PROJECT TITLE : SPRAY PAINTING ROBOT.

Abstract: The primary aim of the project is to design, develop and implement
Automatic Wall Painting Robot which helps to achieve low cost painting
equipment. Despite the advances in robotics and its wide spreading applications,
interior wall painting has shared little in research activities. The painting chemicals
can cause hazards to the human 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. When construction
workers and robots are properly integrated in building tasks, the whole
construction process can be better managed and savings in human labour and
timing are obtained as a consequence. 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. These factors motivate the development of an
automated robotic painting system.
Keywords: Building automation; Robotics; Construction; Spray Painting; Safety

INTRODUCTION

Building and construction is one of the major industries around the world. In this
fast moving life construction industry is also growing rapidly. But the labors in the
construction industry are not sufficient. This insufficient labors in the construction
industry is because of the difficulty in the work. In construction industry, during
the work in tall buildings or in the sites where there is more risky situation like
interior area in the city. There are some other reasons for the insufficient labor
which may be because of the improvement the education level which cause the
people to think that these types of work is not as prestigious as the other jobs.
The construction industry is labor-intensive and conducted in dangerous situations;
therefore the importance of
construction robotics has been realized and is grown rapidly. Applications and
activities of robotics and automation in this construction industry started in the
early 90‟s aiming to optimize equipment operations, improve safety, enhance
perception of workspace and furthermore, ensure quality environment for building
occupant. After this, the advances in the robotics and automation in the
construction industry has grown rapidly.
Despite the advances in the robotics and its wide spreading applications,
painting is also considered to be the difficult process as it also has to paint the
whole building. To make this work easier and safer and also to reduce the number
of labours automation in painting was introduced. The automation for painting the
exterior wall in buildings has been proposed. Above all these the interior wall
painting has shared little in research activities. 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. These factors motivate the development of an
automated robotic painting system. This project aims to develop the interior wall
painting robot. This automatic wall painting robot is not designed using
complicated components. This robot is simple and portable. The robot is designed
using few steels, conveyor shaft, spray gun and a controller unit to control the
entire operation of the robot. This robot is compact because of high speed and
pressure capabilities they have. They also have a very small weight to power
output ratio and predictable performance ie., losses are minimum due to less
number of moving parts and so gives expected performance. Due to elegant and
simple control systems it can control noise vibration and does silent operation and
no vibration is produced. It has longer life, flexibility and it is efficient and
dependable, and the installation is simple and the maintenance is also easy. Some
of the conditions that have to be considered while using this robot is that the
system is operates in pneumatics, so it needs air tank or compressor and the electric
shock is always there, which makes the machines ugly and dust and dirt are
adhering to them. The life of the parts like seals, packing and gaskets etc., are very
short but, they are essential to prevent leakage so that the system becomes costlier.
PROBLEM DEFINITION :

Paint application on the external surfaces is normally done manually which

leads to issue of quality and time . Normally labors paint the surfaces using a paint
brush or roller arrangement. The quality of painted surface is dependent on the
operator , so problems of uniform coat , complete area coverage and shade in
adjacent painted surface see variations.

Hence there is need of an special device that will coat the entire surface in a
mechanical step by step manner to ensure that the complete surface is painted
without form of patches , change in sade or non uniformity of paint.

SOLUTION

Wall painting robot is a simple device that carries the entire paint application
set up from one end to other end wall to other using a moving platform, uniform
coat is provided by a reciprocating arrangement where as the up and down motion
is achieved using a lead screw and nut arrangemen.

This machine easily solves the above problem which other wise is really
difficult without such aid. The machine needs compressed air supply for paint
application where as movement of the robot and painting set up is done using DC
motors .
CONSTRUCTION & WORKING :

1. Base Frame : The Primary base frame is the base element provided with
castor wheels, The primary base is made of mild steel square tube and mild
steel plate. It supports the entire assembly of the spray paint system

2. Vertical motion system: The vertical motion system comprises of the screw
and nut , lifter screw held in two ball bearings and nut connected to the
carrier. Rotation of screw is converted to translation of the spray paint
system u or down

3. Paint storage : Paint storage is done in a small tank of 0.8 to 1.2 liter
capacity mounted on the structure . The compressed air is supplied through
the chamber to carry the paint to the spray rotor end.

4. Paint application : Paint application is done by means of a spray which is

reciprocated in linear guide by crank and connecting rod mechanism
opearated by motor.

5. Control circuit : The paint quality ie , the thickness of paint will be

controlled by the control the speed of the motor , so also the speed of the
translation of the setup will be controlled by the speed of translation.

