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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
1.0
A mechanical wall and ceiling painting device is a desired space below a ceiling meeting the wall. A paint applying device is removable mounted on the guide for movement along the length of the guide and includes a roller in abutment with the wall. A railing and cord arrangement is mounted on the guide and coupled to the paint applying device for moving the paint applying device along the length of the guide, as desired. The moving mechanisms are real transmission, bicycle mechanism, idler gear and bevel gear. This mechanical wall and ceiling painting device is design considering: •
The device should be suitable for local manufacturing capabilities.
•
The attachment should employ low-cost materials and manufacturing methods.
•
It should be simple to manufacture, operate, maintain and repair.
•
It should be as multi-purpose as possible, providing perfect painting effect during painting process.
•
Standard tools used in machine shop such as drill press; small lathe and milling machine should be adequate to fabricate the parts needed for the dual-purpose bicycle.
•
It should be safe for the user because the mechanism is not using combustion.
•
It is also should be user friendly design and easy to assemble by the user.
PAINTING DEVICE
1
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
2.0 BIL 1 2 3 4 5 6 7 8
CONTENT Abstract Table of content Introduction Literature review Main body Conclusion Reference Appendix
PAGES 1 2 3 4 5 11 12 13
3.0 The goal of every painter is to paint neatly and quickly. This can be challenging because painter have to stand at uncomfortable position for along time during painting. As a result they cannot achieve their goal to paint neatly and quickly. The new design from our group had overcome all the constraint. The design process start with identify problem for current painting device. Then we gather the information by brainstorming and searching in the internet. Finally we are generating the concept for this mechanical wall and ceiling painting device. PAINTING DEVICE
2
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
The system of this mechanical wall and ceiling painting device is as power is supplied to the shaft by means of a chain from the bike's chain wheel (crank) to a ratcheted sprocket on the shaft. The painter start cycle the bicycle paddle, the rotation will transmit the human power through bevel gear. As the painter engages the forward gear, the bevel gear will be attached to a support that is connected to the directional control system in order to rotate the shaft forward. The roller starts to paint the wall upward. The rotating shaft has the sprocket connected to chains that control the roller movement. In order to roller move downward, the painter needs to engage backward gear that attached to idler gear. By reversing the direction of the rotating shaft, the roller will move downwards. After completed painting vertical direction the painter will move forward, the system also will move forward. The direction and the power for the apparatus is provided by a unique combined of bevel gear and idler gear unit whose transmit the human power to rotating shaft that control the painting roller. The bike will be kept in a side by side position by a railing support. After generating the concept, we evaluate the design by making a specification and design requirement. The specification and design requirement consist of cost, environment, safety, materials selection, manufacturing and work schedule in order to produce the product on time.
4.0
The main objective of this design project is to transmit human power to mechanical system. The concept we adapt to transmit human power to mechanical system is using bicycle mechanism and the medium to transmit power is using bevel gear, idler gear and real transmission gear. The mechanism enables the painter to efficiently apply both arm and leg power for motive force. Specifically the moving mechanism has oscillation shaft and a linkage connectable to the human power through bevel gear. We had seen designs PAINTING DEVICE
3
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
for devices that take power from the bicycle mechanism by means of a friction roller pressed against it and we had doubts about the efficiency of this arrangement. In order to improve efficiency we used roller chains, sprockets and railing. During completing the design, we are using Pugh method in order to choose the best concept. First concept is mechanical wall and ceiling painting device, moving horizontally with rollers, railings, basic rear transmissions using idler gear and bevel gear as main components. Second concept is mechanical painting device moving vertically using transmission gear using bevel gear as its mechanism and third concept is mechanical painting device moving vertically and horizontally using transmission gear using chain as its mechanism. After considering all criteria in Pugh method, first concept is the best. Analysis also has been done for failure and strength of the gear and other component in order to avoid failure during conducting it. The analysis calculation is using principle stress formula and ductile failure formula. As a result the dimension and the material selection has been decided according to calculation guide.
5.0 5.0.1 PHASES OF DESIGN PERFORMED (PHASE I) 5.1 Identify problem: Problem statement - Time consuming in painting process - Ineffective - Messy - Require man power PAINTING DEVICE
4
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
5.2 Gather information: - Internet - Magazine -
Present painting device
-
Discussion and brainstorming
-
Lecturer guidance
5.3 Generating concept: . Concept Ideas a) Concept 1 Mechanical wall and ceiling painting device, moving horizontally with rollers, railings, basic rear transmissions using idler gear and bevel gear as main components. b) Concept 2 Mechanical painting device moving vertically using transmission gear using bevel gear as its mechanism.
c) Concept 3 Mechanical painting device moving vertically and horizontally using transmission gear using chain as its mechanism. 5.4 Concept evaluation: 1- Pay more attention on roller, railing, and a real transmission mechanism. 2- Roller design 2.1- Roller with brush 2.2- Back-up brush to paint edged or cornered area. PAINTING DEVICE
5
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
3- Real transmission mechanism. 4- Railing system to support the chain and roller and at the same time allow their movement.
