lArba Minch University

Arba Minch University

Arba Minch Institute of Technology

Department of mechanical engineering

A Report on Internship Work At

Raya Brewery S.C

By:
Haile Eyasu Hagos ID: 859/08

28/01/2012 E.C
 ACKNOWLEDGEMENT
First of all, I would like to thank our God for helping and giving me his strength to practice and write
this report and I would like to give a great respect and appreciation to Raya brewery S.C for providing
this precious opportunity that enable me to familiar with practical skill and it is great pleasure to thank
for those people who individually helped me during the internship program and for those who
contributed valuable efforts when we prepare this project work. I heartily thank my company adviser
Mr. Aligaz and my university adviser Mr.Teshome who guided us during work and made the
necessary correction. I would like to express our deepest gratitude to: Atomelaku, for great assistance
throughout the company. I would like to thank for all mechanical and electrical operators for their
encouragements. Lastly, I heartily thank my family and friends for their support and encouragement.

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 EXCUTIVE SUMMERY
The report covers about four-month internship report that I have enjoyed in Raya brewery. It includes
the background of my internship hosting company That is Raya brewery S.C, its main services and
customers, as well as its overall organization and work flow of each section .This four months report
generally deals with the activities done in three main production parts of the company these are malt
handling area, Brew house, CIP room, fermentation room, utility room and keg unit and it also
includes my overall internship experience and practical skills that I have found from the internship
program. Finally, this report also includes the benefits and experiences gained from the internship
program and my conclusion and recommendations based on my design to my hosting company Raya
brewery S.C

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Contents
acknowledgement...............................................................................................................................2

excutive summery..............................................................................................................................3

list of acronyms..................................................................................................................................7

chapter one.........................................................................................................................................8

background of the company...............................................................................................................8

1.1 introduction...............................................................................................................................8

1.2 vision of the company...............................................................................................................9

1.2 mission......................................................................................................................................9

1.3 objective..................................................................................................................................10

1.4 main product and service of raya brewery s.c........................................................................10

1.5 main customers (end users of) raya brewery s.c..................................................................10

1.6 raya brewery organizational structur......................................................................................11

1.7 over all work flow of raya brewery........................................................................................12

chapter two.......................................................................................................................................13

work, responsibilities and assignments............................................................................................13

2.1 working section in the company.............................................................................................13

2.2 how does the work flow in the section look like?...................................................................13

2.3.1 malt handling area............................................................................................................13

2.3.2 malt cleaning process.......................................................................................................16

2.3.3 brew house........................................................................................................................19

2.3.4 fermentation......................................................................................................................23

2.3.5 filtration............................................................................................................................24

2.3.6 keg filling line...................................................................................................................25

2.3.7 utility plants......................................................................................................................25

2.4 my responsibilities during internship time..............................................................................30

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 2.4.1 solving the company’s problem........................................................................................31

chapter three.....................................................................................................................................32

technical aspect of the internship.....................................................................................................32

3.1 maintenance pulley.................................................................................................................32

3.2 maintenance of idlers and other parts.....................................................................................33

3.3 over all benefit gained from the internship.............................................................................33

3.3.1 in terms of improving practical skills...............................................................................33

3.3.3 in term of improving interpersonal communication skills...............................................33

3.3.4 in terms of improving team playing skills........................................................................34

3.3.5 in terms of improving leadership skills............................................................................34

3.3.6 in terms of understanding about work ethics and related issues......................................34

3.3.7 in terms of entrepreneurship skills...................................................................................34

3.4 problems encountered during the internship period...............................................................35

3.5 contributions...........................................................................................................................36

rack and pinion cleaner machine......................................................................................................37

4.1 introduction.............................................................................................................................37

4.2 problem statement...................................................................................................................38

figure 4.1 some place from the company......................................................................................38

4.3 objective of project.................................................................................................................38

4.3.1general objective...................................................................................................................38

4.3.1specific objective...............................................................................................................38

4.3.2 significant of the project...................................................................................................39

4.4. literature review.....................................................................................................................39

4.4.1 floor cleaning machine.....................................................................................................39

4.4.2 multi-use floor cleaning machine.....................................................................................39

4.5. methodology..........................................................................................................................40
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 4.6.1 geometric analysis............................................................................................................41

4.6.2 standard specification of machine....................................................................................41

4.6.3 gear design........................................................................................................................42

4.6.4 design of toothed belt pulley............................................................................................50

4.6.5 design of shaft...................................................................................................................55

4.6.6 design of key.....................................................................................................................58

4.6.7 design and selection of bearing........................................................................................60

4.6.8 selection of belt bucket elevator.......................................................................................64

4.6.9 design and selection of tanker..........................................................................................65

4.6.10 design of main frame......................................................................................................66

4.6.11 selection of wheel...........................................................................................................68

4.7 cost assumption.......................................................................................................................70

chapter five...................................................................................................................................71

conclusion and recommendation......................................................................................................71

5.1conclusion................................................................................................................................71

5.2 recommendation......................................................................................................................71

reference...........................................................................................................................................72

appendix...........................................................................................................................................73

part drawing.....................................................................................................................................75

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LIST OF NOMENCLATURE
Symbol Nomenclature
P Power
ω Angular speed
T Torque
N Rotational speed
D Diameter
R Radius
σy yield strength

σ ult Ultimate tensile strength

τ all Allowable shear stress

σs Principal shear stress

𝐹.𝑆 Safety factor

σc crushing stress

I moment of inertia
α Pressure angle
wt Tangential load

Li Bearing life

c0 Static load

F force
C Dynamic load
γ Specific weight
φ Capacity factor
θ angle
Q Hourly capacity

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LIST OF ACRONYMS

Acronym Extension form

BBT Bright Beer Tank
CCT cylindrical canonical tank
EBI Empty bottle inspection
FBI Full Bottle Inspection
VBI Visual bottle inspection
PLC Program Logic Control
S.C Share Company
UIL university industry linkage
UBT unfiltered beer tank
FBT filtered beer tank
ESLSE Ethiopia shipping and logistic service enterprise
HL Hectoliter
PVPP Poly vinyl poly pyrrolidone
CIP Clean internal part
ANSI American National Standards Institute

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 CHAPTER ONE
BACKGROUND OF THE COMPANY
1.1 INTRODUCTION
Raya Brewery S.C is a new brewery production plant occupying an area of 15 hectares was
established in 2010 by 58 founding shareholders, including TsadikanGebretinsay (Let.Gen), former
army chief of staff, and Ambachew Abraha, former head of Ethiopian Shipping and Logistics Service
Enterprise (ESLSE), has now reached about 2,441 shareholders at Bohera Mountain, south of Tigray,
667km from Addis Ababa and is named after the society of Raya and its annual production capacity is
estimated to be 6 million hectoliters. Raya brewery S.C is inaugurated on February 14 and 15, By the
President of the Federal Democratic Republic of Ethiopia Mulatu Teshome (PhD) which is the sixth
Ethiopian brewery. And is expected to higher the annually Ethiopians beer production capacity from
5.6 million hector litters to around 12 million hector litters. The brewery has now 680 permanent
&contract employees, which 568 &112 are permanent and contract employees respectively with
sexual ratio of 73%male and 27%female. In addition, the brewery also creates job opportunities for
350 daily labor workers. At the pre- expansion period the brewery created job opportunities for 266
permanent &contract employees, without considering temporary employees. In line with this, modern
technology diffusion and vital human resource capacity development work is under taken.

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 Figure 1.1 background of the company

1.2 Vision of the company

The Company vision serves as the framework for their success and guides every aspect of their
business by describing what they need to accomplish in order to continue achieving sustainable,
quality growth. The main visions of Raya brewery are: -
 Be a great place to work where people are inspired to be the best they can be.
 Nurture a winning network of customers and suppliers, together we create mutual, enduring
value.
 Be a responsible citizen that makes a difference by helping build and support sustainable
communities.
 Maximize long-term return to shareowners while being mindful of our overall responsibilities.
 Be a highly effective, lean and fast-moving organization
1.2 Mission
 To support socio economic development of tigray region in particular and to the overall
development of the country in general.
 To give value for eco environment in friendly manner.

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  To by generated profit to improve the socio-economic wellbeing of the society.
 To product and seek quality beer at reasonable profit.
1.3 Objective
The main objectives of Raya brewery S.C are:
 To create broadband sustainable market by supplying competitive products that fulfills
customer’s requirements.
 Develop human resources and create job opportunities.
 To improve the type, quality and quantity of product.
 To produce beer and draft with quality within country as well as export in Europe
1.4 Main product and service of raya brewery S.C
The main products of Raya brewery are: -
 Pasteurized Drought beer
 Raya beer, Castle beer and St Gorge’s beer
1.5 Main customers (end users of) Raya brewery S.C
The end users (customers) of Raya brewery S.C are every person aged above 18 years old. There is no
any limit or boundary in order to be a customer for Raya beer. And Raya brewery S.C is new brewery
company so the company is working hard to distribute in to different regions of Ethiopia and outside
country.
 To All direction of Ethiopia ,California, Israel, Australia and Southern Sudan

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 1.6 Raya Brewery Organizational Structur

General Assembly

Board of Directors

CEO

Auditor Senior Legal advisor

CRS & PR Manager Project Optimization Manager

Corporate Dep’t Manager Corporate Planner

Executive secretary

Director of Operation Director of Procure. & Logistics Director of Commercial Director of Business Service

Production Procurement Sales & Distribution HRD & Admin

Quality Assurance Logistics Marketing Finance

Technical IT

Figure2.1 Raya Brewery Organizational Structure

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1.7 Over all work flow of Raya brewery

Figure 1.1 over all work flow of Raya brewery

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 CHAPTER TWO
WORK, RESPONSIBILITIES AND ASSIGNMENTS
2.1 Working section in the company
In the company our working section is specified, I have been working in the whole process of beer
production especially in malt handling; brew house fermentation, utility and keg unit of the beer
production and maintenance work in machine shop. Thus, the company accepted internship from
different university and different techniques schools. These company assignee techniques students to
maintain different machines (like; pulley, belt, Rollers, gear box, coupling and shaft.) and assignee
university students in finding of problem in the company and to solve and modify things as we learned
in the university before internship knowledge. During my internship time I have looked on the whole
process of the factory and maintenance work in the machine shop and I have got knowledge how the
beer is produced, how maintain parts and the different departments are interrelated with each other. At
that time and additional of some day’s side by side we read on the documentation about the general
process by giving emphasize to the production process that we have seen on site.