6. Reciprocation system
For uniform application of paint the spray painting gun is reciprocated to
and fro using a slider crank mechanism comprising of crank, connecting rod
 Motor for reciprocation and up-down motion

Motor is an 12 volt DC motor , with following specification:

Voltage : 12 Volt DC
Power = 5 watt
Speed = 60 rpm
Mounting : Flange mounted

2. Pinion & gear for reciprocation and updown

Pinion and gear for reciprocation is standard spur gear pair of Nylon-66
material with 12 teeth on pinion and 60 teeth on gear, module of gear is 1.25
module

DP/DT switch:
The DP/DT switch is an electrical direction control switch which changes
the direction of rotation of the motor and there by controlling the motion
of the screw rotation and thereby the up down motion of the

WORKING

DP/DT switch has an central OFF position, when operated to one of the ON
position, the motor will rotate in clockwise direction , operating the motor and
thereby the pinion . The pinion rotates to rotate the gear and thereby the main
screw and the nut translates up or down to move the spray gun slide up or down.
When other switch is operated the motor will rotate the and the gear with
crank shaft is rotated. This motion is converted to reciprocation with help of
connecting rod. The spray painting gun is mounted on the slider that reciprocated
to give uniform painting.
ADVANTAGES :

1. The painting process is virtually impossible without the painting robot set
up.
2. The painting robot saves on time required for painting.
3. The painting robot saves on the labor cost.
4. As robot is automatic , it reduces human effort.
5. Easy to maintain.
6. Cost effective.

APPLICATIONS:

1. Wall painting
2. Painting internal and external surfaces of storage tanks
3. Painting process industry installations
4. Painting oil refinery installations
 Work action plan
PROJECT ACTION PLAN (APPROXIMATE ESTIMATE 4 MONTHS)

PHASE 1 : DATA COLLECTION (DURATION : 1 WEEK)

Data collection phase involves the collection of reference material for project
concept, the idea is taken from book Ingenious mechanisms for designers and
inventors

(1 week)

PHASE 2 : SYSTEM DESIGN (DURATION :2 WEEKS)

The system design comprises of development of the mechanism so that the given
concept can perform the desired operation. The system design also determines the
system components and their shape and overall dimensions , the parts are as shown
in part list above.

(1 week)

PHASE 3 : MECHANICAL DESIGN( DURATION : ( 3WEEKS)

The parts mentioned above in the part list will be designed for stress and strain
under the given system of forces, and appropriate dimensions will be derived. The
standard parts will be selected from the PSG design data handbook.

(2weeks)

PHASE 4 : PRODUCTION DRAWING PREPARATION ( DURATION :2

WEEKS)

Production drawings of the parts are prepared using Auto Cad ,with appropriate
dimensional and geometric tolerances. Raw material sizes for parts are also
determined.

(2 weeks)
PHASE 5 : MATERIAL PROCUREMENT & PROCESS PLANNING
( DURATION :2 WEEKS)

Material is procured as per raw material specification and part quantity. Part
process planning is done to decide the process of manufacture and appropriate
machine for the same.

(1 week)

PHASE 6 : MANUFACTURING ( DURATION :2 WEEKS)

Parts are produced as per the part drawings.

(3 weeks)

PHASE 7 : ASSEMBLY –TEST & TRIAL( DURATION : (1 WEEKS)

Assembly of device is done as per assembly drawing ,and test and trial is
conducted on device for evaluating performance.

(1-week)

PHASE 8 : REPORT PREARATION( DURATION :2 WEEKS)

Report preparation of the activities carried out during the above phases is done .

(2 weeks)
 DESIGN

Design consists of application of scientific principles, technical information

and imagination for development of new or improvised machine or mechanism to
perform a specific function with maximum economy & efficiency .
Hence a careful design aPPZoach has to be adopted . The total design work ,
has been split up into two parts;

 System design
 Mechanical Design.

System design mainly concerns the various physical constraints and ergonomics,
space requirements, arrangement of various components on main frame at system,
man + machine interactions, No. of controls, position of controls, working
environment of machine, chances of failure, safety measures to be provided,
servicing aids, ease of maintenance, scope of improvement, weight of machine
from ground level, total weight of machine and a lot more.

In mechanical design the components are listed down and stored on the basis of
their procurement, design in two categories namely,
 Designed Parts
 Parts to be purchased

For designed parts detailed design is done & distinctions thus obtained are
compared to next highest dimensions which is readily available in market. This
amplifies the assembly as well as postproduction servicing work. The various
tolerances on the works are specified. The process charts are prepared and passed
on to the manufacturing stage.

The parts which are to be purchased directly are selected from various
catalogues & specified so that any body can purchase the same from the retail shop
with given specifications.
 SYSTEM DESIGN

In system design we mainly concentrated on the following parameters: -

1. System Selection Based on Physical Constraints
While selecting any machine it must be checked whether it is going to be used in a
large-scale industry or a small-scale industry. In our case it is to be used by a
small-scale industry. So space is a major constrain. The system is to be very
compact so that it can be adjusted to corner of a room.
The mechanical design has direct norms with the system design. Hence the
foremost job is to control the physical parameters, so that the distinctions obtained
after mechanical design can be well fitted into that.
2. Arrangement of Various Components
Keeping into view the space restrictions the components should be laid such that
their easy removal or servicing is possible. More over every component should be
easily seen none should be hidden. Every possible space is utilized in component
arrangements.
3. Components of System
As already stated the system should be compact enough so that it can be
accommodated at a corner of a room. All the moving parts should be well closed
& compact. A compact system design gives a high weighted structure which is
desired.
4. Man Machine Interaction
The friendliness of a machine with the operator that is operating is an important
criteria of design. It is the application of anatomical & psychological principles to
solve problems arising from Man – Machine relationship. Following are some of
the topics included in this section.
Design of foot lever
Energy expenditure in foot & hand operation
Lighting condition of machine.