PUGH METHOD Criteria Easier mechanism to be design
Concept 1 +
Concept 2 _
Concept 3 _
Easier to manufacture
+
-
+
Cost to manufacture
+
-
+
Present device
(complexity)
PAINTING DEVICE
6
PROJECT REPORT KJM 553
Smooth movement of the painting
EM 220 (EMC6M1)
+
+
+
Uniform movement of the roller
+
+
+
Uniform painting area during
+
+
+
Weight of the system
-
+
_
Time taken for painting process
+
+
+
Human power consumption
+
+
+
User friendly
+
+
+
∑+ ∑∑S
9 1 0
7 3 0
8 2 0
process
painting
Justification 1. In Pugh method, Concept 1 has maximum summation of positive criterion compare to concept 2 and concept 3. 2. Concept 2 is the most accurate mechanism for painting process than others but it require high cost of manufacturing 3. Concept 3 overcome the problem statement which are time consuming in painting process, ineffective, messy and require man power. 4. Concept 1 is the simplest concept using chain, transmission gear and railing.
PAINTING DEVICE
7
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
5. The complexity for Concept 2 is the most complicated design followed by concept 1 and concept 3.
5.0.2 PHASE II Finally, selection of the best design model is Concept 1 which is: The Mechanical wall and ceiling painting device with rollers, railings and basic real transmissions using idler gear and bevel gear as main components. 5.1 Product architecture SPECIFICATION AND DESIGN REQUIREMENT a. b. c. d. e. f.
Cost Environment Safety Materials selection Manufacturing Work schedule.
No Specification & design requirement 1 Cost
PAINTING DEVICE
Item Painter roller Chain Railing Bevel gear Normal gear Bearing house Bearing Sprocket Shaft Hollow pipe Screw
Quantity 1 unit 1 feet 1 feet 1 unit 1 unit 1 unit 1 unit 1 unit 1 feet 1 feet 100 gram
Cost (RM) 7.00 28.00 8.00 400.00 21.00 52.00 19.00 8.00 17.00 12.00 6.00 8
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Nut Bolt Adjustable rod Hand pump No Specification & design requirement 2 Environment
100 gram 100 gram 1 feet 1 unit • • • •
3
Safety
• • •
4
5
materials selection
Manufacturing
• • • • • • • • • • • • • • •
6.50 6.50 1.50 5.00
Use 100% human power to move the mechanism. Involve no combustion process and therefore produce no hazardous substances Clean and environment friendly Generate less noise and vibration Moving mechanism enclosed in safety housing Gear mechanism is equip with engage system to prevent unwanted movement (roller drop accidentally) Improve occupational safety of personnel due to ergonomic design. Gear, bearing, sprocket, pinion shaft, bevel gear, idler gear- Cast iron Roller connection- Aluminum Shaft –Steel Chain-steel Railing-aluminium Bolt & nut –steel Housing – mild steel Stand rod- steel Bicycle mechanism- steel Welding Bending Sheet metal cutting Punching Turning Milling
5.2 Configuration Design Analysis done & calculation - Gear ratio - Stress analysis
PAINTING DEVICE
9
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
CALCULATION OF GEAR RATIO
WALL
H = 2.5 m t = 15 s
Upper sprocket Lower sprocket
First bevel gear
Second bevel gear = Ordinary gear 1
Ordinary gear 2
Net distance PAINTING DEVICE
10
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Idler gear
Ordinary gear 3
=0 Ordinary gear 4
TORQUE CALCULATION 24.5 N
24.5 N r
R = 0.035 m
R = 0.035 m ;
Overall torque requires both sides. PAINTING DEVICE
11
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Toverall = 0.858(2) = 1.718Nm Power require to rise and down the roller.
SCHEMATIC OF POWER TRANSMISSION
Force applied by the operator
Upper sprocket 20cm
pedal
W = π rad/sec PAINTING DEVICE
12
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Lower sprocket
Human force to raise the roller *Since the friction forces are negligible, the power transmission between input and output are similar. Therefore: Power = 8.179W
=
Stress Analysis In our project, we have decided to apply the stress analysis at the most critical part of the system. It is at the joint shaft connecting gear system and railing part. There are 2 joining parts, but with the same total force, torque and moment, hence we only explained one of them. Free Body Diagram
PAINTING DEVICE
13
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Both point A and B are welded areas on hollow shaft. The material used for the shaft is mild steel with Yield Strength, σy = 250 Mpa and Young Modulus, E = 210 Gpa.
F = 40 N
A
M = 0.5 Nm
B 0.25 m
T = 0.5 Nm 0.10 m
z y x
Force F is obtained from total weight of upper system acting on the shaft, consists of roller, paint tray, chain, etc. Moment and Torque are produced by the vibration of gear movement and cycling action on the shaft.
