4.3. Techniques applied in our work tasks

➢ To tighten and loose bolts and nuts extension levers are used to
multiply force.
➢ To prevent rest, we smear the bolt with anti-rest glue during
tightening.
➢ During engine disassembly we use punch to identify the correct
position for final assembly.

2.5. Problems and challenges faced during working

➢ There was no responsible person to organize us.

➢ Shortage of money to survive us.
➢ We can't communicate easily with the workers
➢ Working time is too long makes us tired
➢ The industry has no internet conection, due to this we have
been in dificult situation to search necessary data for the
project.
➢ some workers have no awarness what they do and for what
purpose when we ask to get clarification

2.6. The measurements taken

➢ To solve shortage of money we obliged our family to take

additional birr
➢ We use our mobile data to collect necessary data for the project
➢ We tried to get detail information about the machine by asking
operators
➢ Make close relationship with each of workers & operator of the
company,
➢ Being patient to get something what we want
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2.7. Over all benefits gained from the internship

Internship has an important role to develop practical knowledge of the students,

increased the social interaction and help students to solve their problems by
confidence from this internship we improve the following,

2.7.1. Improving our practical skill

During our internship period we have got the following practical skills,

➢ Idetify vehicle parts most specially bus systems,components,

and parts with their integration position as well their function.
➢ Understand how to mount engine,and all other related
components for the system to function correctly.
➢ Examine operation of pneumatic hoses which actuates
breaking,suspension, door locks, air conditioners and others.
➢ Improve the installation of all electrical harnesses
➢ Improve our practical skills of disassembling, inspecting,
measuring, servicing and assembling of an engine of different
vehicles
➢ Learnt how to handle wrenches and other tools when operating
on a component including proper spreading of foots for balance
➢ We have learnt how to be safe in a working environment.
➢ And also we have learnt how body,and system modifications
are made. Like suspension sytem, steering system, starting
system modifications.

2.7.2. Upgrading theoretical knowledge

In addition to the practical skill this program helps to upgrade our theoretical
knowledge. The practice depends first on theory, it is easy to work for the one having
good theoretical base. Theoretical knowledge is dependable on principles, logic and
calculations. The following are some points that we improved our theoretical
knowledge:

➢ The fundamentals of vehicle technologies e.g. vehicle systems

such as ignition system, charging system, starting system,
brake system, steering system, fuel system and etc.
17
 ➢ The types, and associated characteristics, of bus e.g. front- or
rear-wheel drive, four-wheel drive, automatic or manual
transmission etc.
➢ Diagnose the names of components and tools with their
Working principle of different machines

2.7.3. Team playing skill

Since most of the works in every industry done by a group of workers, there should be
good relationship between each member. There are stations for that groups of
mechanics,electricians work together their is a close relation in station workers and in
between stations . So we have improved our team playing skills by gaining the
following benefits:
➢ Appreciating & encouraging each other
➢ Communicates constructively
➢ Listening each other and rise ideas or ask for ambiguous terms
➢ Helping one another in many tasks 18
➢ Shares ideas openly and willingly
➢ Compromise others mistakes
➢ Flexible & Simple to one another
➢ Shows commitment to the team
➢ Works as a problem- solver
➢ Treats others in a respectful and supportive manner
➢ Confidence and Effective communication

2.7.4. Improving our leadership skills

From this internship program we got the experiences how to Control the work flow of
the production. In the company the work flow of the production done by PPC
(production planning and control) they control the work flow by adjusting the
manufacturing time of the production and record rejects material and recommends the
material produce again. Control the workers by preparing attendance sheet to control
the presence of the worker on their working time due to this we improved our skill in: -
➢ Committed to the work
➢ Understanding others idea

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 ➢ Peaceful with fellow workers and others
➢ Being a role model to the workers
➢ Upgrading with knowledge and etc.…

2.7.5. Understanding about Related Work Ethics & Industrial Psychology

Work ethics is a set of values based on hard work and diligence. It is also a belief in
the moral benefit of work and its ability to enhance character. From this program we
can help how to improve work related issue before we meet such an organization or
when we contact our self in such social network environment some of them includes: -
➢ Punctuality
➢ Respecting each worker with their workGive attention to
what they are doing
➢ Office disciplines
➢ Reliability
➢ Honesty
➢ Cooperative
➢ Good leadership
➢ Self confidence
➢ Conducting quality work