5.Chances of Failure
The losses incurred by owner in case of any failure is an important criteria of
design. Factor safety while doing mechanical design is kept high so that there are
less chances of failure. Moreover periodic maintenance is required to keep unit
healthy.
6.Servicing Facility
The layout of components should be such that easy servicing is possible.
Especially those components which require frequents servicing can be easily
disassembled.

7.Scope of Future Improvement

Arrangement should be provided to expand the scope of work in future. Such as to
convert the machine motor operated; the system can be easily configured to
required one. The die & punch can be changed if required for other shapes of
notches etc.
8.Height of Machine from Ground
For ease and comfort of operator the height of machine should be properly decided
so that he may not get tired during operation. The machine should be slightly
higher than the waist level, also enough clearance should be provided from the
ground for cleaning purpose.

9.Weight of Machine
The total weight depends upon the selection of material components as well as the
dimension of components. A higher weighted machine is difficult in transportation
& in case of major breakdown, it is difficult to take it to workshop because of more
weight.

MECHANICAL DESIGN

Mechanical design phase is very important from the view of designer .as
whole success of the project depends on the correct deign analysis of the problem.

Many preliminary alternatives are eliminated during this phase. Designer

should have adequate knowledge above physical properties of material, loads
stresses, deformation, failure. Theories and wear analysis , He should identify the
external and internal forces acting on the machine parts

These forces may be classified as ;

1. Dead weight forces
2. Friction forces
3. Inertia forces
4. Centrifugal forces
5. Forces generated during power transmission etc
Designer should estimate these forces very accurately by using design equations .If
he does not have sufficient information to estimate them he should make certain
practical assumptions based on similar conditions
which will almost satisfy the functional needs. Assumptions must always be on the
safer side.

Selection of factors of safety to find working or design stress is another important

step in design of working dimensions of machine elements. The correction in the
theoretical stress values are to be made according in the kind of loads, shape of
parts & service requirements.

Selection of material should be made according to the condition of loading shapes

of products environment conditions & desirable properties of material.

Provision should be made to minimize nearly adopting proper lubrications

methods.

In ,mechanical design the components are listed down & stored on the basis of
their procurement in two categories

 Design parts
 Parts to be purchased

For design parts a detailed design is done & designation thus obtain are compared
to the next highest dimension which is ready available in market.

This simplification the assembly as well as post production service work.

The various tolerance on the work are specified. The process charts are prepared &
passed on to the work are specified.

The parts to be purchased directly are selected from various catalogues &
specification so that any body can purchased the same from the retail shop with
the given specifications.
 Motor selection for the forward and reverse motion:

Assuming that the maximum weight of robot with all parts is not to exceed 6 kg
the net load on all four wheels = 6 x 9.81 =58.9 N

Assuming that the maximum wheel diameter for the robot is to be 110 mm
Coefficient of friction of rubber tyre on metal = 0.5

Coefficient of friction for a range of material combinations

combination Static Dynamic
  dry lubricated dry lubricated
steel-steel 0.5...0.6 0.15 0.4...0.6 0.15
copper-steel - - 0.5...0.8 0.15
steel-cast iron 0.2 0.1 0.2 0.05
cast iron - cast iron 0.25 0.15 0.2 0.15
friction material - steel - - 0.5-0.6 -
steel-ice 0.03 - 0.015 -
steel-wood 0.5-0.6 0.1 0.2-0.5 0.05
wood-wood 0.4-0.6 0.15...0.2 0.2...0.4 0.15
leather-metal 0.6 0.2 0.2...0.25 0.12
rubber-metal 1 - 0.5  
plastic-metal 0.25...0.4 - 0.1...0.3 0.04...0.1
plastic-plastic 0.3-0.4 - 0.2...0.4 0.04...0.1

Rolling resistance
　 Cr [-]
Steel wheel on rail 0.0002...0.0010
Car tire on road 0.010...0.035
Car tire energy safe 0.006...0.009
Tube 22mm, 8 bar 0.002
Race tyre 23 mm, 7 bar 0.003
Touring 32 mm, 5 bar 0.005
Tyre with leak protection 37 mm, 5 bar / 3 bar 0.007 / 0.01

The coefficient of friction between two materials in relative sliding may depend on contact
pressure, surface roughness of the relative harder contact surface, temperature, sliding velocity
and the type of lubricant whether the level of contamination. It's the reason that the data found in
the many reference tables available may show a large variation. Motor Torque