For welded area, maximum Yield Strength allowed, σall = 0.60 σy Hence, σall
=
0.60 (250)
σall
=
150 Mpa
(Ans)
Shaft Dimension External diameter,
do
=
0.030 m
Internal diameter,
di
=
0.024 m
PAINTING DEVICE
14
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
* wall thickness of 3 mm I
=
do 4 - di 4
64 =
(0.030)4 - (0.024)4
64 I
=
2.347 x 10-8 m4
J
=
(Ans)
do 4 - di 4
32 =
(0.030)4 - (0.024)4
32 J
=
4.695 x 10-8 m4
(Ans)
Consider Element A σy xy σx
σx xy σy
PAINTING DEVICE
15
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Stresses Calculation σx
=
Mx . c
where c = r = 0.015 m
I =
40 (0.25) (0.015) 2.347 x 10-8
σx
=
6.39 Mpa σy
(Ans)
=
My . c I
=
0.5 (0.015) 2.347 x 10-8
σy xy
=
=
0.32 Mpa
(Ans)
T.r J
=
40 (0.1) + 0.5
(0.015)
4.695 x 10-8 xy
=
1.44 Mpa
(Ans)
Consider Element B σy xy σx
σx xy σy
PAINTING DEVICE
16
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Stresses Calculation σx
=
Mx . c
where c = r = 0.015 m
I =
(0.5) (0.015) 2.347 x 10-8
σx
=
0.32 Mpa σy
(Ans)
=
My . c I
=
40 (0.10) (0.015) 2.347 x 10-8
σy xy
=
=
2.56 Mpa
(Ans)
T.r J
=
(0.5) (0.015) 4.695 x 10-8
xy
=
0.16 Mpa
(Ans)
Principle Stresses of Element A σ1,2
=
σx + σy
±
2 =
+ xy2
½
6.39 – 0.32
2
σx - σy
2
2
6.39 + 0.32
±
2 σmax
=
3.355 ±
=
6.714 Mpa
PAINTING DEVICE
+ (1.44)2
½
2 3.359 σmin
=
- 0.004 Mpa
(Ans)
17
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Principle Stresses of Element B σ1,2
=
σx + σy
±
2 =
+ xy2
½
0.32 – 2.56
2
σx - σy
2
2
0.32 + 2.56
±
2 σmax
+ (0.16)2
½
2
=
1.13
±
=
2.57 Mpa
1.44 σmin
=
- 0.31 Mpa
(Ans)
Safety Factor will be calculated based on 3 Theorems for Ductile Material; a)
Maximum Normal Stress Theorem (MNST)
b)
Maximum Shear Stress Theorem (MSST)
c)
Distortion Energy Theorem (DET)
Safety Factor of Element A =
√ σ12 + σ22
=
√ (6.714)2 + (-0.004)2
σA
=
6.714 Mpa
i)
Maximum Normal Stress Theorem (MNST)
σA
P
=
√ P x 2 + Py 2 P
SF
=
PAINTING DEVICE
P
=
√ (150)2 + (-29)2
=
152.78 Mpa
=
152.78 18
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
σA
6.714 SF
ii)
=
Maximum Shear Stress Theorem (MSST) Q
=
√ Q x 2 + Qy 2 Q
SF
=
Q
=
√ (125)2 + (-25)2
=
127.48 Mpa
=
127.48
σA
6.714 SF
iii)
22.8
=
19.0
=
√ (138)2 + (-27)2
=
140.62 Mpa
=
140.62
Distortion Energy Theorem (DET) R
=
√ Rx 2 + R y 2 R
SF
=
R σA
6.714 SF
=
20.9
Safety Factor of Element B =
√ σ12 + σ22
=
√ (2.57)2 + (-0.31)2
σB
=
2.589 Mpa
i)
Maximum Normal Stress Theorem (MNST)
σB
P
=
√ P x 2 + Py 2 P
SF
=
PAINTING DEVICE
P
=
√ (150)2 + (-29)2
=
152.78 Mpa
=
152.78 19
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
σB
2.589 SF
ii)
=
Maximum Shear Stress Theorem (MSST) Q
=
√ Q x 2 + Qy 2 Q
SF
=
Q
=
√ (127)2 + (-24)2
=
129.25 Mpa
=
129.25
σB
2.589 SF
iii)
=
49.9
=
√ (137)2 + (-27)2
=
139.64 Mpa
=
139.64
Distortion Energy Theorem (DET) R
=
√ Rx 2 + R y 2 R
SF
=
R σB
2.589 SF
5.0.3
59.0
=
53.9
PHASE 3
BLUE PRINT-Assembly drawing -Production drawing
PAINTING DEVICE
20
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
6.0 As a conclusion, we manage to complete the design project successfully with Mr Afzan guide and all group members. This project is very challenging because we had just learned CATIA software. We spent lot of time to draw the model. Even though it is difficult, we manage to finish it. This KJM 533 subject is very relevant subject to train us expose to designing field. The chapters introduce in this subject guide us to proceed with the design project. The mechanical wall and ceiling painting device is design to improve current painting device. The concept we adapt to transmit human power to mechanical system is using bicycle mechanism and the medium to transmit power is using bevel gear, idler gear and PAINTING DEVICE
21
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
real transmission gear. The mechanism enables the painter to efficiently apply both arm and leg power for motive force. Specifically the moving mechanism has oscillation shaft and a linkage connectable to the human power through bevel gear. This mechanical wall and ceiling painting device we have been design consist of many parts. This is because the moving mechanism is the major parts. In order to reduce the parts and minimize the human power, we need to combine with motor as the moving mechanism.