2.7.6. Improving entrepreneurship skill

We gained how to perform tasks in easily way of method and to create good working
condition, identifying problems in easily in equipment and making the company to
challenge with other companies to produce a first-choice product. This goes through
creating profitable and good challenger best company in the market. Generally, we
gained that in terms of entrepreneurship skills: -

➢ Being confident for decision making

➢ As an entrepreneur willing to come over every mistake, gets
upon new challenges and willing to change
➢ Being risk taker over work tasks that we took

2.7.7. Improving our interpersonal communication skills

In this internship period we gained how to communicate with all company employees
and gained confidence for every communication in working area. And also help us how

19
to explain and express our task to the higher-level person. Generally, we gained that in
terms of our interpersonal communication skills:
➢ We increase our confidence when communicate with the
company managers and other employees
➢ Because of personal communicating skill we gained different
data that what we want
➢ Because of personal communicating skill we gained
knowledge about the company

2.8. Conclusion and Recommendation in the internship

2.8.1. Conclusion
After going through the whole period of internship as an intern we have been
looking so many professional activities and learnt as well. This internship was very
fruitful for us because according to share our theoretical knowledge and turns it to
practical experience. For example, like improving our leadership skill,
entrepreneurship skill and communication skill. And we gained a confidence to
perform our tasks and allow us to take a risk and find a solution easily. To conclude,
this internship was very beneficial and important for us as we learnt a lot and it
made us to discover works in a real world.

2.8.2. Recommendation
We do appreciate the time and opportunity given to us as a student as far as internship
training is concerned, however there is a need to review in ways in which internship is
handled and address some of above-mentioned challenges by both organization and
university.
➢ There is a great need to facilitate students during internship. This is
because students when go for internship may be in need to buy pc
computer, need internet access etc.
➢ There should be some person who can take the responsibility and
guides the intern.
➢ The difficulty of obtaining internship placement to different
organization is time and effort consuming so we would recommend
the faculty(university) to always get involved in making

20
 communication with the organization to obtain internship placement
to their students.

➢ Only one-time students go to the training is not enough for them to

gain enough practical experience, and, so the university should find
a way of increasing on a number of times students go to the fields.

21
 CHAPTER THREE

Project

3.1. Background of the Project

This project produces a design and construction of an automatic car painting machine
powered by DC motor source and describes the process of fabrication and controlling
the machine. This paper compromises many steps from choosing its design, sizing the
required motor, method of controlling it, end effecter and method of actuation of the
spray gun.in our country almost all industries use compressed type spray painting
technique which is hazardous, boring and exhausting technique which makes it an
excellent cause automation.

The design and fabrication of an automatic paint spraying machine is important with
the foundation of simplicity, reducing human effort, improve the quality, accuracy
and constant painting. The primary aim of the project is to design, develop and
implement paint automation which helps to achieve low cost painting process. The
biggest advantage of automation is that it is used to reduce human effort, improve the
quality, precision and accuracy.

This automatic car painting machine is not designed using complicated components.
This painting is simple and portable. In this project we use scissor lift mechanism to
lift the paint gun so that the paint is applied to the entire height of the vehicle. The
paint gun is actuated by pneumatic cylinder. The process is controlled by the control
unit. An IR sensor placed at the top of the paint gun is used to detect the paint surface
and to detect the upper limit of the vehicle so that the spray can be stopped when the
paint gun reaches the top of the car and if the paint surface is far apart over 15 cm
range. The pneumatic cylinders are controlled using solenoid valve

In this paper the problem statement, literature review, methodology, analysis and
conclusion are included.

22
3.2. Problem statement and justification

3.2.1 Problem statement

Generally, in Ethiopia and in many other countries we use conventional method of
painting is by applying paint manually with the help of workers. Problems like
material wastage, limited, production, and poor quality are some common issues
related to manual painting, but hazardous fumes in arising spray painting is a major
health concern and therefore, automatic spray painter are used for spray painting in
large manufacturing sector. The painting chemicals can cause hazards to the painters
such as eye and respiratory system problems. Also, the nature of painting procedure
that requires repeated work and hand rising makes it boring, time and effort
consuming.