2.2 How does the work flow in the section look like?
2.3.1 Malt handling area
Beer is an industrial product. A beer is one of the oldest and most complex in the preparation of drink.
To create the final product brewers, use the latest technology and very expensive equipment. But, as
before, the integral components of beer are 4 ingredients. These are: –

 Malt

 Water

 Yeast

 Hop and other additives.

Malt is the main raw material for beer production. The raw material for malt is barley. Its uses depend
on the fact that barley has high starch content and the husk still adheres to the gain, even after
threshing and processing to malt. Consequently, it is able to form the wort filtration layer required in a
later production stage. Malt is delivered to the brewery, weighed, conveyed, cleaned, stored and made
available for worst production. The malt reception department is subdivided into two sections.

 The first section consists of the unloading of the bulk product, its conveyance and cleaning
with subsequent storage in silos.

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  In the second section, the malt is conveyed from the storage silos, cleaned, milled and after
dry milling stored in grist hopper. Different impurities like dust, stones, metals, husks, are
removed.

In Raya brewery the different conveying equipment used for this purpose are: -

 Bucket elevators

 chain conveyers and

 Screw conveyor all these should be aspirated to remove dust, stones, husks and other
impurities which are usually collected at some point around the malt handling area.

Initially, malt is often roughly screened (sieved) to remove coarse and fine impurities by the
drum sieve and is passed over the de-stoner to remove stones from the grain. Magnetic
separator to remove fragments of metal is also another treatment before milling. The removal
of metal items and de- stoning are necessary.

 to reduce wear on conveying equipment

 to reduce the risks of sparks which can lead to fires or explosions

Raya brewery receives malt from two sources

 Local

 imported malt

The local malt comes from Assela malt factory where as the imported malt is from Belgium. Raya
brewery has six silos; these silos are used to store the malt. The four silos are work by container but
next two silos are work manually or by human being. Silo 1-4 has capacity to store 300 tons of malt
each. It is used to store pale malt Silo 5-6 has the capacity to store 30 tons of malt that used to store
roasted malt

1. - Screw conveyors

Screw conveyors are the most used conveying elements for inclined and horizontal transfer of bulk
goods such as barley and malt. It consists of continuous helical screw fastened to a shaft which is
rotated in a U-shaped trough to push the malt through the When rotating, the screw pushes the malt
gently forward to the discharge position provided in the form of discharge slide. Advantage: Despite a
high energy usage the screw conveyor is an inexpensive conveying device for horizontal transfer (or

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inclined up to 30 short) for transport over distance in malting screw conveyors is therefore generally
used.

Mechanical components of screw conveyor

 U shaped Trough

 Trough casing
 Bearings
 Driving motor and
 screw fastened to a shaft

Figure2.1 Screw conv

eyors
2. - Bucket elevator

This also called a grain leg, is a type of conveyor used for vertical transportation of malt. It consists of
a rubber belt with plastic buckets. Pulleys several feet in diameter are used at the top and bottom of the
elevator. The top pulley is driven by electric motor. Vertical elevators depend entirely on the action of
Centrifugal force to get the material in to the discharge chute. Material is fed in to an inlet hopper.
Buckets dig in to the material and convey it up to and over the head sprocket or pulley, then throwing
the material out of throat. The emptied buckets then continue back down the boot to continue the
cycle. Mechanical components bucket elevator

 Buckets to contain the material

 belt drive

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  Casing for enclosing and protecting the elevator

 Discharge outlet

 A belt to carry the buckets and to transmit the pull

3- Chain conveyor

The troughed chain conveyor is a transporting device for horizontal and inclined transport. An endless
chain link chain with specifically arranged cross pieces runs at a speed of 0.4 to 0.6 m/s in rectangular
flat trough. The trough can be 2/3 to 3/4 filled with malt. The malt conveyed while being directly in
contact with the chain. The drive motor is provided by a sprocket wheel in the drive unit.

Components of chain conveyor

 Drive motor

 Conveyor casting

 Shaft with sprocket

 chain and bearing

2.3.2 Malt cleaning process

2.3.2.1- Drum sieve:
It is used to separate the malt from it husk and impurities (over size) with a rotary mechanism.

Figure2.3Drum sieve
2.3.2.2- Dry De Stoner:
De-Stoners machine is applied for the efficient separation of stones, metal, glass, & other high density
impurities from the malt which are still present because they are the same size as the malt. The

17
excellent removal of high-density impurities protects the downstream processing equipment and thus
reduces its wear and tear.

Figure2.4 Dry De Stoner

2.3.2.3- De dusting unit
It is the process of suck air & dust particle from drum sieve, de stoner & hopper. Air evacuated to the
atmosphere and the solid particle is removed to the dust hopper.

Component of de dusting unit

 Motor

 Shaft

 Suction line

 Solid dust removing line

2.3.2.4. Milling (Classic mill)

The classic milling is used to convert the malt in to grist. It consists of a rotor made of plates with pins
to carry the hammer. Malt milling is required in order to be easily broken down the malt enzymes
during mashing process. The malt must be broken in to small fragments (grist). These processes are
calls milling. Milling is a mechanical process which determines how fine grist. The dry grist is usually
place in intermediate storage in grist case before it was added to the pre masher.

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 Figure2.5Classicmill
2.3.2.5. Grist hopper or grist dose been
 It is used store grist malt

 It consists 5.5 tone or 5500kg of grist malt

 From this machine there is limit switch and motion detector in the conveyor

Figure2.6 grist hoper

Electrical equipment in malt handling

 Motion detector sensor in each conveyor

 Temperature sensor in each silo

 Limit switch sensor in each door conveyor

 Level sensor in each silo

 Conveyor driving motors

 Gate valve motor: for closing/open of malt from silo

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  Fan motors: for protecting of the malt from over temperature in the silo

2.3.3 Brew house

Figure2.7working flow of malt handling area

2.3.3.1. Mash in tank (pre-masher)

It is used to mix hot water, cold water, and grist at a temperature of 52°cMashing is the process that
combining a mixture of milled malt with brewing water. The process of mixing 1Kg of milled malt
with 2.5L water (hot and cold) takes place. It can mix 5000Kg milled malt within 20 minutes. This
temperature is adjusted by temperature sensor.

Mechanical Part in mash in tank

• Pump: There are two types of pump.

• Centrifugal pump: a centrifugal pump is a pump at which the shaft and the impeller are
an angle of 90 degrees (perpendicular to each other). Used to transport less viscosity
material like water.

• Positive displacement pump: appositive displacement is a pump at which the shaft and
the impeller are at angle of180 degrees (parallel to each other). This type of pump is used
to transport high viscosity material wort, yeast etc.

• Pneumatic valve: This mechanical part is used to open and close any fluid material like
water.

• Slide get valve: used to regulate the amount of malt grist

• Motor; is used to change electrical energy to mechanical energy.

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 • Gear box; is used for reduction of speed and used to increase torque.

Figure 2.8 -mush-in tank

2.3.3.2. Mash tun (mash kettle)
After mixing of the malt with water in mash kettle it transfers to mash tun by the help of progressive
cavity pump. In mash tun three types of additives are added in order to convert complex starch
(mainly α amylase and β amylase) to simple sugar, maltose, and maltose dextrose that are more
readily fermented.
Mechanical Components
 Agitator
 Electric motor
 Gear box and cylindrical cone casing.
2.3.3.3. Mash filter Mash filter
Is a very much like plate and frame filter. It consists of a series of grid type plates alternating with
hollow frame plates that are suspended on side rails. it is used to separate wort from the spent grain.
After the separation of the wort and spent grain wort is collected in the wort collector tank.

Figure 2.9-mush filter

Spent grains hopper and conveyor

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The mash filter is usually delivered with its spent grains hopper and conveyor,
Installed just below the mash filter, allowing the collection and pneumatic transfer of
The spent grains discharged from the mash filter chambers, up to the storage silo. The detailed
documentation of this equipment is part of the global mash filter technical file.

Figure 2.10-spent grain hoper and conveyor

2.3.3.4. Wort collector
It is used to store the wort temporarily and that go to the wort pan.

2.3.3.5. Wort pan (wort kettle)

Wort pan is conical cylindrical tank used to mix the wort with hop to change color of the wort and to
increase its alcoholic content by the rotating agitator at a temperature about 96 0C.

 This also called boiler

 To concentrate and sterilize the wort

 To inactivate enzymes

 In this wort pan two types of hop are added

– hop extract for bitterness of beer

– Hop pellet for aroma of beer

 Also zinc sulfate is added for yeast nutrient

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2.3.3.6. Whirl pool
Whirl pool is used to separate trub from the hopped wort and then the hopped wort is transferred in
to fermentation tank but trub is stored in trub tank. Used to

 separate hoped wort and hot trup

 The hot trub send to hot trup tank Wort collector; is used to store the wort
temporarily and that go to the wort pan.

2.3.3.7. Trub tank

Used to store west wort and that is recycled wort boiler until 24 hours but after 24 hours it must be
rejected

Brew house sensors and their function

 Temperature sensors –used for controlling of the desired temperature.

Example: for pre-masher, mash kettle and for wort pan

 Level sensors-used for controlling the level of vessels Example: level for pre-masher,
level for mesh kettle level for wort pan and level for whirl pool etc.

 Pressure sensors-used to control pressure of liquid and gas Example: in compressed air
line of brew house and pre-mesh pump

 Flow sensor used to control flow of the mash and wort.

Figure 2.11- working flow of brew house

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2.3.4 Fermentation
2.3.4.1Yeast propagation
Yeast propagated in the yeast propagation tank. The steps of yeast propagation are the following...