7.0 http://www.technologyforthepoor.com/PedalPowerReport/PedalPowerReport.htm http://www.ncl.ac.uk/gears/services/transmission/index.htm http://auto.howstuffworks.com/transmission1.htm http://adventure.howstuffworks.com/bicycle4.htm http://www.calculatoredge.com/ file:///E:/Pedel%20Power%20Report.htm http://en.wikipedia.org/wiki/Gear#Bevel_gears
PAINTING DEVICE
22
PROJECT REPORT KJM 553
PAINTING DEVICE
EM 220 (EMC6M1)
23
PROJECT REPORT KJM 553
8.0
EM 220 (EMC6M1)
APPENDIX (MINUTE MEETING AND RELEVANT DOCUMENTS OR INFORMATION)
MINUTE OF MEETING DATE: 11th Sept 2008 ATTENDANCE: ALL MEMBERS No 1
ISSUES Discuss the design concept – all
ACTION
DUE DATE
Concept Ideas
PICTURE
7/11/08
members give an idea before the best concept was selected.
a) Concept 1 Mechanical wall and ceiling painting device
moving
horizontally
-as attached in Appendix I
with
rollers, railings, transmission gear and bavel gear as main components. -idea: Noor Idayu ,Ummi Zulaikha & Faizal Mohd -as attached in Appendix II
PAINTING DEVICE
24
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
b) Concept 2 Mechanical painting device moving vertically with transmission gear using bevel gear as its mechanism. -idea: Mohd Faizal & Mohd Hazwan
No
ISSUES
ACTION
DUE DATE
PICTURE
c) Concept 3 Mechanical painting device moving vertically
and
horizontally
-as attached in Appendix III
using
transmission gear using chain as its mechanism. -idea: Shadila
PAINTING DEVICE
25
PROJECT REPORT KJM 553
No
EM 220 (EMC6M1)
ISSUES
ACTION
DUE DATE
Concept 2 1- Pay more attention on roller, railing using transmission gear using bevel gear as its mechanism 2- Roller design 2.1- Roller with brush 2.2- Back-up brush 3- Chain mechanism. 4- Railing system to support the chain and roller and at the same time allow their movement.
DATE: 18th SEPT 2008 ATTENDANCE: ALL MEMBERS
PAINTING DEVICE
26
PICTURE
PROJECT REPORT KJM 553
No 1
ISSUES The mechanism designing.
EM 220 (EMC6M1)
ACTION 1- Upper and lower support design idea.
DUE DATE 7/11/08
-idea: Syadilla 2- The adjustable rod is suggested to be used. - idea: Ummi Zulaikha 3- Use transmission gear as moving mechanism. -idea: Noor Idayu 4- Bevel gear as moving mechanism -idea: Mohd Faizal 5- Bicycle mechanism to transmit human power to moving mechanism -idea: Mohd Hazwan th
DATE: 20 SEPT 2008 ATTENDANCE: ALL MEMBERS
PAINTING DEVICE
27
PICTURE
PROJECT REPORT KJM 553
No 1
EM 220 (EMC6M1)
ISSUES New concept
ACTION
DUE DATE
1- Concept of using gear mechanism
PICTURE
7/11/08
2- All members generate ideas to this new concept design. 3- All discussion more towards the disadvantages
rather
than
the
advantages of this concept, such as: - The designing of this concept faced difficulty for roller to move upward and downward continuously - Difficulty in solving moving transmission gear.
DATE: 25th SEPT 2008 ATTENDANCE: ALL MEMBERS No
ISSUES
PAINTING DEVICE
ACTION
DUE DATE
28
PICTURE
PROJECT REPORT KJM 553
1
Discuss the best concept
EM 220 (EMC6M1)
1- All members stick with the one 7/11/08 concept to be the best product and mechanism. 2- Mechanism involved: - Transmission gear - Chain - bearing - sprocket - shaft 3- The cost and other factors had been considered.