The most common quality issues in painting arise from dust particles, which effects
surface finish. The paint distance is not uniform when we apply paint manually. This
reduces the quality and accuracy. Therefor it is necessary to know the distance
between the nozzle and work piece. That is, if the nozzle is too close, paint
accumulates and causes issues like runs drips and sags, if it is too far away, too much
paint is wasted to surrounding areas. Those factors motivate the development of the
paint booth automation system.

3.2.2. Justification
We present the automatic painting device as a solution to the drawbacks of the
traditional system. Automation industries uses machines for painting of their products
and those are very much feasible because the production rate is high. In addition, it
would offer the opportunity to reduce or eliminate human exposure to difficult and
hazardous environments, which would solve most of the problems connected with
safety when many activities occur at the same time.

Certain important assumptions must be taken into consideration:

➢ That the vehicle to be painted is certain distance from the

paint machine.
➢ The paint surface is stationary.

Thus, the proposed solution would be to:

23
First: the use of a scissor lift that provides the vertical movement. And a four-
wheeled Base that provides the horizontal movement.
Second: the use of micro controller with IR sensors measuring the horizontal distance
for one side and vertical distance from ground. These boards would, as well, control
the direction and speed of the lift and turning the Spray gun ON/OFF with the
application of pneumatic actuator.

3.3. Objective

3.3.1. General objective

The main objectives of this project are to:

➢ To design and analysis car body painting machine.

3.3.2. Specific objective

➢ Design a scissor lift with approximate maximum height of four
meter
➢ To design hydraulic cylinder.
➢ To design base to carry the lift and remaining part
➢ Design pneumatic actuator for lift and spray gun operation.

3.4. Scope
The scope of this machine is not limited only to automotive industries. It is also
applicable in construction industry for house wall painting.

3.5. Literature review

The related works detailed in this section was conducted to ascertain and understand
the success and failure of painting system that have been designed before.

[1]: Mohamed Abdullatif: - In this paper author describe the design and
working of an autonomous painting device. The conceptual design of a
movable painting machine to be used for painting interior walls of
residential building had been described. It uses roller fed with liquid paint
and keeps contact with the wall surface. The machine enables the roller to
scan vertically as well as horizontally to the painted walls.
[2]: Dhaval Thakar: - this paper gives basic information about small and
medium scale industries manufacturing components have to paint for
protecting from rusting so the spray application consumes maximum time
24
 and paint which required the skilled worker emerged with the application.
They cannot manage the arrangements for higher efficiency so the rise of the
such process have to be made which is affordable, gives better accuracy,
consumes minimum time for coating so objective has to developed such
mechanism which coat the object with the dipping technique having semi-
automatic arrangement which is suitable for our requirement and which can
be valuable for small and medium scale industries.
➢ [3]: P. Keerthanaa: -He studied that automatically paint the wall surface of
given dimension has been designed and implemented in effective manner.
The approach uses Infrared transmitter and Infrared receiver to identify the
appearance of wall. The microcontroller unit to regulate the movement of
the DC motor. The devices wipe out the hazards caused due to the painting
chemicals to the human painters and also the nature of painting techniques
that require imitated work and hand rising makes it dull, time consuming.
The machine is cost effective, reduces work force for labors, and reduces
time consumption. The drawback of the project is that it continuous painting
later the end of the wall so it can be eliminated by adding some indicating
objects such as alarms.

3.5. Methodology and design procedure analysis

This paper wants to make automatic paint spraying machine by following the correct
procedure of design analysis and interpretation. And also, data can be analyzed from
secondary and primary source.

3.5.1. Data collection

Necessary data required for analytical and model design will be collected from
different sources. This include collecting data from primary sources like፦

➢ Observation
➢ Measurement
➢ Asking question

And secondary data like፦

➢ Website
➢ Manual reading
25
 ➢ literature review

3.5.2. Data analysis

The data analysis work will be done using mathematical formula, concept analysis
and software support analysis including

➢ Under taking weight and actuator force

➢ Undertake take detail analysis for the components
➢ Using diagram and CATIA software modeling of part.