Traction torque ( Torque required to roll the tyre on pavement) is given by

T= Cr x F x r ---

Where ,

Cr- Coefficient of rolling resistance -= 0.05

F= µ Rn =0.05 x 58.9 = 2.9.45N

T = 2.945 x 55 = 161.9 N-mm

=0.162N-m

T= 0.2 N-m (torque required by mechanism)

Thus selecting motor of following specifications :

SELECTION OF MOTOR
100 RPM Side Shaft 37mm Diameter Compact DC Gear Motor
60 RPM Side Shaft 37mm Diameter Compact DC Gear Motor is suitable for small
robots / automation systems. It has sturdy construction with gear box built to
handle stall torque produced by the motor. Drive shaft is supported from both sides
with metal bushes. Motor runs smoothly from 4V to 12V and gives 1000 RPM at
12V. Motor has 6mm diameter, 22mm length drive shaft with D shape for
excellent coupling.

PRODUCT DESCRIPTION:

Features: Base Motor RPM: 100

Rated RPM: 100

Gear ratio: 1:10

Rated voltage (V): 12

Rated current (mA): 300 Rated

power (W): 1.3

Rated Torque (Kgcm): 4 KG-CM

Stall Torque (N-m) : 0.3 N-m

Shaft length (mm): 15

Shaft diameter (mm

Design of Nylon -66 gear considering beam strength of tooth
Power = 5 watt

Speed = 100 rpm

b = 10 m

Reduction ratio (i) = 2.5

Gear speed = 100/2.5 = 40 rpm

Material of gear Nylon- 66

Tensile strength =55 N/mm2

Service factor (Cs) = 1.5

Now; T = Pt x dg

We know that the stalling torque of the motor is 0.3 N-m hence the failure load

Net load on gear tooth will be

ÞPt = 300/ (75/2 ) = 8N.

Peff = Pt x Cs = 8 x 1.5 = 12 N

Peff = 12 N --------(A)
Lewis Strength equation

WT = Sbym

Where ;

Y= 0.484 – 2.86

Þ yg = 0.484 - 2..86 = 0.2456

12

Þ Syg = 13.5

WT = (Syp ) x b x m

=13.52 x 10m x m

WT= 135.2 m2----------(B)

Equation (A) & (B)

135.2 m2 = 12

Þm=0.29

selecting standard module =1.27 mm

GEAR DATA

Pinion = 24 teeth

Module = 1 .25 mm

No. of teeth on gear =60

Analysis of Gear

Statistics
Nodes 31708
Elements 17378
Mesh Metric None
The maximum stress induced in the gear is 1.486 MPa which is below allowable
stress hence the part is safe
Analysis of Pinion

Statistics
Nodes 31734
Elements 18046
Mesh Metric None
The maximum stress induced in the gear is 2.55 MPa which is below allowable
stress hence the part is safe
DESIGN OF SCREW

MATERIAL SELECTION : - Ref :- PSG (1.10 & 1.12) + (1.17)

ULTIMATE YEILD
TENSILE STRENGTH

STRENGTH N/mm2

N/mm2

EN 24 800 680

ASME CODE FOR DESIGN OF SHAFT.

Since the loads on most shafts in connected machinery are not constant , it is
necessary to make proper allowance for the harmful effects of load fluctuations

According to ASME code permissible values of shear stress may be

calculated form various relation.

= 0.18 x 800

= 144 N/mm2

OR

fs max = 0.3 fyt

=0.3 x 680 =204 N/mm

considering minimum of the above values ;

 fs max = 144 N/mm2

Shaft is provided with dimples for locking ; this will reduce its strength.
Hence reducing above value of allowable stress by 25%
  fs max = 108 N/mm2

This is the allowable value of shear stress that can be induced in the shaft
material for safe operation.

Torque at motor shaft = 0.49 n-m

Reduction ratio of gear and pinion is 60/24 =2.5

 T d = 0.3 x 2.5 = 0.75N-m

CHECK FOR TORSIONAL SHEAR FAILURE OF SHAFT.

But as per manufacturing considerations we have an H6h7 fit between the carrier
and shaft and to achieve this tolerance boring operation is to be done and minimum
boring possible on the machine available is 16mm hence consider the minimum
section on the shaft to be 16mm

Assuming minimum section diameter on input shaft = 16mm

 d = 14 mm

Td = /16 x fs act x d3

 fs act = 16 x Td

 xd3

= 16 x 0.75 x 10 3

 x (16) 3

 fs act = 0.93 N/mm2

As fs act < fs all

SCREW is safe under torsional load

MOTOR SPECIFICATIONS

TORQUE =0.75 N-m

Tdesign = 0.75 N-m

The total external torque applied to toggle jack screw is 15 N-m

Therefore,

(Mt) = 0.75 N-m---------(A)

 W X T = 0.75N-m= 750N-mm

Where ; T = (dm/2) tan ( + )

Initially assuming dimensions of screw , which we shall check under the given system of forces.