 Sterilization
 Stepwise cooling
 Yeast pitching

The function of any fermented is:

- To be a vessel to contain the fermenting wort.

- To allow CO2 to escape or be collected.

-To provide cooling to manage the fermentation.

The fermentation tanks in raya brewery are dividing in to the three by the volume.

1, cct0 350 hl

2, cct1-cct6 each holds 1000 hl

3, cct7-cct14 each holds 1500 hl

2.3.4 .2 Steps of fermentation

Filling: The wort from whirlpool pass through plate exchanger then it cools down to 90c, here we
measure the original extract, PH and then the cold wort after aeration and yeast pitching transfers to
the fermentation tanks.

Primary fermentation; in this process mainly, temperature adjustment takes places.

Secondary Fermentation; this fermentation process occurs after12 hours of primary fermentation. At
this time the majority of sugar is used by yeast and converted in to ethanol and carbon dioxide.

Intensive cooling one; - In this stage the temperature decreased from 12 0c to 40c by the help of
glycol.

Intensive cooling two; -In this stage after yeast is harvested, the temperature decreased from 40c to 0
0c. Then, after 72 hours, the beer is transferred to laagering step for maturation.

Laagering; - In this stage, the temperature is decreased from 00c to -1.5 0c without forming into ice.
Now, the beer is matured and ready for filtration.

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Then an indicative analysis is done by chemists such as Original gravity of beer, alcohol amount, and
carbon dioxide. Then above 4 days of the laagering age, beer is transferred to filtration.

2.3.5 Filtration
Filtration is the process of clarifying the beer which contains spent yeasts, protein polyphenols,
complex and other unnecessary material to make the beer bright and clean. It is also the clarification
of beer to a standard that is acceptable for consumers or customers. It is done after the beer has been
laagered or matured.

Sequence of operation during filtration

1. Yeast separators: the laagered beer is flow to the centrifugal separator from fermentation
tank or CCT. This centrifugal separator rotates at higher speed of 7000rpm. Then, spent dead
yeasts are trapped in this separator and removed as waste into the spent yeast storage tank.

Figure 2.12 yeast separator

2. Pvpp preparation

Pvpp is prepared by mixing of 25 kg of pvpp and 400l of degassed water. This chemical is
prepared and dosed to adsorb poly phenols that contribute haze to the beer.

3. Filling of unfiltered beer tank: it services as buffer so it protects the pump and the candle filter
from damage.

4. Kiselgular preparation: before the beer is entered to the candle filter tank there is a small
dosing tank near to the candle filter tank. In this tank, filter aids such as DICB, CBR and CBL
which are called kieselghur are prepared and dosed into the beer line and baked in the candle
filter tank. The DICB is coarse in particle; CBR is medium whereas CBL is fine. Ways of Pre-
coating the Filter aids on candle filter

5. Filtration
25
 6. Blending

7. Bright beer tank: The filtered beer is pumped into the bright beer tank and stored for 2 – 3
days.

2.3.6 Keg Filling Line

1. DE palletizer: To remove empty kegs from pallets and to present them to a conveyor for
transport to the line. But this is done manually.
2. Empty pack Inspect: To check that the empty and undamaged.
3. External keg Washer: To clean the outside of the keg and to remove all label residues.
4. Internal Washer Filler: to clean and sterilize the inside of the keg and Filling to the specified
volume of beer.
5. Full pack Inspect: To check that the full kegs from the filler are filled with the correct volume
of beer
6. Palletizer

Figue2.24 keg work flow

Table 2.1 difference between beer and draft

2.3.7 Utility plants

From the utility plant we are able to understand the following plant area those are;

2.3.7.1-Co2 recovery plant

The main function of this plant is to purify of c02 and store in the form of liquid.

To purify co2 the following machines will be used those listed below are presented by their
working sequence.
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1. Foam separator: This machine is used to trap foam that comes from CCT with co2 gas.

Components

 2 ports water spray nozzle

 better fly valve foam detector

2. Gas balloon

• Gas balloon is using us a temporary storage in the recovery plant.

• Balloon size always depending on plant /fermentation capacity

3. Pressure booster

To compress the co2 gas from a lower pressure to a higher pressure

Provides positive pressure necessary to overcome distance line and gas washer resistance

Increase the suction pressure on the first stage

Components

- 2 ports - Motor -pulleys

- Belt -Impeller - Gauges

4. Gas washer

• Remove water dissolvable impurities from incoming co2 gas

• To increase compressor valve life.

Components

 ports Sensors

 Regulator Purge valve

5. Co2 compressor

• To compresses co2 gas at higher temperature and pressure that comes from gas washer.

• It contains two stages.

Components

-Motor - Piston -Fly wheel

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 -Belt - Connecting rod - Gauges

-Shaft -Coupling -Bearing

6. ACF/driers

• Remove the impurities from the co2 gas that are not already been removed in the gas washer by means
of active carbon

Components

 Heater ports

 3-way valve Sensors

7. Co2 condenser

• To liquefy the co2 that is coming from ACF/driers

• To separate non-condensate gasses from the co2

• To maintain pressure in the co2 storage tanks

• Basic configuration of cooling system:

- Cooling compressor - Refrigerant condenser

- Co2 condenser

8. Re boiler

• It contains temperature stole

•Used to boil the condensed co2 liquid that comes from the condenser.

9.Co2 tank: To store produced liquid co2 of the recovery system

10.Co2 evaporator: To evaporate liquid co2 from the tank storage into gas–

11.Co2 reducing valve

Back pressure station:

• To hold minimum pressure in the co2 storage tanks Reducer station:

• To reduce the co2 system pressure to a pressure that is desired by the customer.

Components are (spring, Reducing valve, gauges and tension)

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 Figure 2.25-co2workflow
2.3.7.2. Cooling plant
• The main function of this plant is to cool degas water.

Components

 ammonia leakage sucker and ammonia condenser

 expansion valve

 heat exchanger

 piston type compressor

Figure 2.26 Cooling plant

2.3.7.3. BOILER PLANT
• The main function of this plant is to change free water in to steam.
Components
1. Softener resin 2. Condenser tank 3. Motor 4.fan
5. Fire tube 6. Water tank 7. Burner 8. oil filter
9. Centrifugal pump 10. Gear pump 11. Solenoid valve 12. nozzle
13. safety valve 14. Sensors

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 Figure 2.27boiler plant
2.3.7.4. Water treatment plant
•The main function of this plant is to treat the water.

Components
- Brew and service tank - Active carbon filter
- CR pump -UV filter
- Mechanical filter - Softener resin
-sand filter

Figure 2.28 wtp

2.3.7.5. West water treatment
Components
- Scraper - Softener resin - rotary screen
- Level and pressure sensor - screw conveyor - man hole
-Submersible pump - end suction pump - Softener resin

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 Figure 2.29 wwt

2.4 My Responsibilities during Internship Time

I perform during maintenance of different machine. Most of the time

Oiling of the machine

 At Lubrication time
 Helping the mechanics at the time of disassemble different gearbox

Figure 2.30 at time of disassemble of gear box

31
2.4.1 Solving the company’s problem
Identifying and as much as possible solving a problem were duties of me in my internship time. So, I
have tried to solve the company’s technical, personal or organizational problems by following the
procedure.

Objective
 Give a solution for problems which are found in the companies for a long time. Based on the
principles of mechanical engineering
 Upgrade the productivity of the company
Mission
 Upgrade the production and quality of the company
Method

By observing the problems of the company carefully and by discuss on the problems with our
advisor I have prepare proposal based on the company’s proposal writing out line and present my
proposal to my advisor’s and my proposal gets acceptance and I continued I project.

Procedure
 Observing the company’s problem
 Discuss with our advisor
 Prepare proposal
 Get the acceptance from the office
 Then, begin the project
 Submit the project to our advisor

32
 CHAPTER THREE
TECHNICAL ASPECT OF THE INTERNSHIP
The technical aspects of my internship were maintaining materials in the machine shop. The
maintenance process was takes place in the machine shop which contains different lathe machines
and other machines.

Some of them are;

 Maintenance of pulleys and chain

 Pulleys cylindrically shaped solid object, which used to transport materials by driving
belt. The pulleys are generally made of cast iron, because of their low cost. The rim is
held in place by web from the central boss or by arms or spokes.
 Maintenance of idlers and other materials that needs maintenance
3.1 Maintenance pulley
Objective of the task

 To smooth the pulley

 To be have a smooth rotation of belt

 To reduce friction between the belt and pulley

 To prevent slip of the belt

Method

 By putting the pulley at the center of the chuck of the lathe machine to give the stability
of the pulley and to became smooth.

Procedure

Step 1: adjust the pulley on the chuck

Step 2: adjust the cutting tool towards the working material

Step 3: start the motor

Step 4: rotate the work piece and providing the length to be smooth

Step 5: finish the material and put in proper place

33
3.2 Maintenance of idlers and other parts
Conveyor idlers were generally considered a consumable element of the conveyor. Their unit value
was relatively low when compared to the price of a pulley, Plummer blocks or the conveyor belting.
3.3 Over all benefit gained from the internship
3.3.1 In terms of improving practical skills
 When I get the theoretical part in practical, we have tried to relate the theoretical knowledge
with the practical part.

 I gained more knowledge by working on the project from requirement gathering to the end of
the project.

 I developed how to face any challenge in life by different direction and finding the solution
skills.

 I saw the job environment widely. In the future we will not fresh to work anymore.

 I also developed communication and operation machines.

3.3.2 In term of upgrading Theoretical Knowledge

With regard to upgrading theoretical knowledge, I have gained much knowledge by working some
controlling and fault management jobs, learning from the employees and our supervisor on the system
the use on their daily activities of work and installing them practically and get the theoretical lessons
that we have taken previously.

3.3.3 In term of improving Interpersonal communication skills

 listening carefully

 Asking clearly and shortly.

 Increase understanding skill by different methods.

 Respect each other

 Tolerate group members and others

 Staying focused

 Problem solving.