PREPARED BY: ……………………… (NOOR IDAYU) DATE: 25th SEPT 2008
PAINTING DEVICE
CHECKED BY:
APPROVED BY:
………………………..... (UMMI ZULAIKHA)
………………………. (MR. MOHD AFZAN)
DATE: 25th SEPT 2008
DATE:7/11/2008
29
PROJECT REPORT KJM 553
PAINTING DEVICE
EM 220 (EMC6M1)
30
EM 220 (EMC6M1)
1.0
A mechanical wall and ceiling painting device is a desired space below a ceiling meeting the wall. A paint applying device is removable mounted on the guide for movement along the length of the guide and includes a roller in abutment with the wall. A railing and cord arrangement is mounted on the guide and coupled to the paint applying device for moving the paint applying device along the length of the guide, as desired. The moving mechanisms are real transmission, bicycle mechanism, idler gear and bevel gear. This mechanical wall and ceiling painting device is design considering: •
The device should be suitable for local manufacturing capabilities.
•
The attachment should employ low-cost materials and manufacturing methods.
•
It should be simple to manufacture, operate, maintain and repair.
•
It should be as multi-purpose as possible, providing perfect painting effect during painting process.
•
Standard tools used in machine shop such as drill press; small lathe and milling machine should be adequate to fabricate the parts needed for the dual-purpose bicycle.
•
It should be safe for the user because the mechanism is not using combustion.
•
It is also should be user friendly design and easy to assemble by the user.
PAINTING DEVICE
1
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
2.0 BIL 1 2 3 4 5 6 7 8
CONTENT Abstract Table of content Introduction Literature review Main body Conclusion Reference Appendix
PAGES 1 2 3 4 5 11 12 13
3.0 The goal of every painter is to paint neatly and quickly. This can be challenging because painter have to stand at uncomfortable position for along time during painting. As a result they cannot achieve their goal to paint neatly and quickly. The new design from our group had overcome all the constraint. The design process start with identify problem for current painting device. Then we gather the information by brainstorming and searching in the internet. Finally we are generating the concept for this mechanical wall and ceiling painting device. PAINTING DEVICE
2
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
The system of this mechanical wall and ceiling painting device is as power is supplied to the shaft by means of a chain from the bike's chain wheel (crank) to a ratcheted sprocket on the shaft. The painter start cycle the bicycle paddle, the rotation will transmit the human power through bevel gear. As the painter engages the forward gear, the bevel gear will be attached to a support that is connected to the directional control system in order to rotate the shaft forward. The roller starts to paint the wall upward. The rotating shaft has the sprocket connected to chains that control the roller movement. In order to roller move downward, the painter needs to engage backward gear that attached to idler gear. By reversing the direction of the rotating shaft, the roller will move downwards. After completed painting vertical direction the painter will move forward, the system also will move forward. The direction and the power for the apparatus is provided by a unique combined of bevel gear and idler gear unit whose transmit the human power to rotating shaft that control the painting roller. The bike will be kept in a side by side position by a railing support. After generating the concept, we evaluate the design by making a specification and design requirement. The specification and design requirement consist of cost, environment, safety, materials selection, manufacturing and work schedule in order to produce the product on time.
4.0
The main objective of this design project is to transmit human power to mechanical system. The concept we adapt to transmit human power to mechanical system is using bicycle mechanism and the medium to transmit power is using bevel gear, idler gear and real transmission gear. The mechanism enables the painter to efficiently apply both arm and leg power for motive force. Specifically the moving mechanism has oscillation shaft and a linkage connectable to the human power through bevel gear. We had seen designs PAINTING DEVICE
3
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
for devices that take power from the bicycle mechanism by means of a friction roller pressed against it and we had doubts about the efficiency of this arrangement. In order to improve efficiency we used roller chains, sprockets and railing. During completing the design, we are using Pugh method in order to choose the best concept. First concept is mechanical wall and ceiling painting device, moving horizontally with rollers, railings, basic rear transmissions using idler gear and bevel gear as main components. Second concept is mechanical painting device moving vertically using transmission gear using bevel gear as its mechanism and third concept is mechanical painting device moving vertically and horizontally using transmission gear using chain as its mechanism. After considering all criteria in Pugh method, first concept is the best. Analysis also has been done for failure and strength of the gear and other component in order to avoid failure during conducting it. The analysis calculation is using principle stress formula and ductile failure formula. As a result the dimension and the material selection has been decided according to calculation guide.
5.0 5.0.1 PHASES OF DESIGN PERFORMED (PHASE I) 5.1 Identify problem: Problem statement - Time consuming in painting process - Ineffective - Messy - Require man power PAINTING DEVICE
4
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
5.2 Gather information: - Internet - Magazine -
Present painting device
-
Discussion and brainstorming
-
Lecturer guidance
5.3 Generating concept: . Concept Ideas a) Concept 1 Mechanical wall and ceiling painting device, moving horizontally with rollers, railings, basic rear transmissions using idler gear and bevel gear as main components. b) Concept 2 Mechanical painting device moving vertically using transmission gear using bevel gear as its mechanism.
c) Concept 3 Mechanical painting device moving vertically and horizontally using transmission gear using chain as its mechanism. 5.4 Concept evaluation: 1- Pay more attention on roller, railing, and a real transmission mechanism. 2- Roller design 2.1- Roller with brush 2.2- Back-up brush to paint edged or cornered area. PAINTING DEVICE
5
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
3- Real transmission mechanism. 4- Railing system to support the chain and roller and at the same time allow their movement.
