Pedal operated washing machine (part-3)
(FULL REPORT FOR DESIGN AND FABRICATION)
2. LIST OF COMPONENTS
2.1 MS FRAME
The steel frame is a building technique with a "skeleton frame" of vertical steel columns and horizontal I-beams, constructed in a rectangular grid to support the floors, roof and walls of a building which are all attached to the frame. Concept The rolled steel "profile" or cross-section of steel columns takes the shape of the letter "I". The two wide flanges of a column are thicker and wider than the flanges on a beam, to better withstand compressive stress in the structure. Square and round tubular sections of steel can also be used, often filled with concrete. Steel beams are connected to the columns with bolts and threaded fasteners, and historically connected by rivets. The central "web" of the steel I-beams is often wider than a column web to resist the higher bending moments that occur in beams. Wide sheets of steel deck can be used to cover the top of the steel frame as a "form" or corrugated mold, below a thick layer of concrete and steel reinforcing bars.
Another popular alternative is a floor of precast concrete flooring units with some form of concrete topping. Often in office buildings, the final floor surface is provided by some form of raised flooring system with the void between the walking surface and the structural floor being used for cables and air handling ducts. The frame needs to be protected from fire because steel softens at high temperature and this can cause the building to partially collapse. In the case of the columns this is usually done by encasing it in some form of fire resistant structure such as masonry, concrete or plasterboard.
The beams may be cased in concrete, plasterboard or sprayed with a coating to insulate it from the heat of the fire or it can be protected by a fire-resistant ceiling construction. Asbestos was a popular material for fireproofing steel structures up until the early 1970s, before the health risks of asbestos fibres were fully understood. The exterior "skin" of the building is anchored to the frame using a variety of construction techniques and following a huge variety of architectural styles. Bricks, stone, reinforced concrete, architectural glass, sheet metal and simply paint have been used to cover the frame to protect the steel from the weather.
2.2SHAFT
A shaft is a rotating machine element, usually circular in cross section, which is used to transmit power from one part to another, or from a machine which produces power to a machine which absorbs power.[1] The various members such as pulleys and gears are mounted on it. The material used for ordinary shafts is mild steel. When high strength is required, an alloy steel such as nickel, nickel-chromium or chromium-vanadium steel is used. Shafts are generally formed by hot rolling and finished to size by cold drawing or turning and grinding.2.3 V BELT
A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most often parallel. Belts may be used as a source of motion, to transmit power efficiently, or to track relative movement. Belts are looped over pulleys and may have a twist between the pulleys, and the shafts need not be parallel. In a two pulley system, the belt can either drive the pulleys normally in one direction (the same if on parallel shafts), or the belt may be crossed, so that the direction of the driven shaft is reversed (the opposite direction to the driver if on parallel shafts). As a source of motion, a conveyor belt is one application where the belt is adapted to carry a load continuously between two points2.4 PULLEY
A pulley is a wheel on an axle or shaft that is designed to support movement and change of direction of a taut cable, supporting shell is referred to as a "block." A pulley may also be called a sheave or drum and may have a groove or grooves between two flanges around its circumference. The drive element of a pulley system can be a rope, cable, belt, or chain that runs over the pulley inside the groove or grooves. Hero of Alexandria identified the pulley as one of six simple machines used to lift weights.[1] Pulleys are assembled to form a block and tackle in order to provide mechanical advantage to apply large forces. Pulleys are also assembled as part of belt and chain drives in order to transmit power from one rotating shaft to another.2.5 BALL BEARING
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races. The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads. It achieves this by using at least two races to contain the balls and transmit the loads through the balls. In most applications, one race is stationary and the other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other. Ball bearings tend to have lower load capacity for their size than other kinds of rolling-element bearings due to the smaller contact area between the balls and races. However, they can tolerate some misalignment of the inner and outer races.
2.6 STATIONARY DRUM
A drum is a cylindrical container used for shipping bulk cargo. Drums can be made of steel, dense paperboard (commonly called a fiber drum), or plastics, and are generally used for the transportation and storage of liquids and powders. Drums are often certified for shipment of dangerous goods. Shipped goods must be matched with the make of drum necessary to comply with applicable regulations.[1] Drums are also called barrels in common usage.2.7 PEDAL
The bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the bicycle. It provides the connection between the cyclist's foot or shoe and the crank allowing the leg to turn the bottom bracket spindle and propel the bicycle's wheels. Pedals usually consist of a spindle that threads into the end of the crank and a body, on which the foot rests or is attached, that is free to rotate on bearings with respect to the spindle. Pedals were initially attached to cranks connecting directly to the driven (usually front) wheel. The safety bicycle, as it is known today, came into being when the pedals were attached to a crank driving a sprocket that transmitted power to the driven wheel by means of a roller chain.2.8 ROLLER CHAIN AND SPROCKET
Roller chain or bush roller chain is the type of chain drive most commonly used for transmission of mechanical power on many kinds of domestic, industrial and agricultural machinery, including conveyors, wire- and tube-drawing machines ,printing presses, cars, motorcycles, and bicycles. It consists of a series of short cylindrical rollers held together by side links.It is driven by a toothed wheel called a sprocket. It is a simple, reliable, and efficient means of power transmission. Though Hans Renold is credited with inventing the roller chain in 1880, sketches by Leonardo da Vinci in the 16th century show a chain with a roller bearing. A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs or even sprockets that mesh with a chain, track or other perforated or indented material. The name 'sprocket' applies generally to any wheel upon which radial projections engage a chain passing over it.