3.6. Component parts

The construction of automatic spray-painting machine includes the following parts

1. Battery; - In order to provide supply to the controller unit battery is used. Lead
acid battery is used in this project. The lead-acid battery is a rechargeable battery.
Despite having a very low energy-to-weight ratio and a low energy-to volume
ratio, their ability to supply high surge currents means that the cells maintain a
relatively large power-to-weight ratio. These features, along with their low cost,
make them attractive for use in motor vehicles to provide the high current required
by automobile starter motors.
2. Control unit: - The control board is the heart of the paint booth automation
system. It controls the motoring operation, pneumatic cylinders’ extension and
retraction, based on the IR sensors output and the power button input.
3. IR sensor: - IR sensor is used for this project. IR (Infrared) is the typical light
source being used in the sensor for robot to detect opaque object. In this project,
no programming, microcontroller and soldering are required. IR Sensor (IR
Receiver and IR Emitter) the basic principle of IR sensor is based on an IR emitter
and an IR receiver. IR emitter will emit infrared continuously when power is
supplied to it. On the other hand, the IR receiver will be connected and perform
the task of a voltage divider. IR receiver can be imagined as a transistor with its
base current determined by the intensity of IR light received.
• IR Sensor Features:
• Input voltage: 5VDC
• Sensing Range: 15cm
• Output signal: analog voltage
• Emitting element: Infrared LED
4. Single Acting 3/2 Solenoid Valve
26
A solenoid is an electrical device that converts electrical energy into straight line
motion and force. These are also used to operate a mechanical operation which in turn
operates the valve mechanism. Solenoids may be push type or pull type. The push
type solenoid is one in which the plunger is pushed when the solenoid is energized
electrically. The pull type solenoid is one in which the plunger is pulled when the
solenoid is energized. The Solenoid control valve is used to control the flow direction
is called cut off valve or solenoid valve. This solenoid cut off valve is controlled by
the electronic control unit. This solenoid valve is used to painting operation into the
materials. The diagrammatic structure of solenoid valve is shown in Fig below

Figure 3.1 solenoid valve circuit

5. DC motor: - DC motors are widely used in speed and direction control because
control of these motors is easier than other motors. Here this motor mainly used to
drive the wheel on the run way rail. The motion of a DC motor is controlled using
a DC drive. DC drive changes the speed and direction of motion of the motor.
Some of the DC drives are just a rectifier with a series resistor that converts
standard AC supply into DC and gives it to the motor through a switch and a
series resistor to change the speed and direction of rotation of the motor.
Specification of DC motor used in this project is mentioned as follows:
• Voltage – 12v
• Load speed – 120 rpm
• Load current – 1400 mA
• Power – 17 watts
6. Single acting pneumatic cylinder: - In this project single acting cylinders is used.
The cylinder is used for the paint sprayer actuation. To detect the object presence,
the IR sensor was placed on the top of the pneumatic cylinder. If the object is
detected by the IR sensor it sends the signal to the control unit and the control unit
sends the actuation signal to the pneumatic cylinder. The actuation of these
cylinders causes the paint sprayer actuation. If the maximum height reached or if

27
 the IR sensor not detect the object presence it immediately stops sending signals
to the control unit. Then the pneumatic cylinders retract back to its original
position.
7. Double acting hydraulic cylinder: - In this project we use two hydraulic
cylinders, the one is used for the up and down movement of the scissor lift and the
other is for the adjustment of the spray gun amount at different angle.