 Motivation politeness

 Self-confidence and Honesty

34
3.3.4 In terms of improving team playing skills
I have learned how to motivate someone to work. I have gained the following values from this intern
ship regarding to improving team playing skills:

 Listening to each other

 Sharing idea

 Communication

 Tolerate and respect in the team

 How can be patient

 Giving respect for others

 Problem solving

3.3.5 In terms of improving leadership skills

 How can establish direction as a leader of a team?

 Alignment people

 Motivating and inspiring

 Focus on team & over all goals

 Communication with each people

3.3.6 In terms of understanding about work ethics and related issues

 I have learned much enough work ethics related issue from the work of organization. The
following are some of the values I have gained from the internship in terms of the improving
work ethics.

 Responsibility and Self-confidence

 Hard working and punctual

 Professionalism and Morality

3.3.7 In terms of entrepreneurship skills

Most skills are included in entrepreneurship skill like management skill, communication skill, the
ability to work, the ability to decide& taking responsibility. I have improved entrepreneurship skill by

35
performing task effectively and working cooperatively with the staff workers. From the internship
program I gained different ideas like;

 Good time management: Good time management is how to use your time to perform task
perfectly. The company workers have good time management and they perform their task on
time including their punctuality. My supervisor on the company advices and help me to
perform my task efficiently and to be punctual. This enables to improve good time
management ability.
 Accountability: Accountability is being responsible for the problem seen on the task you
perform I have been improved the habit of accountability during internship period.

3.4 Problems Encountered During the internship period

The Challenges and problems I have been facing

I have summarized the challenges I encountered during my internship experience. The challenges I
encountered are;

 I had only safety clothes no safety shoes and gland noise protectors so it was hard to
work on different machines because safety comes first.

 When my advisors are busy, there is no one who could show us what to do so we return
without working anything.
 The Company has no any computer lab or Wi-Fi. Due to this reason, we could not get
information from internet unless I go out and use internet service to analyze my project
soon.

Methods used by me to break downs challenge I Mets

In order to solve these challenges, I took the following measurements:

 In order to protect my selves, I used the safety clothes, shoes, helmet and eyeglass we tried to
fulfill them my selves as much as we can to overcome the dangers.
 When my advisors are busy instead of going to my home I wasto asked other operators.
 Become familiar with the workers.
 Preparing plans & methods that plays a great role in destructing those difficulties.
 I use Wi-Fi in other places.

36
3.5 Contributions
During my internship time, my contribution has been based on project design and
maintenance of materials. Before taking any task from my supervisor, I was trying to
recognize the problem of the company. Therefore, in this 4-month internship I worked in
office and field works. In this working time, I saw different problems in the company
challenges the workers to fulfill their tasks. These problems helped me to work in
different projects in order to solve the problem in the company when I was in internship
time. The projects I work on is design of rack and pinion cleaner machine and listed
below (in chapter four) in detail as I work.

37
 CHAPTER FOUR

RACK AND PINION CLEANER MACHINE

4.1 Introduction
Effective cleaning and sanitizing helps and protect the health of the human beings directly and
indirectly. Also, cleaning and sanitizing prevents the pest infestations by reducing residues that can
attract and support bees, pests etc. It also improves the self-life of the floor, walls etc. due to regular
cleaning and maintenance. In recent years, most of the people prefer to use trains or buses for
commuting and hence these places are littered with biscuits covers, cold drink bottles, cork etc. Hence,
it is necessary to clean the bus stands and railways stations at regular interval. There is no one single
cleaning method that is suitable cleaning technique and also the equipment should be user friendly.
Cleaning work can be physically demanding and a need has been identified to developed methods for
systematic ergonomics evaluation robots are getting more popular for busy and aging populations due
to lack of workers. However, in Ethiopia, unemployment is more and hence there is a need to develop
less labor-oriented cleaning machine. Hence, the present work is aimed to design, development and
evaluation of a manually operated floor cleaning machine. In recent years, conventional floor cleaning
machines are most widely used in airports, railway stations, malls, hospitals and in many commercial
places, as cleaning is one of the important parameters for the sanitation and government regulations.
For maintaining such places, cleaning the floor is the major task which is necessary.

There are conventional floor cleaning machines available to perform floor cleaning operations in
above said places. Generally, a conventional floor cleaning machines requires electrical energy for its
operation. In Ethiopia, especially in summer there is power crisis, in majority of places. Hence
cleaning the floor using the conventional floor cleaning machines is difficult without electricity. Floor
cleaning is achieved by different technique which might be of different kinds. Different types of floor
need different type of treatment. The floor should be totally dry after the cleaning process. Otherwise
it may result in hazard. On some floors sawdust is used to absorb all kinds of liquids. This ensures that
there wills no need of preventing them from spill of. The sawdust has to be swept and replaced every
day. This process is still used in butchers but it was common in bars in the past. In some places tea
leaves are also used to collect dirt from carpets and also for odor removing purposes. Different types
of floor cleaning machines are available today such as floor buffers, automatic floor scrubbers and
extractors that can clean almost all types of hard floors or carpeted flooring surfaces in very less time
than it would have taken using traditional cleaning methods. Again, the cleaning would be different
for different floorings.
38
4.2 Problem statement
Most of in the countries there are different traditional floor cleaning methods this leads to the
following problems it increases labor cost, it is difficult to clean by human due to the scrap is broken
bottle glass it is difficult to clean the floor in the bottle washer and in Raya Brewery S.C industry
every cleaning activate are performed by human effort this indicated that there are suffering from
electrical cleaning machine. Due to this lack of electrical cleaning machine, they use traditional source
of energy such as human effort, which cause labor cost and time consume. to solve such problem, we
design and model rack and pinion cleaning machine to clean all the room special in production house
in addition to that clean house hold, office, hospital etc. In addition, this rack and pinion cleaning
machine does not consume manufacturing cost due to the almost all material is available in the
brewery industry.

Figure 4.1 some place from the company

4.3 Objective of project
4.3.1General objective
The general objective of this project is to design and modeling of rack and pinion scarp cleaning
machine.

4.3.1Specific objective
 To design gear (pinion, spur, rack)
 To design tooth belt and pulley
 To design shafts
 To design key & bearing
 To select bucket belt conveyor
 To design frame and to select wheel
39
4.3.2 Significant of the project
 To save time

 Decreasing human power

 To decrease water consumption

 To reduce wastage of compressed pressure

4.4. Literature Review

4.4.1 Floor cleaning machine
Floor cleaning and fabrication of manually operated floor cleaning machine is the conventional floor
cleaning and machines is most widely used in airport platforms, railway platforms, hospitals, bus
stands, malls and in many other commercial places. These devices need an electrical energy for its
operation not user friendly. Machine consist of rollers, water tank, sprocket & chain mechanism,
collector brush assembly, drive wheel, and cotton etc. cotton is wound around supporting roller and
main rollers. But main roller is placed in water tank so that wetted cotton is transfer forward for
cleaning. Cotton is rotate due to use of chain drive. and for chain drive gives the drive from wheel.
Two small rollers is mounted on surface. The compression rollers are used for removing the excess
water. In front of machine the collector is placed for collecting the dirt, dust particle before the
cleaning of surface. When we are push the machine forward direction cotton will be rotate around the
rollers which will clean the surface. This cycle of rotation of cotton will repeated. [1]

Figure: 4.2 Floor cleaning machine

4.4.2 Multi-use floor cleaning machine
Considering Ergonomics position of handle is fixed. To ease of operation 1 switch is provided on the
handle. Almost for the all parts of machine Mild steel is chosen. It is also beneficial in terms of cost
and availability. This machine is simply operated by pushing or pulling the handle with less effort as

40
heavy load wheels are provided. It is mainly designed to clean the Educational institutes, malls,
hostels, colleges, byre, hotels so that hectic work of sweepers can be reduced to great extent. For this
machine speed reduction by belt and pulley mechanism is used. Later 3D modeling and simulation
was carried out using CATIA software. The CATIA tool is used to determine the basic structure of
machine, weight, working visualization of machine. Then to clean the floors, sponge is fixed by nut
and bolts into the bracket. In case of cleaning of byres brushes are fixed. The bracket is fixed onto the
shaft. 5 kg load is applied onto the bracket so that while revolving it sponge will rub the floor very
cleanly. [2]

Figure: 4.3Multi-use floor cleaning machine

4.5. Methodology
The design and modeling of rack and pinion cleaning machine is use for industrial and other
application.

The project methodology shows us how the project started, describe problem and identify the
solution, how data was collected, and how the next steps done.

The following steps will be used to the goals of this project.

1. Specify the dimensions of components.

2. Develop design specifications of the project: Define a Design Specifications document

outlining the design requirements. Document will define performance, weight, and cost
requirements for the project. This document will also describe the analyses and tests required to
meet the specifications.

41
 3. Design of the project by using the solid work, create 3-dimensional model of the rack and
pinion cleaning machine as well as dimensional drawings

4. Drawings for components: Produce detailed drawings for all components. Create assembly
drawing and parts list for all required components.

5. Assemble the rack and pinion cleaning machine: Assemble all components and subassemblies.
Using mechanical engineering software and cost analysis.

4.6. Design analysis

4.6.1 Geometric analysis

In this section it will be discussed about the general mechanisms used for the machine, the
dimensional analysis of the machine. In this design we used a reciprocating mechanism for the
cleaning operation, i.e.it can be operated by using intermittent action of the arm of the mechanism or
forward and back ward motion of the reciprocating mechanism by getting a driving force from the
rotation of the electric motor attached to the link of the mechanism by using a belt drive. The
dimensional analysis of the machine in this project will be discussed below. We used the given
parameters of standards to find out the main principal dimensions of the machine. In this design the
basic standard parameters give the machines dimensions. The width, length, and height of the machine
that will be designed are selected from the parameters.

4.6.2 Standard specification of machine

Standard sizes of the machine found to be

 Length of machine =900mm

 Width of machine =650mm

Table 4.1 dC motor specification

Motor specification

Power 1.5kw

N(rpm 750
)

Phase Single

Weight 15kg
42
The overall height of the machine is assumed up to the handle of the machine. So, the height can
be assumed to be 1m from the groundhog’s assumption is taken by considering the operational

Structure of the machine. A person can operate by this machine when he/she is standing on; the handle
is assumed to be parallel to themed- way of human height.