Selecting material combination for screw and nut

(Ref:Pg. No. 170,Design of Machine elements ,V B Bhandari)

Material Combination Coefficient of Coefficient of

friction(starting) friction(running)

Soft steel-Steel 0.10 0.08

Basic dimensions for square threads

(Ref:Pg. No. 5.69,PSG-Design Data)

Nominal Major Major Minor Pitch Area of

Dia Dia(bolt) Dia(nut) dia Core(mm2)

20 20 20 17 6 227.0

Design Check
d = Nominal /outer diameter (mm) = 20 mm

dc = core / inner diameter (mm) = 17mm

dm = mean diameter (mm) = 18.5mm

Mt = W x (dm/2) tan ( + )

Where , W= Axial load

Ø = friction angle

 = Heilx angle

Helix angle:-

tan  = L

 dm

For the single start sq. thread lead is same as pitch=2

tan = 6

 x 18.5

  = 5.890
 Friction Angle: Ref :- R.S.Khurmi (Table17.5)Coefficient of friction under different conditions

C Condition Average coefficient of friction

Starting Running

Average quality of
material & workmanship & average running
0.18 0.13
conditions

 = tan Ø

0.18 = tan Ø

 Ø = 10.2

Mt = W X18.5/2 x tan (10.2 + 5.85)

Mt = 5.32 X W N-mm --------(B)

Equating (A) & (B)

W =140.97 N

W = 14.3 kg , thus the screw can easily lift load of 14.3 kg with given motor specifications ...where as the maximum
weight assumed to be carried is 6 kg ...hence the screw design is safe
 Selection of motor for reciprocation

Assuming that the maximum weight of robot with all parts is not to exceed 2 kg
the net load on all four wheels = 2 x 9.81 =19.62 N

Assuming that the maximum radius of crank = 90 mm

Coefficient of friction of steel on steel = 0.15

Coefficient of friction for a range of material combinations

combination Static Dynamic
  dry lubricated dry lubricated
steel-steel 0.5...0.6 0.15 0.4...0.6 0.15
copper-steel - - 0.5...0.8 0.15
steel-cast iron 0.2 0.1 0.2 0.05
cast iron - cast iron 0.25 0.15 0.2 0.15
friction material - steel - - 0.5-0.6 -
steel-ice 0.03 - 0.015 -
steel-wood 0.5-0.6 0.1 0.2-0.5 0.05
wood-wood 0.4-0.6 0.15...0.2 0.2...0.4 0.15
leather-metal 0.6 0.2 0.2...0.25 0.12
rubber-metal 1 - 0.5  
plastic-metal 0.25...0.4 - 0.1...0.3 0.04...0.1
plastic-plastic 0.3-0.4 - 0.2...0.4 0.04...0.1

Rolling resistance
　 Cr [-]
Steel wheel on rail 0.0002...0.0010
Car tire on road 0.010...0.035
Car tire energy safe 0.006...0.009
Tube 22mm, 8 bar 0.002
Race tyre 23 mm, 7 bar 0.003
Touring 32 mm, 5 bar 0.005
Tyre with leak protection 37 mm, 5 bar / 3 bar 0.007 / 0.01

The coefficient of friction between two materials in relative sliding may depend on contact
pressure, surface roughness of the relative harder contact surface, temperature, sliding velocity
and the type of lubricant whether the level of contamination. It's the reason that the data found in
the many reference tables available may show a large variation. Motor Torque
Traction torque ( Torque required to roll the tyre on pavement) is given by

T= Cr x F x r ---

Where ,

Cr- Coefficient of rolling resistance -= 0.15

F= µ Rn =0.15 x 19.6 = 2.94 N

T = 3 x 90 = 270 N-mm = 2.75 kg-cm

Reciproction MOTOR
The drive motor is 12 VDC motor coupled to an planetary gear box.
Specifications of motor are as follows:
A )Power 5 watt
B) Speed = 60 rpm
C) TORQUE = 5 Kg-cm torque = 490 N-mm = 0.49 N-m
–OUTPUT SPEED –60 RPM
Analysis-Screw :
SELECTION OF MOTOR FOR RECIPROCATION
60 RPM Side Shaft 37mm Diameter Compact DC Gear Motor

60 RPM Side Shaft 37mm Diameter Compact DC Gear Motor is suitable for small
robots / automation systems. It has sturdy construction with gear box built to
handle stall torque produced by the motor. Drive shaft is supported from both sides
with metal bushes. Motor runs smoothly from 4V to 12V and gives 1000 RPM at
12V. Motor has 6mm diameter, 22mm length drive shaft with D shape for
excellent coupling.

PRODUCT DESCRIPTION:

Features: Base Motor RPM: 100

Rated RPM: 60

Gear ratio: 1:10

Rated voltage (V): 12

Rated current (mA): 300 Rated

power (W): 1.3

Rated Torque (Kgcm): 4 KG-CM

Stall Torque (N-m) : 0.8N-m

Shaft length (mm): 15

Shaft diameter (mm

Design of Nylon -66 gear considering beam strength of tooth
Power = 5 watt

Speed = 60 rpm

b = 10 m

Reduction ratio (i) = 2.5

Gear speed = 60/1.66 = 36 rpm

Material of gear Nylon- 66

Tensile strength =55 N/mm2

Service factor (Cs) = 1.5

Now; T = Pt x dg

We know that the stalling torque of the motor is 0.3 N-m hence the failure load

Net load on gear tooth will be

ÞPt = 800/ (75/2 ) = 21.3N.