8. Flow control valve: - used to control the flow of hydraulic fluid to the cylinder.

9. Scissor lift: - used to move the spray gun in the Z direction.

10. Spray gun: - used to store and spray the painting chemical

Fig 3.2 Spray gun

11. Electrical and electronics system.
12. Caster Wheel

3.7. Material selection

It is necessary to evaluate the particular type of forces imposed on components with a

view to determining the exact mechanical properties and necessary material for each
equipment. A very brief analysis of each component follows thus:
I. Scissors arms
II. Hydraulic cylinder
III. Top plat form
IV. Base plat form
V. Wheels
Scissors link: this component is subjected to buckling load and bending load tending
to break or cause bending of the components. Hence based on strength, stiffness,
plasticity and hardness a recommended material is stainless steel.
Hydraulic Cylinder: this component is considered as a strut with both ends pinned.
It is subjected to direct compressive force which imposes a bending stress which may
cause buckling of the component. It is also subjected to internal compressive pressure
which
28
generate circumferential and longitudinal stresses all around the wall thickness. Hence
necessary material property must include strength, ductility, toughness and hardness.
The recommended material is mild steel.
Top Platform: this component is subjected to the weight of; hence strength is
required, and the frame of the plat form is cast iron.
Base Platform: this component is subjected to the weight of the top plat form and the
scissors arms. It is also responsible for the stability of the whole assembly, therefore
strength. Hardness and stiffness are needed mechanical properties. Cast iron is used.

3.8. Design procedure and analysis

3.8.1. Design of hydraulic scissor lift

Hydraulic scissor lifts are a mechanical device used for rise and lower the spray gun
to a height as we want. achieved by applying pressure to the outside of a set of
supports located at one end of the lift, elongating
Mechanism: - A scissors lift uses linked, folding supports in a crisscross 'X' pattern,
known as a pantograph. The extension is the crossing pattern. This can be achieved
through a double acting hydraulic cylinder.

3.8.1. Design of link

Figure3.2. link
Design of link for bending
From bending stress equation, we have: -
M
∕I = σ ∕Y …………………………………………………………. 1

Where, M= Maximum Bending moment on the link considered as beam.

I= Moment of inertia
Y= Distance of neutral axis from the ends = h/2
σ = Allowable bending stress

σw = σ ∕fos =250/1.5=166.67Mpa σw = working stress

29
For a link design it had been considered that, the entire load was acting on half of link
length. Length of entire link = 800 mm.
Length of link was considered as the beam for calculation purpose= 400mm
Load pattern on link was uniformly varying load (U.V.L.) due to inclination with the
horizontal. The calculation was done for the link in shut height position, i.e. when the
angle made by the links with horizontal was 10˚.

Figure 3.3. U.V.L. on link

Where, b= length of link
w= force per unit length of the beam can be evaluated as follows,
As the load pattern of U.V.L. was a triangle, we can say,
W (total force perpendicular to the link) = ½ × b × w
Assume maximum load that placed on the link is = 20 kg=19602N
Load on 1 link =400÷4=100N
Actual load on one link=100cos10˚= 98.48N
Now we have a formula that
W=½×b×w
98.48N = ½ × 400mm × w
W = 0.5N/mm
We have that the maximum bending moment of a uniformly varying load is
Mmax = wb²∕9√3 …………………………………………… 1

= 0.5 × 400²∕9√3 = 5132Nmm

Assume Y = h/2 and d=6h

d
h
Where, h = thickness of the link and

30
 Figure 3. 4. link Cross section
d= width of the link
Substituting in
M
∕I = σ ∕Y = I=dh³/12

h = ³√ (M/σ)
h = ³√ (5132/166.67) = 3.13mm
Rounding the value to available dimensions h=5mm and b=30mm
I = 5 × 30³/12 = 11250mm4
Therefore, the link dimension was 5 × 30 × 800 mm
Design of link for buckling:
According to Euler’s Formula Method,
Critical load = Pcr = π²EI∕ le ² … …………………………… …… 1

where, le =equivalent length

I = Moment of inertia
E = Modulus of Elasticity
We know that, in our condition one end was fixed and another end was free.
Therefore, by standard consideration
Equivalent length of link = 2 x Length of the link,
Length of link = 800mm
Also, Modulus of Elasticity (E) = 210 GPa =210 x 10³ N/mm² Therefore,
Pcr= (π²×210 x 10³ ×11250)/ (2×800) ² = 9108.2N
We know that,
Area (A) = d × h = 5 × 30 =150mm²
Critical stress (σe) = Pcr/A = 9108.2N/150mm² = 60.7N/mm²
Here, calculated critical stress was less than the standard value of mild steel (300
N/mm²) Therefore, design will be safe.