The overall length of the machine can be estimated by considering the following conditions.

 Based on application
 Based on space used

4.6.3 Gear design

4.6.3.1 Design for pinion
Gears are toothed, cylindrical wheels used for transmitting motion and power from one rotating Shaft
to another. The teeth of a driving gear mesh accurately in the spaces b/n teeth on the driven gear. The
driving teeth push on the driven teeth, exerting a force perpendicular to the radius of the gear. Gear
drives have the following advantages compared with chain or belt drives:

• It is positive drives and the velocity ratio remains constant

• The center distance between the shafts is relatively small

• It transmits very large power than belt or chain drives

• The efficiency of gear drives is very high even up to 99% in case of spur gears

• It can transmit motion at very low velocity, which is not possible with belt drives.

Classification of Gears:

Gears are broadly classified into four spur, helical, bevel and worm gears.

Spur Gear: are recommended when the teeth are cut parallel to the axis of the shaft as the teeth are
parallel to the axis of the shaft spur gear are used only when the shafts are parallel.

Helical Gear: the axis of the shaft is perpendicular to the tooth.

Bevel Gear: when the axis of the shaft is at right angles to each tooth.

Worm Gear: used for shafts the axis which do not intersect and perpendicular to each other.

Selection of Type of Gear:

43
The first step in design of gear drive is the selection of proper type of gear for a given application. the
factor that are consider for deciding the type of gear are general layout of the shaft, speed reduction,
power to transmit, input speed and cost. Spur gears have teeth that are straight and arranged parallel to
the axis of the shaft that carries the gears.

The following are the reasons for spur gear selection.

• The shafts carrying the gears are parallel.

• It minimizes cost of production.

• Easy to manufacture than others

Material selection for gear

The materials used for the manufacturing of gears depend on the strength and service conditions like
wear, noise, etc. cast iron is use for the manufacturing of gears due to its good wearing properties,
excellent machine ability and ease of producing complicated shapes. I select highest-grade cast iron
with 250Mpa

The following data`s are initial data`s that are given

 Power produced 1.5 kw

 In put speed is 750rpm

 reduction factor, rf= 4

 module, m =2.5mm

The minimum number of teeth on the pinion in order to avoid interference for 20 0 full depth involute
gear system is =18…. from table 28.2…. Kurmi text book.

Table4.2. Minimum number of teeth on the pinion in order to avoid interference

Pinion geometry calculation

You should prove for yourself the validity of the following useful relations:

Number of teeth super gear =18

44
 From standard table proportion of gear system at 20̊full depth involutes
Where m = module, m = 2.5mm, all units are in mm

z
 pd =
d
d
 m=
z

d=mz Pitch diameter of pinion, d p=m× Z p=2.5× 18=45mm

G.R = =>TG =G. R×TP =4×18 =72 Teeth.

DG =M G Where DG =Diameter of gear and M =Module =2.5

TG =Teeth number of gear

D.G =2.5*72= 180mm

2 π NP T 60 P
P= T= where T= torque P=power
60 2 π NP
60 ×1.5 kw
T= =19.099Nm N=rpm of pinion
2 π × 750

Table4.3. Standard proportions of gear system

For 200 full depths, involutes system:

 Addendum, a = m =2.5mm

 Dedendum, b = 1.25m =1.25(2.5mm) =3.125 mm

 Working depth, h k = 2m = 2(2.5mm) = 5mm

 Whole depth, ht = 2.25m = 2.25(2.5mm) = 5.625mm

45
 Tooth thickness, t = 1.5708m =1.5708(2.5mm) = 3.927mm

 Minimum clearance, c = 0.25m = 0.25(2.5mm) = 0.625mm

 Fillet radius at root, f r= 0.4m = 0.4(2.5mm) = 1mm

The teeth are uncrowned.

Assume pinion life of 108 cycles and reliability of 90%

0.0225 ×(2 π ×750)

Pitch line velocity of pinion, v = rω = = 1.7m/s
60

The Load Exerted on Pinion Gear

T 19.09
Tangential load: Wt= = =954.5N
r 0.02
Radial load: Wr=Wt tan =954.5×tan20=347.41N

Wt
Normal load =Wn= =954.5÷cos20=1003.6N
(cos )

Maximum bending stress (permissible working stress): - Wt.=δw ×b×m×π×y

0.912
y = 0.154 – =0.1
T

wt 954.5
δw = = =40Mpa
b ×m × π × y 30∗2.5∗π∗0.097

The permissible working stress,

3
Cv = Cv velocity factor v=1.7m/s
3+v

3
Cv = =0.64
3+1.7

46
 δw
δo = =40/0.64 =62.5Mpa
Cv

62.5 Mpa 105Mpa of the material………which is safe.

DYNAMIC LOAD (WD)

WD=WT+WI

21 v (b . c +W T )
WD=WT+WI = WT +
21 v + √ b . c+W T

C= deformation factor=80

WD=1216.9659N

Static tooth load (Ws): Ws =

Where =endurance limit of the material =84 Mpa.

Ws =84*30*3.14*2.5*0.1=1978.85N

For safety against tooth breakage Ws>WD

For steady loads Ws 1.25WD =>1978.85 > (1.25 1216.9659 =1521.21) ……...Which is safe.

Wear Tooth Load Wow =Pd

Where Ww =wear tooth load

2 vr 2∗4
Q =ratio factor = = =1.6
vr +1 4+ 1

K =load stress factor of the material in N/mm2 and Pd =pitch diameter of pinion =45mm

The value of K depends on:

 The maximum fatigue limits.
 Compressive stress and Pressure angle
 Modulus of elasticity of the material.
According to backing ham equation the value of K can be given by:

K=

Where = endurance limit of cast iron =630 Mpa.

=pressure angle =200

47
 EP and EG=modulus elasticity of the material of pinion and gear =cast iron=100KN/mm 2

K=

=1.94N/mm2

Ww = 45*30*1.6*1.92=4147.2N

For safety the wear tooth load must be greater than dynamic load.

That is Ww (4147.2N) > WD=(1216.9659N).

4.6.3.2 Design of spur gear

Spur gears formerly were the type most commonly used in industry due to their simple manufacturing
and reduced cost—a consequence of the alignment of the teeth with the axis of rotation. The profile of
the tooth is designed to maintain constant ratio from one gear to the other gear. This keeps the
tangential velocity from the pinion equal to the gear, ensuring a smooth and quiet operation.

In our design we use spur gear to transmit motion form rotary to linear. You should prove for
yourself the validity of the following useful relations:

Number of teeth super gear = ZG

From standard table proportion of gear system at 20̊full depth involutesWhere m = module,
m = 2.5mm, all units are in mm
Np ZG
Ratio of two gear is =4 = =4
NG Zp
ZG =4* Z p =4*18=72

N G =0.25*750= 187
ZG
 pd =
d
d
 m= d= m× Z G
ZG
Pitch diameter=m× Z G=2.5×64=180mm DG = 0.18m
Addendum = m×1=1×2.5 = 2.5mm
Dedendum = 1.25×m =1.25×2.5 =3.125mm
Outside diameter=d pG +2.5 ×De=127mm

48
 Circular pitch= π ×m=8mm
Tooth thickness = 1.57×m = 1.57×2.5=4mm
Minimum clearance = 0.25× m = 0.625mm
Face width = 8× m =8 ×2.5=20mm

0.09 ×(2 π ×187)

Pitch line velocity of gear, v = rω = = 1.7m/s
60

Following the same procedure to pinion gear we have the following values:

(2 π × N G ) (2 π × 187)
 ω= = =19.58rad/s
60 60
P 1.5 kw
 TG = = =76.6Nm
ω 19.58
TG
Tangential load Wt= =851.11N
r

Radial load: Wr=Wt tan =851.1×tan20=309.778N

Normal load =Wn=Wt / (cos ) =851.1÷cos20=905.73N

The permissible working stress, ,25.6Mpa

=the allowable static stress of the gear =40.156Mpa <105 Mpa o of cast iron. which is
safe?

Dynamic tooth load WD =2103.155N

Static tooth load Ws=2769.48N

Ws> (1.25WD=1.25*2103.155) ……………………………. Which is safe

Wear tooth load Wow=16588.8N

But Wow must > WD. 16588.8 > 2103.155N…………………. Which is safe.

4.6.3.3 Design of Rack

The basic rack represents the normal section of a tooth in any gear-tooth system and determines
the form or shape of tooth as well as the various relations of tooth form dimensions thereof,
namely, the module, the whole depth of tooth, circular pitch and the fillet radius. The straight rack is
translating strictly linearly.

We select grey cast iron for rack rod because it has:

49
  High strength compressive resistance
 High corrosion resistance high wear resistance
 Minimum cost
To determine the circular pitch of rack, since two gears are mesh each other than module and
circular pitch are the same (i.e. module of gear = module of rack =2.5, and circular pitch of sprue gear
(Pc) of rack = 8mm). The length of the rack = 1300mm from design specification Number of tooth
on the rack (Z) = length of rack/linear pitch since incase of rack there is linear motion is equal to linear
pitch = 8mm

Then Z = L/Pc = 1500/8 = 162 teeth

The pressure angle is 20' and the height of the tooth (or whole depth)is 2.25times
the module m. Normally, the maximum value of the radius at the root of tooth r is 0.38 m=, but

in certain cases the maximum value may be exceeded up to 0.45m.All the tooth relations are given

Figure 4.3Basic rack geometry

The profile reference line, MM cuts the basic rack in such a manner that on this line the following
relation exists:

The nominal tooth thickness s = the nominal tooth space width

p
e=half pitch p2 that is; -e= =s
2

Here, p is the circular pitch in mm and m is the module in mm the circular pitch of a gear is
one of the important specification criteria of a gear. It is defined as the length of the arc of the
pitch circle between two adjacent teeth, and is given by

πd πmz
p=s+ e= = =πm =2.5*3.14=7.85
z z

50
 p 7.85
From this we find e= = =3.93
2 2
Where z = Number of teeth of gear, and d = Pitch circle diameter = mz
similarly, the base pitch of a gear is analogous to the circular pitch, except that it is measured
on the base circle, and is given by
˚ πdcosa πmzcosa
pb=circumference of the base= ¿ = = ¿
z z z
We have a=20…………. pressure angle
= pb=πcosa=πcos 20=1.282
The fundamental dimensions bear the following relations
r =0.38 m=0.38∗2.5=0.95
Addendum = ha= rn=2.5
Dedendum =hf= m + c,
where c = Top clearance = 0.25m=2.5×0.25=0.625, as per IS:2535 then
Dedendum =hf= m + c=2.5+0.625=3.125
:. h, = m + 0.25 m = 1.25m=3.125.
Whole depth of tooth = h = ha+ hr= (1+ 1.25) m = 2.25m=2.5×2.25=5.625………... [Ref 3]
Force acting on rack
The force acting on the rack is equal with the force acting on the gear reduction without considering
the factors that reduces the coming force.