Peff = Pt x Cs = 8 x 1.5 = 32 N

Peff = 32 N --------(A)

Lewis Strength equation

WT = Sbym

Where ;

Y= 0.484 – 2.86

Þ yg = 0.484 - 2..86 = 0.2456

12
Þ Syg = 13.5

WT = (Syp ) x b x m

=13.52 x 10m x m

WT= 135.2 m2----------(B)

Equation (A) & (B)

135.2 m2 = 32

Þm=0.486

selecting standard module =1.27 mm

GEAR DATA

Pinion = 36 teeth

Module = 1 .25 mm

No. of teeth on gear =60

DESIGN OF CRANK SHAFT

MATERIAL SELECTION : -Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION ULTIMATE YEILD

TENSILE STRENGTH

STRENGTH N/mm2

N/mm2

800 680
EN 24

ASME CODE FOR DESIGN OF SHAFT.

 Since the loads on most shafts in connected machinery are not constant , it is
necessary to make proper allowance for the harmful effects of load fluctuations

According to ASME code permissible values of shear stress may be

calculated form various relation.

fs max = 0.18 fult

= 0.18 x 800

= 144 N/mm2

OR

fs max = 0.3 fyt

=0.3 x 680

=204 N/mm2

considering minimum of the above values

Þ fs max = 144 N/mm2

Shaft is provided with key way; this will reduce its strength. Hence reducing
above value of allowable stress by 25%

Þ fs max = 108 N/mm2

This is the allowable valve of shear stress that can be induced in the shaft
material for safe operation.

Assuming 100 % efficiency of transmission

Þ T design = 0.8 X 1.66 =1.328 Nm

CHECK FOR TORSIONAL SHEAR FAILURE OF SHAFT.

Torque is applied at the driven gear mounting point on the shaft which is tapered
and 19 mm as minimum diameter

Td = P/16 x fs act x d3
Þ fs act = 16 x Td

P xd3

= 16 x 1.328 X10 3

P x 12 3

Þ fs act = 3.91 N/mm2

As fs act < fs all

ÞCrank shaft is safe under torsional load.

Analysis of Input shaft

Statistics
Nodes 4109
Elements 2311
Mesh Metric None
The maximum stress induced in the gear is 3.70 MPa which is below allowable
stress hence the part is safe
DESIGN OF CRANK PIN

We know that

T= force x radius

1328 = force x 55

 Force = 1328

55

Force =24.14N

Assuming pin diameter =10mm

 MATERIAL SELECTION

MATERIAL TENSILE YEILD

DESIGNATION STRENGTH STRENGTH

N/mm2 N/mm2

EN36 800 680

Check for direct shear of crank pin

Shear stress = shear force

Shear area

= 24.15

/4 x (d2)

=24.15 x 4

 x (10) 2

Shear stress = 0.30N/mm 2

Shear stress = 0.30 /mm 2 < 144 N/mm 2

Design of crank pin is safe.

Analysis-Crankpin
The maximum stress induced in the gear is 2.976 MPa which is below allowable
stress hence the part is safe
 DESIGN (SELECTION OF BALL BRG)---CRANK

In selection of ball bearing the main governing factor is

the system design of the drive i.e.; the size of the ball bearing is of
major importance; hence we shall first select an appropriate ball
bearing first select an appropriate ball bearing first taking into
consideration convenience of mounting the planetary pins and then we
shall check for the actual life of ball bearing.

BALL BEARING SELECTION.

Series 60

ISI NO Brg Basic d D1 D D2 B Basic capacity

Design No
(SKF)

C kgf Co Kgf

20A C02 6004 20 23 42 36 12 7350 4500

P = X Fr + Yfa.

Where ;

P=Equivalent dynamic load ,(N)

X=Radial load constant

Fr= Radial load(H)

Y = Axial load contact

Fa = Axial load (N)

In our case;

Radial load FR= Tangential tooth load

Fa = 0

P= 35.4 N ( (T/r) = 1328/37.5 )

L= (C/p) p

Considering 4000 working hours

Condisering operating speed of the shaft to be 38 rpm

L = 60 n L h = 9.12mrev

106

 9.12 = C 3

35.4

 C = 73.96 N

AS; required dynamic of bearing is less than the rated dynamic capacity of
bearing ;

 Bearing is safe.
DESIGN (SELECTION OF BALL BRG)---SCREW

In selection of ball bearing the main governing factor is

the system design of the drive i.e.; the size of the ball bearing is of
major importance; hence we shall first select an appropriate ball
bearing first select an appropriate ball bearing first taking into
consideration convenience of mounting the planetary pins and then we
shall check for the actual life of ball bearing.

