Acknowledgement

Contents

Lest of table and lest of figure

Abstract

Chapter one

1. Introduction

1.1 Background of the study

1.2 statement of the problem

1.3 Objectives of the Study

1.3.1 General objective

1.3.2 Specific objectives

1.4 Significance of the study.

1.5 Research Methodology and Design

1.5.2 Sampling design

1.5.1 Data collection method

1.5.3 Data processing and analysis

1.6 Scope of the study

1.7 Limitation of the study

1.8 Organization of the paper

Chapter two

2.1 Literature review

2.2 conceptual designs

Chapter three

3. Design analysis

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Chapter two

1 Back ground of pedal powered machines

1.1 Introduction

Pedal power is the transfer of energy from a human source through the use of a foot pedal
and crank system. This technology is most commonly used for transportation and has
been used to propel bicycles for over a hundred years. commonly pedal power is used to
power agricultural and hand tools and even to generate electricity, for different types of
mixer machines ,Some third world development projects currently transform used
bicycles into pedal powered tools for sustainable development.

Ever since the arrival of fossil fuels and electricity,

human powered tools and machines have been viewed as an obsolete technology. This
makes it easy to forget that there has been a great deal of progress in their design, largely
improving their productivity.

The most efficient mechanism to harvest human energy appeared in the late 19th century:
pedaling. Stationary pedal powered machines went through a boom at the turn of the 20th
century, but the arrival of cheap electricity and fossil fuels abruptly stopped all further
development.

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The historical importance of pedal powered machines can be easily overlooked by people
who grew accustomed to fossil fuels and ubiquitous electricity.

Some applications modifications of pedal powered machines;

A boom of pedal powered machines

The cleverest innovation in applying human power to rotary motion only appeared in the
1870s. Some of us still use it as a means of transportation, but it is rarely applied to
stationary machines anymore: pedal power. Initially, pedals and cranks were connected
directly to the front (or sometimes rear) wheel. With the arrival of the 'safety bicycle'
shortly afterwards, this direct power transmission was replaced by a chain drive and
sprockets - still the basics of most present-day bicycles.

The above picture shows the application of pedal power for grinding
purpose.

From 1876 onwards, pedals and cranks were attached to

tools like lathes, saws, grinders, shapers, tool sharpeners and to boring, drilling and
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cutting machines. These machines - which became very popular - were intended for small
workshops and households without electricity or steam power. They were made with
heavy cast-iron bodies that could be collapsed for shipping.

Pedal power is a product of the industrial revolution

Pedals and cranks are products of the industrial revolution, made possible by the
combination of cheap steel (itself a product of fossil fuels) and mass production
techniques, resulting in strong yet compact sprockets, chains, ball bearings and other
metal parts.

Prior to that time, the available materials were not strong enough to take the large force
that was acted upon them. This is even truer for stationary pedal power than for road
bicycles, because the strain on parts is considerably larger. Experiments in the 1970s
designing pedals, cranks and bearings for stationary pedal power units using pre-
industrial materials like wood failed. And while the frame of a pedal powered machine
can be made of wood or bamboo, steel is a better option - contrary to road bicycles, a
lightweight frame is not an advantage for a stationary machine.

1.2 soap mixer machines

Traditional soap making demands hours of stirring by hand. The developed machine
consist of a bicycle pedaled chain drive and gear amplification system that turns impeller
blades in a large stainless steel container, where soap ingredients are stirred and once the
ingredients start to thicken, the magic of soap making has begun, and the mixture is pour
into a mold to set.

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5
6
 Conceptual design
Before choosing the right/proper outline for our machine, we have tried three different
conceptual designs. Thus, here we will see each one by one and select the best based on
the following criteria:

I. Simplicity of Mechanism
II. Cost
III. Manufacturability
IV. Maintainability and
V. Mixing quality/efficiency.

Conceptualdesign–1

Key 1. Mixing vessel 2. Turbine blade 3.bevel gear

4. Connecting Shaft 5.chain and sprocket 6. Saddle seat

7. Handle bar 8. Faucet 9. Mixer support

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Working principle

In this type of machine as the operator applied the force the rotational force transmitted to
the connecting shaft & then to the bevel gear seat .Finally the motion transmitted to the
impeller shaft.

So when we evaluate this machine using the criteria seated we get the following points.