Following the same procedure to pinion gear we have the following values:

NR ZG
= ……………………………………………….. refe gear train [5]
NG ZR

where N G =187rpm Z R=144 teeth ZG = 72

(2 π × N R ) (2 π × 93.5)
then N R=93.5rpm ω= = =9.79rad/s
60 60
P 1.5 kw
TG = = 9.79 =153.19 Nm
ω
TG
Tangential load Wt= =851.055N ≈851.1N
r

Radial load: Wr=Wt tan =851.1×tan20=309.778N

Normal load =Wn=Wt / (cos ) =851.1÷cos20=905.73N

51
The permissible working stress, ,24.56Mpa

=the allowable static stress of the gear =38.22Mpa <105 Mpa o of cast iron. which is safe?

Dynamic tooth load WD =2103.155N

Static tooth load Ws=2909.228N

Ws> (1.25WD=1.25*2103.155) ……………………………. Which is safe

Wear tooth load Wow=27648.0N

But Wow must > WD. 27648.0> 2103.155N…………………. Which is safe.

he permissible working stress, ,25.6Mpa

4.6.4 Design of toothed belt pulley

Timing belts are parts of synchronous drives which represent an important category of drives.
Characteristically, these drives employ the positive engagement of two sets of meshing teeth. Hence,
they do not slip and there is no relative motion between the two elements in mesh. Due to this feature,
different parts of the drive will maintain a constant speed ratio or even a permanent relative position.
This is extremely important in applications such as automatic machinery in which a definite motion
sequence and/or indexing is involved.

The positive nature of these drives makes them capable of transmitting large torques and withstanding
large accelerations the tooth profile of most commonly known synchronous belts is of trapezoidal
shape with sides being straight lines which generate an involutes, similar to that of a spur gear tooth

Figure 4.4Toothed belt pulley

Characteristics of Belt Body Materials

52
Natural Rubber

• High resilience, excellent compression set, good molding properties

• High coefficient of friction; does not yield good ground finish

• High tear strength, low crack growth

• Can withstand low temperatures

• Poor oil and solvent resistance; unusable for ketones and alcohol

• Ozone attacks rubber, but retardants can be added

Timing belt drive selection procedure

 Determination of design load

Drives consist of a driver and a driven pulley. In general, both pulleys are not of the same size;
therefore, a speed reduction or increase occurs. T = 19.09Nm takes from

T peak = T x Service Factor T peak = 38.18Nm Where 1.5 service factor or 2 service factor

 Choice of belt pitch

Different belt pitches can satisfy the same horsepower requirements, also taking into account the
speed of the faster shaft

According table 4.4

By using power(P = 1.5kw) and speed ( N P= 750rpm) of shaft and we get the pitch from the figure
pitch= 3mm GT3

 Check belt pitch selection based on individual graphs

The peak torque, T peak computed previously, plotted against the speed of faster shaft. Since the belt
pitch was chosen in Step 2, reference to these graphs will confirm the validity of the Selection.

. T peak = 38.4Nm and N = 750rpm

We get the pitch p = 3mm GT3 from the figure ……………refer [6]

Determine speed ratio

Are designed to facilitate the determination of these quantities. They list the following information:
N2 = Number of teeth of large pulley
N1 = Number of teeth of small pulley
53
 N2/N1 = Step-up Drive Ratio
N1/N2 = Step-down Drive Ratio
N2/N1 = the transmission ratio obtained when the smaller pulley (N1 teeth) is the input and larger
pulley (N2 teeth) is the output.
N2 – N1 = difference between number of teeth on larger and smaller pulleys.
This number is useful in center-distance determination.

Table4.5. Minimum number of teeth on pulley

From the table minimum number of teeth (XH,750 ,20) ,,,,,,,,,,,[refer 2]

We select Speed ratio of the pulley 10:1
Number of teeth on large pulley 10 N 2
Speed ratio = , = N2=200
Number of teeth on small pulley 1 20
Cmin =621.24 mm

Check belt speed

Belt speeds up to (33.02 m/s) do not require special pulleys. Speeds higher than these require special
pulley materials and dynamic balancing. Speed is computed using the following equations:

V(m/s) = 0.0000524 x pulley P D (mm) x pulley rpm ……...refer [4]

P× N 3× 20
PD = PD1 = P D 1 = 19.1mm
π π

V1 = 0.0000524 x P D 1x N s = 0.0000524 x 19.1x 750 V1 = 0.751m/s

Where P D 1 -Pitch diameter N- Number of teeth, P- Pitch of tooth

N L - Rpm of large pulley, N s rpm of smaller pulley

3× 200
PD2 = =191.1mm
π

54
 PD1 NL 750∗19.1
V1=V2 = N l= = 74.96 ≈ 75rpm
PD2 Ns 191.1

V2=0.0000524 x P D 2x N l = 0.0000524*191.1*75=0.751m/s

Determine belt length

For given pitch, number of teeth on pulleys and center distance, the number of teeth of the belt can be
found from the equation:

( N 2+ N 1) ( N 2−N 1) −1 (N 2−N 1)P

NB = + sin + √ ¿ ¿NB =980
2 π 2 πC

An approximate formula can be used to obtain the belt lengthP D 1=25mm, P D 2 =195mm
2 2
( D 1−D 2) (195−25)
L = 2C+ + 1.57x (D1+D2) = 2x621.24+ + 1.57x (195+25) = 1600mm
4C 4C

Determine the belt width

For the HTD and GT3 drives, the torque ratings shown in these tables must be multiplied by the length
correction factor. This factor is a number smaller than 1 for shorter length and higher for longer belts.
This reflects the fact that a longer belt will be less prone to wear and tear as opposed to a shorter belt.

Belt Width (mm) 6 9 12 15 20

Width Multiplier 1 1.5 2 2.5 3

Belt width is b= 20 from the table

Check the number of teeth in mesh

The arc of contact on the smaller pulley in degrees can be found as follows:

Arc of contact = 180-¿) =164 (degrees)

Where: PD = Large pitch diameter, mm, Pd = Small pitch diameter, mm

C = Drive center distance, mm

The number of teeth in mesh on the smaller pulley can be found as follows:

( Arc ) n
Teeth in mesh = =9
360

55
Where: Arc = Arc of contact; small pulley degrees’ n = number of grooves, small pulley

Drop any fractional part and use only the whole number as any tooth not fully engaged cannot be
considered a working tooth.

The pulleys are used to transmit power from one shaft to another by means of flat belts. The pulleys
made of cast iron. The cast materials should have good friction and wear characteristics. The pulleys
are generally made of cast iron due their low cost. The arms may be straight or curve

The width of pulley (B) =1.25b

Where, b=width of belt

B=width of the pulley

Flat belt width of cast iron and mild steel pulleys in mm.16,20,25,40,50,63,71,80,90,100….

We select width of belt b =20mm B= 1.25×b B=1.25*20= 25mm

Thickness of pulley rim t =D/300 + 2mm to D/200+3mm for single belt

and D/200 + 6mm to for double belt Then t =195/300 + 2mm

t =3mm

NOTE; the pulley less than 200mm diameter are made with solid disc instead of arms. The thickness
of the solid web is taken equal to the thickness of rim measured at the center of the pulley face.
Therefore, the pulley we use for motor shaft is 200mm diameter and thickness3mm

4.6.5 Design of Shaft

A shaft is a rotating member, usually of circular cross section used to transmit power or
motion. It provides the axis of rotation, or oscillation, of element such as gears, pulleys, flywheels,
crank and, sprockets, and controls the geometer of their motion

Deflection is not affected by strength but rather by stiffness as represented by modules of

elasticity, which is essentially constant for all steels. For this reason, rigidity cannot be controlled by
material decisions, but only by geometric decisions. Necessary strength to resist loading stresses
affects the choice of materials and their treatment. Many shafts are made from low carbon, cold drawn
or hot-rolled steel: such as ANSI 1020-1050 steels. From material selection of the shaft I select carbon
steel of grade 40C8 that means the ultimate tensile strength from 560-670 Mpa and yield strength
320Mpa

The selection of the material used for shafts considered to have the following properties:
56
 It should have high strength.
 It should have good machinability.
 It should have low notch sensitivity factor.
 It should have good heat treatment properties and have high wear resistant properties.