BALL BEARING SELECTION.

Series 62

BRG. D DO B C CO
NO.

6003 17 35 10 4650 2850

P = X Fr + Yfa.

Where;

P=Equivalent dynamic load, (N)

X=Radial load constant

Fr= Radial load (H)

Y = Axial load contact

Fa = Axial load (N)

In our case;

Radial load FR = 75 N ( FORCE = TORQUE /RADIUS OF

SCREW)

Axial load (Fa)

Fa = 0

P=X x Fr

=75

No of revolutions of bearing = 60 x 24 x 4000

106

L= 5.76 mrev

L= (C/p) p

L= 60 n L h =5.76 mrev

106
3
 5.76 = C

75

 C = 134.4 N

AS; required dynamic of bearing is less than the rated dynamic

capacity of bearing;
  Bearing is safe.

MATERIAL SPECIFICATION: EN 9
PART NAME : SCREW TOP BRG HOUSING
RAWMATERIAL SIZE: 50X16 X70

Sr. Description Tools Time in minutes

of
No
Operation

Jigs & M/c Cutting Measuring Settin M/c Total

Fixture Instrumen g
Tools Tools Time Time
t
Time

1. Clamp stock M/C Vice Millin - - 15 - 15

g

2. Facing All M/C Vice Millin Facing Vernier 5 14 19

Sides Sq. to g cutter
total length
60x40x12
mm

3. Clamp stock 4 jaw Lathe - - 25 25

on lathe chuck

4. Drilling Ø 4 jaw Lathe Twist drill Vernier 15 10 25

25 through chuck
thickness
 5. Boring Ø 4 jaw Lathe Boring Vernier 15 10 25
26through chuck tool
thickness

6. Counter 4 jaw Lathe Boring Vernier 15 10 25

Boring Ø 32 chuck tool
through
9thickness

MATERIAL SPECIFICATION: EN 9
PART NAME : SCREW BOTTOM BRG HOUSING
RAWMATERIAL SIZE: 50X16 X70

Sr. Description Tools Time in minutes

of
No
Operation

Jigs & M/c Cutting Measuring Settin M/c Total

Fixture Instrumen g
Tools Tools Time Time
t
Time

1. Clamp stock M/C Vice Millin - - 15 - 15

g

2. Facing All M/C Vice Millin Facing Vernier 5 14 19

Sides Sq. to g cutter
total length
60x40x12
 mm

3. Clamp stock 4 jaw Lathe - - 25 25

on lathe chuck

4. Drilling Ø 4 jaw Lathe Twist drill Vernier 15 10 25

25 through chuck
thickness

5. Boring Ø 4 jaw Lathe Boring Vernier 15 10 25

26through chuck tool
thickness

6. Counter 4 jaw Lathe Boring Vernier 15 10 25

Boring Ø 32 chuck tool
through
9thickness

MATERIAL SPECIFICATION : EN24

PART NAME : SCREW RAW MATERIAL SIZE:  22X 550

Sr. Description of Tools Time in minutes

Operation
No
 Jigs & M/c Cutting Measuri Settin M/c Tot
Fixture ng g al
Tools Tools Tim
Instrume
Time e Tim
nt
e

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both Three jaw Lathe Facing Vernier - 5 5

side to total chuck
tool
length 541mm

3 Turning OD Ø Turnin 5 10 15
16mm through g tool
length

4. StepTurning Centers Lathe Turnin Vernier - 14 14

OD to Ø 15mm supports g tool
through length & carrier
50

5. StepTurning Centers Lathe Turnin Vernier - 8 8

OD to Ø 14mm supports g tool
through & carrier
length41

6. StepTurning Centers Lathe Turnin Vernier - 4 4

OD to Ø 15mm supports g tool
through & carrier
length9
 7. Threading M16 Three jaw Lathe Thread Vernier 30 96 126
x 2 pitch chuck ing tool
length482

MATERIAL SPECIFICATION : EN24

PART NAME : L H PILLAR RAW MATERIAL SIZE:  20X 510

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuri Settin M/c Tot

Fixture ng g al
Tools Tools Tim
Instrume
Time e Tim
nt
e

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both Three jaw Lathe Facing Vernier - 5 5

side to total chuck
tool
length 500mm

3 Turning OD Ø Turnin 5 10 15
 12mm through g tool
length

MATERIAL SPECIFICATION : EN24

PART NAME :R H PILLAR RAW MATERIAL SIZE:  20X 510

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuri Settin M/c Tot

Fixture ng g al
Tools Tools Tim
Instrume
Time e Tim
nt
e

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both Three jaw Lathe Facing Vernier - 5 5