3.8.2. Design of Pin

Pin is the major factor in scissor lifter. It played an important role in joining the links
with the top and bottom frame. We know that in scissor lifter, pin goes under shear
stress. Shear stress defined as force per unit cross section area.

31
 figure 3.5. Pin

τall = 0.5 × yield stress/Fos = (0.5 × 250)/4 =31.25N/m²

τall = P/2A where, τall = allowable shear stress in pin (N/mm²)
P = Total force applied on pin (N)
A = Cross section are under in shear (mm²)
31.25 = 4P/πD²
D = √ (4P/31.25π)
D=4.03 ≈ 5mm

3.8.3. Design of Cylinder

Figure 3.6. Cylinder

The hydraulic cylinder was mounted in horizontal position. The total load acting on
the cylinder consists of:
Mass to be put on lift= 10 kg
Taking FOS = 1.5 for mass in pallet 10 x 1.5 = 15 kg
mass of top platform = 3kg
Mass of each link = 1kg (20 * 1kg) = 20kg

Total Mass = 15 + 3 + 20 = 38kg

Total load = 38 ×9.81 =372.78 ≈ 400N
Now the maximum force will act on the cylinder, when the cylinder was in shut
down position i.e. when the scissor links were closed. Let the force output of the
actuator, as a function of time, be 𝐹, and length of actuator be 𝑙 Applying
conservation of energy, we have

32
 h

figure 3.7. scissor mechanism

work done by actuator = work done to take lift to height ℎ

∫l1 l2(F)dl = ∫h1h2(L + B/2) dh
Both sides with respect to actuator length 𝑙 gives the required force equation
Differentiating:
F = (L +B/2) dh/dl
h =n × D sin θ dh/dθ = n × D COS θ

l = b- Dcosθ dl/dh = Dsinθdθ/dh

From this we get dh/dl = n/tanθ

F = (L+ B/2) n/tanθ
Where, h= height to be lift
L = weight to be lifted
l = length of actuator
n = number of levels
θ = angle of link from the horizontal
B = weight of link and top plat form
D = length of link
b = distance between the origin and stationery
end of actuator
Therefore F = (98.1 + 301.9/2) ×5/tan10֯

F =7063N is the minimum force applied by the actuator to lift the object.
For cylinder design we use pressure 20 bar=2N/mm2
Therefore, we know that

33
P=F/A, but A= πd2/4

πd2/4 = 7063/2 = 3531.5mm2

d = √ (4 x 3531.5/ π)

d =67mm

Therefor we select 67 mm diametric cylinder.

3.8.4. Design of top plat form

The top frame in a scissor lift was used to place the load and transfer to the link. Here
it had been found that not much of the stresses are developed in the top plat form. The
dimensions of the top plat form are 1000mm x 500mm x 10mm

Figure 3.8 top plat form

3.8.5. Design of bottom plat form

It provides proper balance to the structure and used to move the link and the top
platform in the Y – direction with the help of the dc motor in the frame run way rail.
The design of this platform was under taken similar as the top plat form.
And we have taken the dimension 1000 x 500 x 10 mm

Fig 3.9 bottom plat form

3. 9. Design of the base frame

This component is subjected to the weight of the whole components. It is also
responsible for the stability of the whole assembly. This component is subjected to

34
both bending and shear stress. So, strength hardness and stiffness are needed. The
recommended material is mild steel.
when the load is applied to the frame it may bend, but the bending has not been
greater than the bending strength of the material to check this let’s do bending stress
analysis, when load applied on frame bending moment created this bending at
maximum bending moment maximum bending stress exit.
First of all, take some assumptions,

➢ Take the frame as beam

➢ The load uniformly distributed throughout the length
➢ The beam is simply supported beam.
Take the dimensions of the beam are 1500 x 1500 x15 length width thickness
respectively. The weight of the link the top platform and the object to be lift is =
400N
The bottom plat form = 3 kg x 9.81 = 29.43N
The mass of the hydraulic cylinder = 1 kg x 9.81N
The mass of the DC motor =1kg x 9.81 = 9.81N
Mass of 4 wheel = 2kg x 6.81 = 19.62N
Total weight = 468.67 ≈ 500N
0.33N/mm