It is distinguished from a gear in that sprockets are never meshed together directly, and differs from a pulley in that sprockets have teeth and pulleys are smooth. Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other machinery either to transmit rotary motion between two shafts where gears are unsuitable or to impart linear motion to a track, tape etc. Perhaps the most common form of sprocket may be found in the bicycle, in which the pedal shaft carries a large sprocket-wheel, which drives a chain, which, in turn, drives a small sprocket on the axle of the rear wheel .
Early automobiles were also largely driven by sprocket and chain mechanism, a practice largely copied from bicycles. Sprockets are of various designs, a maximum of efficiency being claimed for each by its originator. Sprockets typically do not have a flange. Some sprockets used with timing belts have flanges to keep. Sprockets and chains are also used for power transmission from one shaft to another where slippage is not admissible, sprocket chains being used instead of belts or ropes and sprocket-wheels instead of pulleys. They can be run at high speed and some forms of chain are so constructed as to be noiseless even at high speed.
2.9 WHEELS
A wheel is a circular component that is intended to rotate on an axle bearing. The wheel is one of the main components of the wheel and axle which is one of the six simple machines. Wheels, in conjunction with axles, allow heavy objects to be moved easily facilitating movement or transportation while supporting a load, or performing labor in machines. Wheels are also used for other purposes, such as a ship's wheel, steering wheel, potter's wheel and flywheel Common examples are found in transport applications.A wheel greatly reduces friction by facilitating motion by rolling together with the use of axles. In order for wheels to rotate, a moment needs to be applied to the wheel about its axis, either by way of gravity or by the application of another external force or torque.
2.10 SPIN TUB
Spin tub in washing machine is used to rinse and dry the clothes. Initially water is allowed to flow an spin tub is started for 3-5 minutes so that soap water is rinsed from the clothes. After this rinsing action water flow is stopped in the spin tub and spin tub is started to dry the clothes3. DESIGN SPECIFICATION
The most important aspect in the design of the machine is its ability to perform as a device that eases the task of washing clothes. In order to be a viable solution in rural areas, the machine should be able to deliver the same quality of washing without adding excessive over heads(in terms Of water use, clothing wear, effort required to operate, etc.). Thus the design and operation of the Machine should be firmly grounded in the physics of clothes washing, with a special emphasis on the mechanical aspects (since water temperature and detergent composition are likely to vary).The group also identified a number of secondary goals with varying degrees of importance that could help make the machine more useful and thus more successful. The ability to spin-dry clothes would increase water economy by requiring fewer wash cycles, and could relieve the strenuous task of manually wringing the clothes before they are hung to dry. If the layout of the machine allowed the user to perform manual work (hand-craft, food preparation, etc.) while pedaling, we could further reduce the amount of time consumed by washing. A number of safety features should also to be included in order to mitigate the inherent safety issues involved in a chain-driven machine. If them a chine was to be used in a home, insuring its portability of would allow it to be shared among families, transported close to a water source for operation, or used in households where space limited. Another set of specifications for load sizing, water usage and pricing, depend on the targeted Community. Since we are expecting the amount of laundry to vary between families, an initial size was selected based on existing washing machines, and designs allowing for easy re-sizing were preferred4. DESIGN MODELING IN 3D
5. MATERIAL & FABRICATION PROCESS
5.1 PROPOSED TO WORK
TO prepare any machine part, the type of material should be properly selected considering design safety and following points . the selection of ,material for engineering application is given by the following factor 1) Availability of materials 2) Suitsbility of the material for thr required combonents 3) Suitability of the material for the desired working conditions 4) Cost of materials5.2 MANUFACTURING PROCESS
5.2.1 MATERIAL CUTTING
• Start with a standard size of stock „• Remove material to achieve desired geometry
5.2.2 MACHINING
Machining is a part of the manufacture of many metal products, but it can also be used on materials such as wood, plastic, ceramic, and composites. A person who specializes in machining is called a machinist. A room, building, or company where machining is done is called a machine shop. Machining can be a business, a hobby, or both. Much of modern-day machining is carried out by computer numerical control (CNC), in which computers are used to control the movement and operation of the mills, lathes, and other cutting machines.5.2.3 WELDING
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal. In addition to melting the base metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that is usually stronger than the base material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
5.2.4 DRILING
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute
6) DESIGN CALACULATION:
6.1 CALCULATION OF SPEED
(D2 / D3) = (N3 / N2)(0.24 / 0.05) = (N3/ 20)
N3 = 48 RPM = 50 RPM
Rear gear and rear wheel is fixed, so they are rotating at same speed.