PUGH METHOD Criteria Easier mechanism to be design
Concept 1 +
Concept 2 _
Concept 3 _
Easier to manufacture
+
-
+
Cost to manufacture
+
-
+
Present device
(complexity)
PAINTING DEVICE
6
PROJECT REPORT KJM 553
Smooth movement of the painting
EM 220 (EMC6M1)
+
+
+
Uniform movement of the roller
+
+
+
Uniform painting area during
+
+
+
Weight of the system
-
+
_
Time taken for painting process
+
+
+
Human power consumption
+
+
+
User friendly
+
+
+
∑+ ∑∑S
9 1 0
7 3 0
8 2 0
process
painting
Justification 1. In Pugh method, Concept 1 has maximum summation of positive criterion compare to concept 2 and concept 3. 2. Concept 2 is the most accurate mechanism for painting process than others but it require high cost of manufacturing 3. Concept 3 overcome the problem statement which are time consuming in painting process, ineffective, messy and require man power. 4. Concept 1 is the simplest concept using chain, transmission gear and railing.
PAINTING DEVICE
7
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
5. The complexity for Concept 2 is the most complicated design followed by concept 1 and concept 3.
5.0.2 PHASE II Finally, selection of the best design model is Concept 1 which is: The Mechanical wall and ceiling painting device with rollers, railings and basic real transmissions using idler gear and bevel gear as main components. 5.1 Product architecture SPECIFICATION AND DESIGN REQUIREMENT a. b. c. d. e. f.
Cost Environment Safety Materials selection Manufacturing Work schedule.
No Specification & design requirement 1 Cost
PAINTING DEVICE
Item Painter roller Chain Railing Bevel gear Normal gear Bearing house Bearing Sprocket Shaft Hollow pipe Screw
Quantity 1 unit 1 feet 1 feet 1 unit 1 unit 1 unit 1 unit 1 unit 1 feet 1 feet 100 gram
Cost (RM) 7.00 28.00 8.00 400.00 21.00 52.00 19.00 8.00 17.00 12.00 6.00 8
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Nut Bolt Adjustable rod Hand pump No Specification & design requirement 2 Environment
100 gram 100 gram 1 feet 1 unit • • • •
3
Safety
• • •
4
5
materials selection
Manufacturing
• • • • • • • • • • • • • • •
6.50 6.50 1.50 5.00
Use 100% human power to move the mechanism. Involve no combustion process and therefore produce no hazardous substances Clean and environment friendly Generate less noise and vibration Moving mechanism enclosed in safety housing Gear mechanism is equip with engage system to prevent unwanted movement (roller drop accidentally) Improve occupational safety of personnel due to ergonomic design. Gear, bearing, sprocket, pinion shaft, bevel gear, idler gear- Cast iron Roller connection- Aluminum Shaft –Steel Chain-steel Railing-aluminium Bolt & nut –steel Housing – mild steel Stand rod- steel Bicycle mechanism- steel Welding Bending Sheet metal cutting Punching Turning Milling
5.2 Configuration Design Analysis done & calculation - Gear ratio - Stress analysis
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
CALCULATION OF GEAR RATIO
WALL
H = 2.5 m t = 15 s
Upper sprocket Lower sprocket
First bevel gear
Second bevel gear = Ordinary gear 1
Ordinary gear 2
Net distance PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Idler gear
Ordinary gear 3
=0 Ordinary gear 4
TORQUE CALCULATION 24.5 N
24.5 N r
R = 0.035 m
R = 0.035 m ;
Overall torque requires both sides. PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Toverall = 0.858(2) = 1.718Nm Power require to rise and down the roller.
SCHEMATIC OF POWER TRANSMISSION
Force applied by the operator
Upper sprocket 20cm
pedal
W = π rad/sec PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Lower sprocket
Human force to raise the roller *Since the friction forces are negligible, the power transmission between input and output are similar. Therefore: Power = 8.179W
=
Stress Analysis In our project, we have decided to apply the stress analysis at the most critical part of the system. It is at the joint shaft connecting gear system and railing part. There are 2 joining parts, but with the same total force, torque and moment, hence we only explained one of them. Free Body Diagram
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Both point A and B are welded areas on hollow shaft. The material used for the shaft is mild steel with Yield Strength, σy = 250 Mpa and Young Modulus, E = 210 Gpa.
F = 40 N
A
M = 0.5 Nm
B 0.25 m
T = 0.5 Nm 0.10 m
z y x
Force F is obtained from total weight of upper system acting on the shaft, consists of roller, paint tray, chain, etc. Moment and Torque are produced by the vibration of gear movement and cycling action on the shaft.