I. The machine has a simple mechanism as compare to other

II. Low cost since it excludes belt ,pulley & frame
III. Easily manufactured due to less complexity, but it requires best seal between the
interconnection of tank and impeller.
IV. Easily maintainable
V. mixing quality is the same as the first one & there is no power loss
Conceptual design – 2

1. Pulley 2. Belt 3. Bevel gear

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Working principle

As shown in the above pictureWhen the operator applied a force on the pedal, it creates a
rotational energy due to chain & sprocket. This rotational energy transmitted to the bevel
gear set through pulley & belt. And the bevel gear set transmits the power of rotation to
the impeller shaft so to the turbine blade.

Thus, when evaluate this machine using the criteria we set we get the following points:

I. This machine has complex mechanism since it has many parts when compared to
the other models.
II. The cost is considerably high because of its numerous parts.
III. As we have seen in the schematic drawing the bevel gear seat is found above the
mixing vessel so the manufacturing is little beat difficult.
IV. Again due to complexity of the machine the maintenance is difficult.
V. Mixing quality of this machine is the same but there may be a power loss due to
belt slip.
Conceptual design – 3

Key: - 1. Mixing vessel 2.excharge wheel, and 3.U-shape frame

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Working principle

As the operator apply a force on the paddle the rotational motion will produced due to
chain and sprocket and it transfer into the shaft then it rotates the turbine blade inside
the vessel which mixes the ingredients of the soap. In this type the vessel arranged
horizontal. After mixing the ingredients out from the vessel by rotate the vessel.

Thus, when evaluate this machine using the criteria we set we get the following points.

I. It has simple mechanism.

II. The cost is moderate.
III. It requires precise manufacturability
IV. Easily Maintainable since it has less parts, less complexity
V. Mixing quality of this machine is the lowest of all and It requires high power
since there is no power & torque multiplication mechanism.

This is tabulated form of comparison of the above models.

criteria

Mechanism Cost Manufactur- Maintain- Mixing quality

ability (%) ability (%) and Sum
(%) (%) efficiency(%)
(%)
Concep-

tual design

Design -1 5 3 4 3 5 20

Design -2 4 4 4 5 5 22

Design -3 5 4 4 3 3 19

Key :- 5= excellent , 4 = very good , 3 = good ,2 = faire ,and 1 = poor

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 Thus, based on these qualifications, we get design-2 is best for design of soap mixing

machine.

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IMPELLER/IGITATOR SELECTION
High Viscosity Mixers

While turbine mixers can handle low to moderate viscosities, high viscosity fluids100
Pa’s and greater usually require some type of close-clearance impeller design. The
diameter of a typical turbine-style impeller is less than 70% of the tank diameter. Close
clearance impellers for high viscosity applications are 75 to 95% of the tank diameter.
Some close-clearance impellers even have flexible scrapers, which are effectively 100%
of the tank diameter.

Important mechanical features of high viscosity mixers are the low speed and high
torque required to rotate large impellers in viscous fluids. Equally important, but more
subtle, are requirements for the tank to have a very round cross-section. The tank must be
round so that the clearance between the impeller and the wall remain nearly constant, and
the shaft must be centered for the same reason. Shaft and impeller designs are primarily
for strength and based on the hydraulic forces caused by viscous drag.

Forms of High viscosity impellers

High viscosity impellers can take many forms, two of the more common varieties are
the helical-ribbon (Figure 1) and anchor-style (Figure 2) impellers.

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Fig 1 Double helical-ribbon impeller. (Courtesy of Chemineer.) Fig 2 Anchor impeller. (Courtesy of
Lightnin.)

Double Helical Ribbon Impeller

• Proven the best high viscosity, laminar flow impeller

• Highly effective in heat transfer

• Efficiently incorporates surface liquids and solids

• For viscosities over 30,000 Mpa

Anchor Impeller

• Most economical laminar flow impeller available

• Horizontal flow well suited for low-liquid-level geometries

• Solve heat transfer fouling problems with optional

wall scrapers

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 Due to the resones as mentioned above and the physical property of the

ingredients that we want to mix we select a double helical ribbon type impeller
(figure 1).

SPEED OF IMPELLER

Except for some portable mixers, high-shear mixers, and a few special mixers, most
mixers operate below standard speeds. Typical motor speeds of 1800 or 1200 rpm (30 or
20 rps) are reduced to between 350 and 30 rpm (5.8 and 0.5 rps) for most motor drive
mixer. Portable and side-entering mixers usually operate near the upper portion of this
speed range from 420 to 170 rpm (7 to 2.8 rps). Turbine mixers operate in the middle
range, from 125 to 37 rpm (2.1 to 0.6 rps), and high viscosity mixers operate from 45 to
20 rpm (0.75 to 0.33 rps) and slower.

When we come to in our design the impeller speed should not be out of the range
between 45 to 20rpm because the soap has high viscosity, so lets take 40rpm as impeller
speed. And average human operating speed at pedal is 75 rpm also the average power
produced by a man is approximately 75W (0.1 hp).