I e.
N3 = N4 = 50 RPM
(D4/ D5) = (N5/N4)
(0.6 / 0.1) = (N5/ 50)
N5 = 300 RPM
7.2 CALCULATION OF REAR WHEEL:
1. VELOCITYV= (Π D N / 60)
= (π*0.6*50 / 60)
= 1.57 m/s
2. ANGULAR VELOCITY:
ω = (V / R)
= (1.57 / 0.3)
= 5.23rad/s
3. ANGULAR ACCELERATION:
α = ω / t
= 5.23 / 2
= 2.61rad/s
2 4. MOMENT OF INERTIA:
I = (M R2) / 2
= (3* 0.32) / 2
= 0.135 kg-m
2 5. TORQUE:
T = I *
α = 0.135 * 2.61
= 0.35 N-m
6. FORCE REQUIRED IN WHEEL:
FWHEEL = T / R = 0.35 / 0.3 = 1.17 N 7.
PEDAL FORCE FOR ROTATE THE WHEEL:
FPEDAL = FWHEEL
{(R2*R4) / (R1*R3)} = 1.17 {(0.12*0.3) / (0.18*0.05)}
= 4.68 N 7.
WORKING PRINCIPLE
The washing machine will be easy to use by younger and older women. After loading the machine, washing requires three cycles. Between each cycle, the drum spins quickly to draw the water out of the clothing, as it drains out of the drum. In the first cycle, water and detergent are added to the drum. The operator pedals the machine for roughly 25 minutes, spins, and drains the water. The next two cycles are rinse cycles.In each rinse cycle, the operator pours clean water into the machine, pedals for 10 minutes, spins, and drains the drum. After the last rinse cycle, the operator spins the clothes dry and saves the slightly soapy water for the next wash cycle. Our research into existing washers and our earlier prototypes indicate that the power required for washing and spinning is relatively low.
For these experiments, we used a geared transmission from a bicycle. Both younger and older women can generate enough power for the wash and spin cycles. Estimated power generated 50-75 watts. While familiarity with pedaling in general and the machine in particular will reduce the effort expended by the user, no prior experience will be necessary for its operation. The ability to change gearing ratios will allow some level of tuning to individual users and also allow for shorter wash times with more power input or conversely less strenuous operation if the user can pedal for a longer amount of time
ADVANTAGES
1. Eco friendly and non-polluting in every way.2. Less noisy
3. The machine has low manufacturing cost. It is highly economical and affordable to all class of people.
4. Works without electricity so it can be an ideal machine for the people in the electricity deficient Indian villages
5. Less tiring than conventional washing techniques by hand. This would greatly contribute in increasing the productivity of the manual laundries all over the world.
6. Lesser chances of failure than electronic washing machine as the mechanical systems used in the machine have stood the test the time.
7. More reliable: Due to simplicity of design the chances of failure are reduced drastically thus making the machine all the more reliable.
8. Lesser maintenance required: Maintenance of PPWM involves mostly lubricating the various parts which can be done even at home so maintenance cost are drastically cut down. Zero operating cost: Since the machine is manually driven.
DISADVANDAGES
1. Need much human effort 2. Structure is complex 3. Children can’t use APPLICATION 1. It is very useful into the local rural areas2. This whole arrangement will be used as an exercise equipment
3. Use it at the dark areas where there is no any electricity
4. Saving in detergent the water
5. Better wash quality, scale tub
6. Easy to operate and less effort of chemical on the woman hand
9. CONCLUSION
The main objective is to provide a product with an alternative way to wash clothes when there is no electricity. It has to be understood that in rural areas, it is a very stressful and laborious task. So the product which is a pedal driven machine, it satisfies the need of rural people by giving them an alternative way of washing clothes which is quick, cost-effective and eco-friendly. The product designed has zero operating cost, cost-effective, and it can be used with minimal effort.10. REFERENCES
1. Whitt, Frank Rowland, and Wilson, David Gordon. Bicycling Science. 2nd ed. Cambridge, Massachusetts: The MIT Press, 1983.
2. Darrow, Ken, and Pam, Rick. "Energy: Pedal Power," from Appropriate Technology Sourcebook pp.189-196. Stanford, California: Volunteers in Asia, Inc., 1977.
3. BICILAVADORA, REPORT, RADU RADUTA, JESSICA VECHAKUL 4. Wilson, David Gordon. ― Understanding Pedal Power.‖ www.autonopedia.org 30 Aug 2013. http://www.autonopedia.org/renewable-energy/pedal-power/understanding-pedal-power/
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