For welded area, maximum Yield Strength allowed, σall = 0.60 σy Hence, σall
=
0.60 (250)
σall
=
150 Mpa
(Ans)
Shaft Dimension External diameter,
do
=
0.030 m
Internal diameter,
di
=
0.024 m
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
* wall thickness of 3 mm I
=
do 4 - di 4
64 =
(0.030)4 - (0.024)4
64 I
=
2.347 x 10-8 m4
J
=
(Ans)
do 4 - di 4
32 =
(0.030)4 - (0.024)4
32 J
=
4.695 x 10-8 m4
(Ans)
Consider Element A σy xy σx
σx xy σy
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Stresses Calculation σx
=
Mx . c
where c = r = 0.015 m
I =
40 (0.25) (0.015) 2.347 x 10-8
σx
=
6.39 Mpa σy
(Ans)
=
My . c I
=
0.5 (0.015) 2.347 x 10-8
σy xy
=
=
0.32 Mpa
(Ans)
T.r J
=
40 (0.1) + 0.5
(0.015)
4.695 x 10-8 xy
=
1.44 Mpa
(Ans)
Consider Element B σy xy σx
σx xy σy
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Stresses Calculation σx
=
Mx . c
where c = r = 0.015 m
I =
(0.5) (0.015) 2.347 x 10-8
σx
=
0.32 Mpa σy
(Ans)
=
My . c I
=
40 (0.10) (0.015) 2.347 x 10-8
σy xy
=
=
2.56 Mpa
(Ans)
T.r J
=
(0.5) (0.015) 4.695 x 10-8
xy
=
0.16 Mpa
(Ans)
Principle Stresses of Element A σ1,2
=
σx + σy
±
2 =
+ xy2
½
6.39 – 0.32
2
σx - σy
2
2
6.39 + 0.32
±
2 σmax
=
3.355 ±
=
6.714 Mpa
PAINTING DEVICE
+ (1.44)2
½
2 3.359 σmin
=
- 0.004 Mpa
(Ans)
17
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
Principle Stresses of Element B σ1,2
=
σx + σy
±
2 =
+ xy2
½
0.32 – 2.56
2
σx - σy
2
2
0.32 + 2.56
±
2 σmax
+ (0.16)2
½
2
=
1.13
±
=
2.57 Mpa
1.44 σmin
=
- 0.31 Mpa
(Ans)
Safety Factor will be calculated based on 3 Theorems for Ductile Material; a)
Maximum Normal Stress Theorem (MNST)
b)
Maximum Shear Stress Theorem (MSST)
c)
Distortion Energy Theorem (DET)
Safety Factor of Element A =
√ σ12 + σ22
=
√ (6.714)2 + (-0.004)2
σA
=
6.714 Mpa
i)
Maximum Normal Stress Theorem (MNST)
σA
P
=
√ P x 2 + Py 2 P
SF
=
PAINTING DEVICE
P
=
√ (150)2 + (-29)2
=
152.78 Mpa
=
152.78 18
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
σA
6.714 SF
ii)
=
Maximum Shear Stress Theorem (MSST) Q
=
√ Q x 2 + Qy 2 Q
SF
=
Q
=
√ (125)2 + (-25)2
=
127.48 Mpa
=
127.48
σA
6.714 SF
iii)
22.8
=
19.0
=
√ (138)2 + (-27)2
=
140.62 Mpa
=
140.62
Distortion Energy Theorem (DET) R
=
√ Rx 2 + R y 2 R
SF
=
R σA
6.714 SF
=
20.9
Safety Factor of Element B =
√ σ12 + σ22
=
√ (2.57)2 + (-0.31)2
σB
=
2.589 Mpa
i)
Maximum Normal Stress Theorem (MNST)
σB
P
=
√ P x 2 + Py 2 P
SF
=
PAINTING DEVICE
P
=
√ (150)2 + (-29)2
=
152.78 Mpa
=
152.78 19
PROJECT REPORT KJM 553
EM 220 (EMC6M1)
σB
2.589 SF
ii)
=
Maximum Shear Stress Theorem (MSST) Q
=
√ Q x 2 + Qy 2 Q
SF
=
Q
=
√ (127)2 + (-24)2
=
129.25 Mpa
=
129.25
σB
2.589 SF
iii)
=
49.9
=
√ (137)2 + (-27)2
=
139.64 Mpa
=
139.64
Distortion Energy Theorem (DET) R
=
√ Rx 2 + R y 2 R
SF
=
R σB
2.589 SF
5.0.3
59.0
=
53.9
PHASE 3
BLUE PRINT-Assembly drawing -Production drawing
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
6.0 As a conclusion, we manage to complete the design project successfully with Mr Afzan guide and all group members. This project is very challenging because we had just learned CATIA software. We spent lot of time to draw the model. Even though it is difficult, we manage to finish it. This KJM 533 subject is very relevant subject to train us expose to designing field. The chapters introduce in this subject guide us to proceed with the design project. The mechanical wall and ceiling painting device is design to improve current painting device. The concept we adapt to transmit human power to mechanical system is using bicycle mechanism and the medium to transmit power is using bevel gear, idler gear and PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
real transmission gear. The mechanism enables the painter to efficiently apply both arm and leg power for motive force. Specifically the moving mechanism has oscillation shaft and a linkage connectable to the human power through bevel gear. This mechanical wall and ceiling painting device we have been design consist of many parts. This is because the moving mechanism is the major parts. In order to reduce the parts and minimize the human power, we need to combine with motor as the moving mechanism.