Impeller power

Impeller power is a function of the geometry of the impeller, the volume of the
tank/vessel, properties of the fluid (viscosity and density), rotational speed of the impeller
and gravitational force.

VOLUMATRIC ANALYSIS
Lets as assume that the manufacturer produces (supply) 2000 piece of soap for the market
per day in two shift. From the producer we get the overall dimensions of one soap, it has
100mm length , 50mm width ,and 40mm height

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  Volume of one piece of soap (in )
= L*W*H
= (0.05 * 0.04 * 0.1)
= 2*
 The total volume of 2000 piece of soap will be
= 2000 * (2* )
= 0.4

The workers of the company has two shift in a day (morning and afternoon), so our mixer
machine mix 0.4m3 soap in to two cycle to prevent wastage. Based on this we can
calculate the size of the mixer vessel.

To keep proportionality of the vessel let’s take

h = 1.7D

D = diameter of the mixing vessel

h = height of the vessel

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  volume of the mixing vessel

A * h = 0.2m3 where A = cross-sectional area of the vessel

A=

* h = 0.2m3

* (1.7D) = 0.2m3
1.3352D3 = 0.2m3

D = 0.53m

And h = 1.7 * 0.53m

h = 0.9m

 the impeller diameter will be

d = 0.75 * D
d = 0.75 * 0.53m
d = 0.395m or 39.5cm
 rotational speed of impeller
Ni = 80rpm

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2 Design of Chain &Sprocket
Chains are made up of number of rigid links which are hinged together by pin joints in
orderto provide the necessary flexibility for wrapping round the driving and driven
wheels.These wheels have projecting teeth of special profile and fit into the
corresponding recesses in the links of the chain as shown in the fig below.

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Analysis;
Chain selection: Bush Roller Chain type which is a power transmitting chain.

Given

Rated power of the operator =75W = 0.1

=Speed of rotation of smaller sprocket in r.p.m = 80 rpm

= Speed of rotation of larger sprocket in r.p.m = 40 rpm

Let;

= Number of teeth on the smaller sprocket, and

= Number of teeth on the larger sprocket.

 Velocity ratio of chain drives

V.R= ⁄ = ⁄ = 80/40 = 2

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From Table 1, we find that for the roller chain, the number of teeth on the smaller
sprocket orpinion (T1) for a velocity ratio of 2are 27.

Number of teeth on the larger sprocket or gear will be;

= * = 2 * 27 = 54

 Calculate the Design Power

Design Power = Rated power × Service factor ( )

The service factor ( ) is the product of various factors , and .The values of these
factorsare taken as follows:
 Load factor ( ) for variable load with mild shock = 1.5
 Lubrication factor ( ) for periodic lubrication = 1
 Rating factor ( ) for 8 hours per day = 1.25

Service factor, = * * = 1.5 × 1 × 1.25 = 1.875

Design Power = 0.0746Kw * 1.875 = 0.1395 KW

From Table 2, we find that corresponding to a pinion speed of 1000 r.p.m. The power
transmitted for chain No.06 B is 0.25 kW per strand. Therefore, a chain No. 06B with
two strands can be used to transmit the required power.

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  Calculate the parameters of the chain
For a simple chain the parameters of the chain can be gained from the following table;

Pitch, P = 9.525 mm

Roller diameter, = 6.35 mm

Minimum width of roller, w = 3 mm

 Breaking load /
=106
=106 =9.61

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  Pitch circle diameters and pitch line velocity of the smaller sprocket

= P cosec ( ) = 9.79 * cosec ( ) = 82mm = 0.082 m

 Pitch line velocity of the smaller sprocket

V1=

V1= 0.343 m/s

 Pitch circle diameters(d2) and pitch line velocity(V2) of the larger sprocket

= P cosec ( ) = 9.79 * cosec ( ) = 164mm = 0.164 m

V2 = 0.343m/s
 Load (W) on the chain

W= = = 0.222 kn

 Factor of safety/ n
n= = ⁄

This value is more than the value given in Table 4, which is equal to 7.8, so it is safe.

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  Center distance between the sprockets (X)
X = 40 P = 40*9.79 = 454 mm

In order to accommodate initial sag in the chain, the value of center distance is reduced
by 2 to 5 mm.