A C D B
Assume
AB = 170mm AC = 78mm CD = 43mm D c =60mm
DB =49mm θ = 180 W = 50N D D=45 mm
T1
=3 τ = 40 MPa
T2
Where - DC Diameter of pinion gear θ Angle of contact
D D Diameter of pulley
T 2 Tension of pulley at slack side T 1 Tension of pulley at tight side
We know that power is constant
P =T×w = constant P1=P2 T G × wG =T P ×w p T G × nG=T P × nP
T G × nG
TP = Where: - P - Power P1 - Power of gear P2 -Power of pinion
nP
T G -Torque of gear T P -Torque of pinion nG - Speed of gear n P - Speed of pinion
ThereforeT p =19.099N n p =750rpm nG =187rpm
19.099× 750
TG = = 76.36Nm
187
We know that the torque acting on the shaft at C,
PD1
T P = (T 1- T 2) 19.09= (T 1- T 2)×0.03
2
763.96= ( T 1- T 2 ) ………………………………. (1)
T1
3= ………………………………… (2)
T2
Then T 1 = 3T 2 From eq-1 763.96 = 3T 2−T 2 T 2=381.98N T 1 = 3×381.98
T 1=¿1145N
Horizontal load acting on the shaft at C
57
 The belt is at angle of 45 0
T H 2 =T 2 ×cos 45 0 = 270.1N
T H 1 =T 1 ×cos 45 0 = 809.63N
W DH =T H 2+T V 1= 270.1+809.63 = 1079.63N
And vertical load acting on the shaft at C
T V 2 =T 2 ×sin 45 0 = 270.1N
T V 1 =T 1 ×sin 45 0 = 809.63N
W DV =T V 2+T V 1 =270.1+809.63 = 1079.63N
Therefore, the tangential force acting on the gear D
W t =954.5N
And the normal load acting on the tooth of gear D,

Wt 954.5
Wc = = =1015.75N
cos α cos 20

The normal load acts at 20° to the vertical

Resolving the normal load vertically and horizontally, we get

Vertical component of WC i.e. the vertical load acting on the shaft at D,

W cV = W c cos 20 = 1015.75×cos 20 = 954.5N

And horizontal component of WC i.e. the horizontal load acting on the shaft at D,

W cH = W c sin 20 = 1015.75×sin 20 = 347.4N

Now let us find the maximum bending moment for vertical and horizontal loading.

First of all, considering the vertical loading at C and D. Let R AV and R BV be the reactions at the
bearings A and B respectively.

We know that R AV + R BV =2034.13

Taking moments about A, we get

R BV ×170= 954.5×121+1079.63×78¿ 1174.73 N

R AV =2034.13-1174.73 = 859.39N

The vertical load that is support by the shaft

58
 1079.63N 934N
78mm Vertical force
C 49mm
A 170mm D
=1174N
=859.36N B
diagram
Shear force

=67032Nmm
Bending
moment
diagram

Now consider the horizontal loading at C and D. Let RAH and RBH be the reactions at the bearings A
and B respectively.
We know that R BH + R AH = 1427.03N
Taking moments about A, we get
R BH ×170=347.4 ×121+1079.63×78 =742.62N
R AH = 1427.03-742.62 = 684.4N
The horizontal load that support by the shaft

1079.63N 347.2N
Horizontal force
78mm
A C 170mm D 49mm
B =742.6N
=684.4N

Shear force diagram

=53383.2Nmm
Bending moment diagra

Maximum bending moment is obtaining from bending moment diagram

Maximum bending moment is found at D
59
Therefore M V =67032.442Nmm M H =53383.2Nmm
And resultant B.M. at D
M=√ M V 2 + M H 2 =√ 67032.4422+ 53383.22 =1943.6889Nmm
We know that the equivalent twisting moment,
T e =√ M 2+T P2 =19.19Nm

Now we determine the shaft diameter

40
factor safety = 2 𝜏 =40Mpaτ_all = =20MPa
2

π
T e= ×𝜏 × D3Let D= Diameter of the shaft
16
3
T e ×16
D =
π ×τ
D =16.96mm we select 20 mm
4.6.6 Design of Key
Key is a piece of mild steel inserted between the shaft and hub or boss of the gear or between the shaft
and rotating disc in order to connect these together for the purpose of preventing relative motion
between them. Keys used as temporary fastening and are subjected to considerable crushing and
shearing stress.

From the different types of keys, I select sunken key with rectangular cross-section due to:
 Easy to manufacture.
 Appropriately assembles to the internal part of gear or shaft. Or it is easy to assemble spur
gear with the shaft.

Figure 4.5 rectangular sunk key

Steel, C-45 σ y =360 MPa σ ut = (630-710) MPa E = 210 GPa

Assumption

Type of key is sunk key (i.e. w = t)

Factor of safety = 4
60
 Given:

Diameter of the shaft, d = 20 mm

Analysis Dimension of the Key

W = t = d/4 = 20/4 = 5mm

In order to find the length of the key, let see the

 The failure of key due to shearing

3
τ = 2T/L×w×d T = π/16 × d × τ 1 Where τ = shear strength of the key material

τ 1 = shear strength of the shaft material

Therefore

L = πd 2/8w = π202/8×5 = 31.5mm

 The failure of key due to crushing

σ c = 4T/L*t*d …………… T = π/16 × d 3 × τ 1

L = πd 2 τ 1/4 σ c t = π202 ×40/4×90×5 = 28mm

Taking the larger of the two values, we have

L = 31.5mm, say 32mm

 Checking the shear strength of the key against the normal strength of the shaft Strength of the shaft
with key way

T 1 = π/16 × d 3 × τ × e

Where e = shaft strength factor e= 1 – 0.2(5/20) – 1.1(5/2×20) = 0.8125

Therefore T 1 = π/16 ×20 3 × 45 ×0.8125 = 57.43kN

Shear strength of the key

T 2= L×w×τ×d/2 T 2= 32×5×45×20/2 = 72kN

Therefore, Shear strength of the key/Normal strength of the key = 72/57.43 = 1.25

 Therefore, the key is quite safe.

61
 4.6.7 Design and selection of bearing
Bear type for camshaft at both end of shaft or on frame are used to support the rotating shaft by
preventing wear. The bearing type is selected a ball bearing of radial ball bearing. Since the load is not
extremely high ball bearing could not select.

The ball bearing has the following merits;

 Accuracy of shaft alignment

 Reliability of service
 Low cost of maintain ace as no lubrication is required while it is in service
 Small overall dimension
 Ability with stand momentary shock loads
 Clean lines
 Easy to mount and erect

Now let see the analysis;

The basic load rating (Co) in Newton for ball bearings, may be obtained as follow

Co = ( f 0 × i × z × d× cosα )

Where i = 1 number of rows of ball take

α =nominal angle of contact between the line of action ball and a plane perpendicular to the axis of
bearing, =15 Z=number of balls per row

f 0 =factor depends upon the type of bearing (12.3 for radial and angular contact groove bearing)

Bearing is a machine element that manufactures to take radial loads, thrust loads or a combination of
both. The bearing life is depending upon the number of revolution or house of life a given bearing at a
rated load

Rating life; life at which 90 of a group of bearing pass or exceed level of performance-termed L10 or
B10 life. Medium bearing life is typically 4 to 5 times the L10 life. The graph is shown below

Bearing life at various loadings can be approximately the relationship is

62
 L1
=¿ )2
L2

Where L1 -bearing life at load level, 1000,000 revolution or hours of operation at constant speed.
Fi=radial load σ = 3 for ball bearing σ =3.33 for roller bearing

The bearing life can be calculated

N i=60 LI ni where LI - bearing life in hours N i - operating speed of bearing (rev/min)

N i- bearing life in revolution

For our design purpose ball bearing is selected.

Table 4.5 Life of bearing for various types of machine

s.no Application of bearing Life of bearing in hour

1 Machines used for short periods or intermittently and whose breakdown 1000 – 2000
would not have serious consequences e.g. hand tools, lifting tackle in
4000 – 8000
workshops, and operated ma

2 Machine work 8 h r per day 12000-20000

3 Air craft engine 1000-20000

4 Machines working 24 hours per day e.g. separators, compressors, pumps, 40000-60000
mine hoists, naval vessels.

For ball bearing L=60 ×N× LH

L=60×750×5000 =255×10 6rev

The material used for ball bearing are high carbon steel, chromium steel and the ball manufactured by
hot forging on hammers from steel rods.

Principal dimensions for radial ball bearing

Table 4.6 standard dimension of ball bearing

63
From the above standard table for diameter of shaft 20mm

Bearing Number 304

Diameter of ball is 14mm Outside diameter is 52mm

Width is 14mm, serial number of 304(bearing number).

Given N =750 rpm, LH = 24 000 hours W = 1kN

We know that life of the bearing corresponding to 99% reliability

L99 = 60 N× LH L99 = 60 × 750× 5000 = 225×10 6 rev

Let L90 = Life of the bearing corresponding to 90% reliability. Considering life adjustment
factors for operating condition and material as 0.9 and 0.85 respectively, we have
1
1 b 1
1 1.17
log e log e
L99 R 99 L99 0.99
=[ ] ×0.9×0.85 =0.9×0.85 [ ]
L90 1 L90 1
log e log e
R 90 0.9

L99 L99 270× 10

6
=0.1026 L90 = L90 = L90=2631.5×10 6rev
L90 0.1026 0.1026

We know that dynamic load rating

1 6 1
L90 k 2631.5 ×10 3
C =W [ 6
] C =1 [ 6
] (k = 3, for ball bearing)
10 10

C = 13KN

64
After finding the design basic dynamic radial load capacity, the selection of bearing is made from the
catalogue of a manufacturer. The following table shows the basic static and dynamic capacities for
various types of ball bearings.

Table 4.7standardvalue of force of ball bearing

From standard

Bearing number 304 series and single row angular contact ball bearing

Static load C 0 =8.3kN Dynamic load C =13.7kN

LUBRICATIO PURPOES OF BALL BEARING

 Reduce friction and wear

 Prevent resting
 To dissipate heat
 To protect the bearing surface from water and dirt

4.6.8 Selection of belt bucket elevator

Bucket elevator is a type of vertical or inclined transport equipment that efficiently moves goods
between floors, vessel or other structure. Elevator is generally powered by electrical motors that either
drive traction cables or counterweight system like a hoist or pump hydraulic fluid to raise a cylindrical
65
piston like jack. Generally, it is preferred for short in distance compared to belt conveyor. It is more
preferable to transport the materials vertically or inclined.

Material name Aluminum

Bulk density–mass/volume –– kg/m3 2442kg/m3

Select a bucket 328 mm wide x 82 mm projection with a volume of 1.3 liter.