 side to total chuck tool
length 500mm

3 Turning OD Ø Turnin 5 10 15
12mm through g tool
length

PART NAME : TOP ARM

MATERIAL SPECIFICATION: EN 9

RAWMATERIAL SIZE: 63X19 X340

Sr. Description Tools Time in minutes

of
No
Operation

Jigs & M/c Cutting Measuring Settin M/c Total

Fixture Instrumen g
Tools Tools Time Time
t
Time

1. Clamp stock M/C Vice Millin - - 15 - 15

g

2. Facing All M/C Vice Millin Facing Vernier 5 34 39

Sides Sq. to g cutter
total length
50x16x332
mm

4. Drilling Ø M/C Vice Lathe Twist drill Vernier 15 10 25

11.5 through
 thickness

5. REAMING M/C Vice Lathe Boring Vernier 15 10 25

Ø 12 tool
through
thickness

6. Drilling Ø M/C Vice Lathe Twist drill Vernier 15 10 25

11.5 through
thickness

7. REAMING M/C Vice Lathe Boring Vernier 15 10 25

Ø 12 tool
through
thickness

MATERIAL SPECIFICATION: EN 9
PART NAME : BOTTOM ARM
RAWMATERIAL SIZE: 63X19 X340

Sr. Description Tools Time in minutes

of
No
Operation

Jigs & M/c Cutting Measuring Settin M/c Total

Fixture Instrumen g
Tools Tools Time Time
t
Time

1. Clamp stock M/C Vice Millin - - 15 - 15

g
2. Facing All M/C Vice Millin Facing Vernier 5 34 39
Sides Sq. to g cutter
total length
50x16x332
mm

4. Drilling Ø M/C Vice Lathe Twist drill Vernier 15 10 25

11.5 through
thickness

5. REAMING M/C Vice Lathe Boring Vernier 15 10 25

Ø 12 tool
through
thickness

6. Drilling Ø M/C Vice Lathe Twist drill Vernier 15 10 25

11.5 through
thickness

7. REAMING M/C Vice Lathe Boring Vernier 15 10 25

Ø 12 tool
through
thickness
COST ANALYSIS ( ROTARY PERISTALTIC PUMP)

 BILL OF MATERIALS:-
SR PART DESCRIPTION QTY MATERI
NO. CODE AL

1. SPR-01 CRANK MOTOR 01 STD

2. SPR -2 SCREW 01 MS

3. SPR -3 CRANKGEAR 01 STD

4. SPR -4 CRANK 01 MS

5. SPR -5 CONNECTING 01 MS

6. SPR -6 SCREW TOP HSG 01 EN9

7. SPR -7 SCREW BOTTOM 01 EN9
HSG

8. SPR –8 SCREW 01 EN24

9. SPR –9 LH PILLAR 01 EN9

10. SPR –10 RH PILLAR 01 EN9

11. SPR –11 CRANK BRG 01 EN9

HOUSING

12. SPR –12 LM BEARINGS 02 STD

13. SPR –13 GM NUT 01 STD

14. SPR –14 BASE PLATE 01 MS

15. SPR –15 LINEAR GUIDES 04 STD

16. SPR –16 CASTOR 04 STD

17. SPR –17 CIRCLIPS 08 STD

18. SPR –18 LIVTER NUT 01 STD

19. SPR -19 FRAME 01 MS

20. SPR -20 BEARING 6002Z1- 05 STD

SCREW /4 DRIVER /DRIVEN
SHAFT—F/R MOTION

21. SPR -21 BEARING 6003Z 01 STD

22. SPR -22 BEARING 6004Z 01 STD

 23. SPR-23 BRG 608 02 STD

MATERIAL PROCUREMENT

Material is procured as per raw material specification and part quantity. Part
process planning is done to decide the process of manufacture and appropriate
machine for the same.

GENERAL MATERIAL USED

EN24- ALLOY STEEL

EN9- PLAIN CARBON STEEL

MS-MILD STEEL

STD- STANDARD PARTS SELECTED FROM PSG DESIGN

DATA/MANUFACTURER CATALOGUE

RAW MATERIAL COST

The total raw material cost as per the individual materials and their
corresponding rates per kg is as follows,

Total raw material cost = Rs6600/-

 MACHINING COST
OPERATION RATE TOTAL TIME TOTAL
COST Rs/-
Rs /HR HRS

LATHE 80 30 2400

MILLING 90 10 900
 DRILLING 60 4 240

TOTAL 3580

MISCELLANEOUS COSTS
OPERATIO COST(Rs)
N

GAS 300
CUTTER

SAWING 120

TOTAL 420

COST OF PURCHASED PARTS :-

SR DESCRIPTION QTY COST
NO.

1. MOTOR 02 2950

2. CASTOR 04 440

3. GRUB SCREW 09 36

4. BEARINGS 09 780
 5. GEAR 01 1200

The cost of purchase parts = Rs 5406

TOTAL COST

TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost + cost
of Purchased Parts +Overheads

Hence the total cost of machine = Rs 15600/-

BIBLIOGRAPHY

1. MACHINE DESIGN

:- R S KHURMI

2.DESIGN OF MACHINE ELEMENTS

:- V B BHANDARI
3.P S G DESIGN DATA

4.PRODUCTION TECHNOLOGY

:- P C SHARMA