7.0 http://www.technologyforthepoor.com/PedalPowerReport/PedalPowerReport.htm http://www.ncl.ac.uk/gears/services/transmission/index.htm http://auto.howstuffworks.com/transmission1.htm http://adventure.howstuffworks.com/bicycle4.htm http://www.calculatoredge.com/ file:///E:/Pedel%20Power%20Report.htm http://en.wikipedia.org/wiki/Gear#Bevel_gears
PAINTING DEVICE
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PROJECT REPORT KJM 553
PAINTING DEVICE
EM 220 (EMC6M1)
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PROJECT REPORT KJM 553
8.0
EM 220 (EMC6M1)
APPENDIX (MINUTE MEETING AND RELEVANT DOCUMENTS OR INFORMATION)
MINUTE OF MEETING DATE: 11th Sept 2008 ATTENDANCE: ALL MEMBERS No 1
ISSUES Discuss the design concept – all
ACTION
DUE DATE
Concept Ideas
PICTURE
7/11/08
members give an idea before the best concept was selected.
a) Concept 1 Mechanical wall and ceiling painting device
moving
horizontally
-as attached in Appendix I
with
rollers, railings, transmission gear and bavel gear as main components. -idea: Noor Idayu ,Ummi Zulaikha & Faizal Mohd -as attached in Appendix II
PAINTING DEVICE
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PROJECT REPORT KJM 553
EM 220 (EMC6M1)
b) Concept 2 Mechanical painting device moving vertically with transmission gear using bevel gear as its mechanism. -idea: Mohd Faizal & Mohd Hazwan
No
ISSUES
ACTION
DUE DATE
PICTURE
c) Concept 3 Mechanical painting device moving vertically
and
horizontally
-as attached in Appendix III
using
transmission gear using chain as its mechanism. -idea: Shadila
PAINTING DEVICE
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PROJECT REPORT KJM 553
No
EM 220 (EMC6M1)
ISSUES
ACTION
DUE DATE
Concept 2 1- Pay more attention on roller, railing using transmission gear using bevel gear as its mechanism 2- Roller design 2.1- Roller with brush 2.2- Back-up brush 3- Chain mechanism. 4- Railing system to support the chain and roller and at the same time allow their movement.
DATE: 18th SEPT 2008 ATTENDANCE: ALL MEMBERS
PAINTING DEVICE
26
PICTURE
PROJECT REPORT KJM 553
No 1
ISSUES The mechanism designing.
EM 220 (EMC6M1)
ACTION 1- Upper and lower support design idea.
DUE DATE 7/11/08
-idea: Syadilla 2- The adjustable rod is suggested to be used. - idea: Ummi Zulaikha 3- Use transmission gear as moving mechanism. -idea: Noor Idayu 4- Bevel gear as moving mechanism -idea: Mohd Faizal 5- Bicycle mechanism to transmit human power to moving mechanism -idea: Mohd Hazwan th
DATE: 20 SEPT 2008 ATTENDANCE: ALL MEMBERS
PAINTING DEVICE
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PICTURE
PROJECT REPORT KJM 553
No 1
EM 220 (EMC6M1)
ISSUES New concept
ACTION
DUE DATE
1- Concept of using gear mechanism
PICTURE
7/11/08
2- All members generate ideas to this new concept design. 3- All discussion more towards the disadvantages
rather
than
the
advantages of this concept, such as: - The designing of this concept faced difficulty for roller to move upward and downward continuously - Difficulty in solving moving transmission gear.
DATE: 25th SEPT 2008 ATTENDANCE: ALL MEMBERS No
ISSUES
PAINTING DEVICE
ACTION
DUE DATE
28
PICTURE
PROJECT REPORT KJM 553
1
Discuss the best concept
EM 220 (EMC6M1)
1- All members stick with the one 7/11/08 concept to be the best product and mechanism. 2- Mechanism involved: - Transmission gear - Chain - bearing - sprocket - shaft 3- The cost and other factors had been considered.
PREPARED BY: ……………………… (NOOR IDAYU) DATE: 25th SEPT 2008
PAINTING DEVICE
CHECKED BY:
APPROVED BY:
………………………..... (UMMI ZULAIKHA)
………………………. (MR. MOHD AFZAN)
DATE: 25th SEPT 2008
DATE:7/11/2008
29
PROJECT REPORT KJM 553
PAINTING DEVICE
EM 220 (EMC6M1)
30