1.2m
Figure 3.10 free body diagram of U.D.L load
From bending stress equation, we have: -
M
∕I = σ ∕Y Where, M= Maximum Bending moment on the link considered as beam.
I= Moment of inertia
Y= Distance of neutral axis from the ends = h/2
σ = Allowable bending stress
The maximum bending moment of a simply supported uniformly distributed load is =
Wl2/8…………………………………………. 1
Mmax = (0.33 x 12002)/8 = 59400Nmm
I = bh3/12
Assume Y =h/2 and b =100h
Where, h = thickness of the link and

35
 d= width of the frame
σ for mild steel = 200MPa
σw = σ/fos = 200/2.5 =80MPa
Substituting in
M
∕I = σ ∕Y we get
h =3√ (3 x M/50σw)
h =3√ (2 x 59400/5 x 80)
h = 6.55mm ≈ 10 mm
b = 1000 mm
Therefore, the dimension of the frame is =1200 x 100 x 10 mm
Checking for shear

We know that Shear stress ‘τave’ = max shear force /area Max shear force for a beam
carrying U.R.L. is = WL/2 = 0.33 X 1200= 396N the area of the beam Is = b x L =
1200 X 1000 = 1.2 x 106mm2 τave=396N/1.2 x 106mm2= 3.3 x 10-3N/mm2 which is
less than the allowable shear stress of mild steel that is 300MPa therefore the design is
safe.

Figure 3.11 base frame

3.10. Design of power transmitting shaft from DC motor to wheel

It is necessary to design a shaft which transmits power from motor to wheel. Material
selection, since it is transmission shaft carbon steel (40c8) is selected due to it has
strength, machinability, low notch sensitivity, and other mechanical properties. It has
Allowable shear tress without key way allowance: 56Mpa.
We have power generated by motor = 17w and 120rpm
We know that T =60p/2Πn …………………………………… 2
T=60 x 17 x 103/ (2 xπ x 120) = 1353Nmm

36
And we have also known that T= πτd3/16=1353Nmm
d = 3√ (16 x 1353/56π)
d =5mm but the standard transmission shaft has a minimum of 25mm diameter with
allowance of 5mm therefore this shaft should be approximated to 25m.

3.11. Results and Discussion

When the system is switched on, the painting surface is detected by an IR sensor. This
causes the spray-painting process to start by actuating the paint gun. The hydraulic
cylinder extends to raise the scissor lift to cover the entire surface area of the job.
When the paint gun is lifted above the job size, the IR sensor stops detecting the
surface. This stops the spray paint and the hydraulic cylinder retracts to its starting
position.
The main idea of this project is to reduce the human interference in the painting
process of the automotive industry is successfully done. By improving the component
fixture design, it can be made to accommodate various sizes of components. The
automated painting process with less human interference results improvement in
accuracy and the quality of the painting is enhanced. The number of workers needed
per paint booth is reduced by one since the worker only has to handle the system.
Also, the cycle time for the painting operation of a single component was reduced and
the productivity of the paint booth is enlarged.

37
 Fig 3.12 Final result

3.12. Conclusion and recommendation

3.12.1. Conclusion
The painter automatic paint system has achieved optimum benefits with regard to
reliability, safety appearance, and ease of use. Automatically paint the vehicle of a
given dimensions has been designed and implemented which is applicable up to 4m
height. The approach uses IR sensors to measure distance and provide feedback to the
controller which in turn controls the actuator. This is designed for the purpose of
automating the painting process in automotive industry, making it easier and more
efficient. The machine eliminates the hazards caused due to the painting chemicals to
the human painters such as eye and respiratory system problems and also the nature of
painting procedure that requires repeated work and hand rising makes it boring, time
and effort consuming. This design is simple in nature and relatively easy to
implement in comparison with the reminder painting techniques. Adding to that, the
stability of its structure, and the fact that it can be built using any other material,
judging by its availability, affordability and in accordance to the needed specifications.
A full-scale painting machine based on this project would be beneficial to the
automotive industry field of manufacturing, granting these corporations the ability to
provide painting services in addition to the actual manual work, which gives an
advantage over other painting techniques.
38
3.12.2. Recommendations
For future work we recommend the following:

➢ Using remote to control easily.