Selection of bucket types

In the case of sticky loads more suitable are open buckets of the flat-bottom configuration.

Loading chutes are best suitable for coarsely broken and abrasive loads.
Bucket width b is adopts taking into account the lump size, from the relationship. b ≥ ka
Where a is the maximum lump size and k is a factor taken at 2-2.5 for un sized material and at 4-5 for
a sized one Lump size a=82 and k=4 for sized material
b ≥ 4×82 and b≥328mm
Select a bucket 328 mm wide x 82 mm projection with a volume of 0.0013m3.
Bucket height is finding by volume of bucket
1 1
V= a×b×h, 0.0013m3= 82×328×h h=96.66mm
2 2
Height of the conveyor is 1.1m with 45 ̊ degree
The weight of a bucketful load in kg is given G=i× γ × φ
The weight of a bucketful load in kg is given G=i× γ × φ
where i=the struck volume of bucket [m3]
kg
γ =¿ spesific weight [ 3]
m
φ =capacity factor ranging between 0.6 and 0.9 depending upon the nature of the material (lower
values are ascribed to coarsely broken loads)
G=0.0013m3 × 0.7 ×2442kg/m3 G=2.22kg
Using 2/3 of the volume give a capacity of 0.86 liter.
66
0.86 lt. is 0.00086 m3 and holds 0.85 kg of product. (0.00086 m3 x 2442 kg/m3).
πdN π∗191.1∗75
And also, we have belt speed of large pulley v= = =0.75 m/s
60 60
And the speed of the upper shaft of the bucket conveyor and the speed of large pulley or head pulley
are equal. that means vp=vb=0.75 m/s this speed is also the speed of the conveyor or bucket.
As we know the total length of the bucket conveyor belt is 2041mm.we can make the chute in four
places of the conveyor at equal spacing. that means we put each chute at distance of
ltotal 2041
= =510.3 mm
4 4
Then to find the contact time of the chute and the cleaner head can be calculated by using relative
velocity between the chute and the head of rack or cleaner brush.
This is calculated as v b/ v =vr −vb where vr =velocity of the rack and
r

vb=volecity of the chute bucket

We have vb=0.75 m/ s and vr=1.7 m/ s then v b/ v =1.7−0.75=0.95 m/ s
r

Then to find the contact time or the time at which the brush and the chute is contact is calculated using
sr −sb
the formula v b =vr−vb= t
v r

where t=contact time

sr=distance moving by the rack head∨brush ¿ minimum limit ¿ maximumlimit
¿,
sb=distance beteween the chute∨spacing .
then sr =851 mm∧sb=510.25
sr−sb 851−510.25 340.75 0.341
v b =vr−vb=0.95= = = =
vr
t t t t

0.95 t=0.341
0.341
t= =0.4 m/ s This is the point of contact
0.95
4.6.9 Design and selection of tanker
The tanker is designed to be fed in a vertical position only the hopper should able to carried enough
amount of scrap of bottle up to fulfill then it should be come out the scrap of bottle ready to thresher.
The material used for the tanker construction is stainless steel sheet metal in order to carries the scrap
of bottle which has the following properties.

 Higher strength
 Wear resistance

67
Sut =420 Mpa , S y = 240 Mpa

Density of the scrap bottle is 2441 Kg/m3

The volume of the tanker (V t ) is can be calculated in order to collect the scrap of bottle
2
V t= π × D × H where: D = diameter of the tanker
4
H = height of the tanker = 350mm =35cm
We considers these dimensions we taken in order to carries the mass or the weight of the scarp bottle
2 2
V t = π × D × H V t = π × 32 ×30 =0.0241m3
4 4

Mass of scarp bottle = density of scrap of bottle × volume of tanker

m= 2441×0.0241 =58.89kg

Therefore, the tanker must store maximum 50 kg

4.6.10 Design of Main Frame

The design of main frame loaded the shaft at center of the length and highly subjected to both bending
and shears forces at a maximum height. Since the frame is to carries pulley and bearing rack and
pinion gears motor chain and re sprocket shaft and other components. dial ball bearing

The weight of mass of the rack and pinion

 The weight of pulley and bearing

 The weight of motor
 The weight of shaft
 The weight of bucket
 The weight of other components

Material Selection

For this application and due to the nature of the load applied on the beam the material we select
stainless steel from table 3.3 due to the following properties.

Stainless steel is the corrosion resistant steel that contains at least 10.5 chromium.

It has high strength

Sut = 870 Mpa and Syt = 650 Mpa

Height of the frame =95cm

68
 Length of the frame =150cm

Wide of the frame =65 cm

The two design factors considered in determining the material required for the frame are weight and
strength Weight of tanker = 250N when it is loaded at maximum load

Weight of bucket= 100N, Weight of rack and pinion =100N,

Weight of shaft = 50N

Weight of motor = 100N, Weight of pulley and bearing = 50N,

Weight of another component = 50N

Calculating the reaction at A and B

550N C100N D 350N

A c B

RA RB

∑M A = 0 100N×274mm + 350N×430mm = R B ×850mm

R B = 209N

∑F = 0 550N+350N+100N- R B- R A = 0

550N+350N+100N-209N- R A = 0 R A = 790N

Then we can find the maximum bending moment using shear force diagram

Therefore, the maximum bending moment is M MIX =87600Nmm.

69
To calculated the thickness of the main frame taking some cross-section area.

From bending moment diagram the maximum bending occur at point D of beam (173831Nmm). And
assume the stress-concentration factor K is unit and we can take small amount of cross sectional from
the main frame.

Where, M - maximum bending moment I - moment of inertia

1 3 1
C - Centroid Cross-section of the frame I = (40+2t) × (20+2 t) - 40×20 3…refer [6]
12 12

I =1.33t 4+66.6t 3+1200t 2+9333.3t

40+2 t K× M×C S ut 870

C= =20+tσ all = but σ all = = =290 Mpa FS=3
2 I FS 3

Therefore, by substituting all giving data we get

1 × 87600 Nmm ×(20+t)

290Mpa=
1.33t 4 + 66.6 t 3 +1200 t 2 + 9333.3t

1752000Nmm = 385.7 t 4+19314.3 t 3 +348000t 2+2619057t

0=t 4+50t 3+902t 2+6790.4t-45542.3904

Using try and error method we get thickness of frame

t=2.81mm ≈ 3mm

4.6.11 Selection of Wheel

Wheel must be light in weight if it is to maintain grip when the harvesting machine is traveling over a
hump surface at high speed. Therefore, we need to use tired wheel in order to decrease friction
between the wheel and the ground and to have light weight. We have seen that the maintenance of bolt
in the wheel. There are three types of bolts used for the wheels

1. Pressed steel disc: It is a rolled steel rim welded to a center disc.

2. Wire bolt: A steel rim attached to the hoop by wire spokes to give light weight supports wheel.

3. Light alloy: It is light weight comparatively high cost of wheel.

The selected material for the wheel is cast iron in order to perform at high speed, it can also carry high
load and the friction is less, it can resist the wear generated due to increase in friction.

70
 Figure4.6: Wheel with its terminology
Let us assume the outer diameter as 350mm which is good enough for the machine to
move freely on the ground.
Then the inner diameter become
Do=di+2t =350mm, t=20mm 350= di + 2*20
di=350mm- 40mm = 310 mm

No Part name Quantity Material Density Mass in Cost Total

71
 in kg/m3 kg per kg cost
In birr In birr
1 Pinion gear 1 Cast iron 7250 1.6992 35.6 60.49
Larger gear 1 6.7968 241.966
Rack gear 1 6.7968 241.966

2 Input Shaft 1 Mild 7850 0.9864 24.5 254.7575

Over-hanging 1 Steel 2.235 367.05
Output shaft 2 7.4909 4.1668

3 Key 4 Mild steel 7850 0.3768 24.5 37

4 Bearing 8 Mild Steel 7850 2400.0

5 Bolt 10 Mild Steel 7850 586.54

6 Nut 10 Mild Steel 7850 283.5

7 Pin 4 Mild Steel 7850 345.75

8 Dc motor 1 1500

9 Pulley Teflon 570

10 Bucket Aluminum 450

11 TOTAL 7338.9
COST

72
4.7 cost assumption
CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1Conclusion
Actually, this internship program is provided to introduce and to give knowledge on how the
professional life looks like, and to make a bridge that links the student life with the professional life, in
addition to observe and fill the gap between the theoretical and practical knowledge. I got practical
work experiences and benefits at raya brewery S.C

Multi -use floor cleaning machine is designed and manufactured using A.C. induction Motor.
Manually operated floor cleaning machine is an alternative for an automated floor cleaning machine
during power crisis. The equipment will result more beneficial when it is compared to other existing
floor cleaning machines. Manufactured machine is flexible and effortlessly operated. Effective power
given to the bracket does number of cleaning tasks. The need of this project is satisfied and with the
help of machine, cleaning of the floor can be done easily. Our project is based on very simple rack and
pinion mechanisms which can be easily operated by any person. Any fault in machine can be easily
identified and can be corrected on the spot.

5.2Recommendation
We have recommended that the companies to manufacture our design and we have also recommended
companies economically profitable from this lighting service manufactured.

We have also recommended the future re designers to design this project within a minimum initial
cost.

When the rack and pinion cleaning machine is in the operation the machine make it is sure that in
normal position if not in normal position damage will be cause.

Keep the machine in dry place to keep the machine from rest.

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Reference
[1] International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 5, May 2017
[2] INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND
TECHNOLOGY [IJIERT] ISSN: 2394-3696VOLUME 4, ISSUE 3, Mar.-2017
[3] Technical-Section-Timing
[4] Rack and Pinion Drive – Calculation and Selection
[5] R.S KHURMI and J.K GUPTA (2005), Theory of machines C had(s) & COLTD, New Delhi,
India
[6]The company technicians and internets

74
Appendix
Table 4.8Standard proportions timing belt drive selection procedure

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Table 4.5 Standard proportions timing belt drive selection production

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Part drawing

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