Correct center distance

x = 454 – 4 = 455 mm

 The number of chain links (K)

K=

= 40.5 + 72.52+0.118
= 113.14

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  Length of the chain (L)
L=K*P

L = 9.79 * 113.14 =1107.64 mm = 1.107 m

 power transmitted by the chain

The power transmitted by the chain on the basis of breaking load is;

P=

Where = Breaking load in newton

v = Velocity of chain in m/s

n = Factor of safety, and

KS = Service factor = K1.K2.K3

P= = 0.0456 KW

Principal Dimensions of Tooth Profile

According to Indian Standards (IS: 2403 – 1991), the principal dimensions of the tooth
profile as

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 1. Tooth flank radius (re)

= 0.008 ( + 180)

= 0.008(

2. Roller seating radius (ri)

= 0. 505 * + 0.069

= 0.505 * 27 + 0.069 = 7.9

3. Roller seating angle (α)

= 140º –
= 1400 – 900/27
= 136.6º

4. Tooth height above the pitch polygon (ha)

= 0.5( )

= 0.5(27-9.79)

= 10 mm

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 5. Pitch circle diameter (D)
=
⁄

= 9.79/sin(180/27)

5.1 Top diameter (Da)

= D+ p (1- ⁄ )-

6. Root diameter (Df)

= D– 2 ri
= 84.7-2*7.9
= 71.4 mm
7. Tooth width (bf1

= 0.93 , p<12

= 0.093*27

=2.5 mm

8. Tooth side radius (rx)

= 9.79 mm

3 Design of Shaft
This shaft carries the pinion/ small sprocket, which is drive by the larger sprocket from
the man power, and the chain to drive the pinion bevel gear.

Analysis

Material Selection

Steel 37 ; with the following properties

 Ultimate tensile strength  U

= 360Mpa.
 Yield strength  y
= 205Mpa.

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  Modulus of elasticity (E) = 205Gpa
Allowable tensile strength: taking factor of safety, F.s=2.5, and considering allowance
of 0.95  all for keyways, allowable stress will be:

 all =0.95x
205
2 .5

= 80Mpa.

From shear stress theory, allowable shear stress will be:

 all = 0.5x  all = 40Mpa.

Manufacturing selection: Either Machining

The torque transmitted by the shaft;

T= = = 5.44 N-m = 5.44

For main power-transmitting solid shafts the diameter of the shaft can be found;

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 Let L= length of shaft=350 mm

Moment at B;

=250mm*(181.33N)

=45.33* =

The shaft is under the combined action of bending and twisting moments

A. Using twisting moment.

The equivalent twisting moment is given by :-

=√

=√

= 45.65N-m

We also know that

= * *d3

45.65N-m = * 40*106 N⁄

45.65N-m= 7.85*106d3

d3 = 5.81*

d = 0.0179 m or d 18mm

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B. Using bending moment
The equivalent bending moment is given by :-

Me = (M +√ )

Me = (M +Te)

Me = (45.65N-m +45.33)

Me = 94.525N-m

we know that :-

Me = * *d3

* 80*106 ⁄
* 3
94.525N-m = d

d3 = 27.03*10-6m

d 30 mm

2) Considering fatigue load.

When the shaft is subjected to a gradual load with a minor shock the equivalent
twisting and bending moment are given by:-

=√

Me = [K m * √ ]
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Where:- Km = combined shock and fatigue factor bending=1.5

Kt= combined shack and fatigue factor for torsion=1.0

Table 4.5 Recommended values for Kmand Kt

 The equivalent twisting moment will be

Te = √

Te = √

Te = 68.21N-m

We also know that

Te = * *d3

68.21N-m = * 40*106 ⁄ *d3

d3 = 8.68* m

d 20.5 mm

 Using the bending moment.

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 The equivalent bending moment on fatigue is given by:-

Me = [K m * M√ ]

Me = [(Km * M) + Te]

Me = [(1.75 * 44.6) +95]

Me = 86N-m

And also we know that:-

Me = * *d3

86N-m = * 55*106 ⁄ *d3

d3 =1.592 *10-5

d = 0.02516m

d = 25.16mm

The diameter of the shaft will be the largest of the four values we obtained l

d=30 mm …………………………………………. Shaft diameter.

 Failure checking

1) Failurity due to induced shear stress.

Since mild steel is a ductile material we use ductile material failure theories.
 Maximum shear stress theory for ductile materials predicts yielding when

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 - “Sy” is the yield strength
And = the torsion we get using the diameter of the shaft.

So = = = 102.5Mpa

Since =

= 1.026 Mpa

= 102.5Mpa is much more greater than, =1.026 Mpa so the shaft is safe

2) Check for failurityof shaft due to induced bending stress in the shaft.

can be calculated from the bending moment as follows, we know that

= = = 17.10mpa

>>16.64Mpa .......................................................................…...safe

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