➢ increase the number of sensors to cover more work area.
➢ Utilize a liquid level sensor to halt the operation when the paint runs out. And
a pressure sensor on the spray gun to alert if the spray gun nozzle is blocked
by previous dry paint.

3.12. Cost analysis

The price or cost of this automatic color painting is very cheap when we look at our
country standard. Hear in this section the cost of each individual component are
analyzed based on the current market available. The total cost required in this project
is the algebraic sum of the cost of each component, manufacturing cost manual cost
etc.in the previous chapter we use mild steel for design of scissor link top and bottom
plat form as well as base farm. Some of the components are available easily in
markets.

Cost analysis for link

Cost of Mild steel =birr/kg

Volume of link(v)

V=l*w*h=0.8*0.005*0.03-3*3.14(0.005*0.005) *0.005/4=0.00012m3

Mass of link(m)=ρ × v where ρ= density of mild steel = 7850 kg/m3

m = 0.00012 m3 × 7850 kg/m3 =0. 94 kg

The price of mild steel is 87.23 birr/kg in current Ethiopian market
price of each link = 87.23 birr/kg× 0.94kg=255 birr
Total cost for link material= n×255birr where n= number of links =20
Total cost =20×255 =5100 birr
total cost for link material = 5100 birr
Cost analysis for pin

The pin material is stainless steel

Volume(v) = volume of pin =3.14×d2/4 ×l
V=3.14×0.0052//4 *0.4 = 7.85*10-6m3
39
Density (ρ)= 7700 kg/m3
Mass (m) = ρ * v = 7700 kg/m3*7.85*10-6m3
=0.06kg
Price of stainless steel per kg =$10 = 280 birr/kg
0.06 kg *280 = 16.8 birr
Cost for base frame
Volume of base frame(V) = l*w*t
Where, l= length of base farm
W = width of farm
t= thickness
V = 1.2m*1m*0.01m - 0.96m*1.16m*0.01m
V = 0.0009m3
Density(ρ) = 7850 kg/m3
Mass(m) =ρ*V = 7850 kg/m3 ×0.0009m3 = 7.0865 kg
Price of mild steel per kg = $5 = 140 birr/kg
Cost of material of base frame =140 birr/kg*7.0865kg =992.11 birr
Cost of bottom plat form
Material cast iron
Volume(v) = 1m*0.5*0.01-(0.96*0.36*0.01) =0.001m3
Density(ρ) =7300 kg/m3
Mass(m) = 7300kg/m3*0.001m3 =7.3 kg
Price of materials of bottom plat form = $1.42=39.46 birr
Cost for bottom plat form = 7.3*39.46 = 290.46 birr
Cost analysis for top plat form
Material cast iron
Volume(V) = 0.92m*0.4m*0.02m-(0.36m*0.9m*0.015m) = 0.00025m3
Density(ρ) = 7300 kg/m3
Mass(m) = = 7850kg/m3*0.00025m3 = 1.83 kg
Cost = 1.83 kg *39.46 birr/kg =72 birr
Components’ like IR sensor, battery, dc motor, solenoid valve, actuators, controller
and Electrical wire are available in market and listed in table below.

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Table 1 cost of material

No Component name Quantity Total

Unit price
price(birr)
(birr)
1 Battery 1 2200 2200
2 IR sensor 1 270 270
3 DC motor 2 300 600
4 Single acting 3/2 solenoid valve 1 750 750
5 Pneumatic cylinder 1 150 150
6 Hydraulic cylinder 2 600 1200
7 Pin 10 16.8 168
8 Base frame 1 992.119 992.11
9 Bottom plat form 1 290.46 290.46
10 Top plat form 1 72 72
11 Control unit 1 600 600
12 Machining cost 1000
13 Laboure cost 2000
14 Total cost 10292.57

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 References
1. A textbook of strength of material by r.k bansan
2. A textbook of machine design by r.s khurmi and j.k. gupta
3. J.e shigley and c.r mischke, mechanical engineering design, mcgraw hill
publication, 5th edition 1989
4. Bishoftu automotive engineering industry manual

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