Executive Summary

In this report, we outline the design process that our team went through to design a power transmission
system for a cart that houses an existing automated window cleaner and the battery pack within.

As per the specifications, the cart needs to be able to move horizontally along an existing railing, while
controlling the vertical movement of the automated window cleaner. The power transmission system that
we have in place allows the horizontal movement to achieve the desired speeds of 0.15ms -1, and the
system that controls the vertical cleaner movement allows it to be moved at the needed speeds of 0.1 –
1.5ms-1. The two systems operate independently, so they can be treated as two separate systems, in terms
of operation and maintenance. This means an increase in reliability, and in event of a failure, it will be
easier to deal with. This is further established by the positioning of the battery power pack, as it physically
separates the two systems, allowing for a neater arrangement of the components, less complexity and
easier access.

Reliability was one of our primary attributes for the design of the system, as the cleaner needed to be
controlled accurately, safely and consistently. One way to address this was on include a safety factor of 2
in the calculations so that the chance of failure is greatly reduced. This is necessary as the cleaner is
operating at a great height, with individual parts that are quite heavy, and it could be disastrous if a part
was to fall.

Also, a SELUBE chain and sprocket linkage system was used to transmit power to the components. This
ensures that the shafts rotate at exactly the required speed, and be controlled precisely and with greater
reliability. The selected chains are also self lubricating, which increases performance and greatly reduces
the effort that would otherwise be needed to ensure their smooth running.

Both the motors selected are high quality Reynold electric motors, with excellent performance and
reliability, and further specifications are mentioned in the report. Similarly, the bearings and plummer
blocks chosen are high grade SYT bearings which guarantee smoother shaft rotation. All the components
have been mounted using appropriate loading and placement calculations to minimise any deflection or
yielding of material.

All of the selected components and design for the power transmission system emphasis its reliability,
safety and excellent performance, as well as longevity, which makes it an ideal system for DesigNZ to
use.

1
Introduction
DesigNZ have developed an automated window cleaner to be used on the face of buildings without human
intervention. A power transmission system needs to be designed and implemented to guide the cleaner
across the building face at night time, in vertical and horizontal direction, and DesigNZ has enlisted us to
carry it out. The quality of the design must be high, as it will be operating in elevated regions, so safety
and reliability are vital in its design. The system should have a lifespan of at least 5 years, and work in
harmony with the cleaner and existing battery pack without failure for repeated daily use.

Product Design Specification

2
1.0 Conceptual Design

Development of design options

The primary function of the system is to allow the pod to move in the horizontal and vertical direction
independently. Therefore we decided to isolate the two systems and treat each one distinctly. Clearly this
meant using two separate motors. Since we had a limited building envelope to work in, the position of the
large battery pack was the first thing that we needed to decide on. After that was decided, we could move
on to the selection of the motor and its placement, and the selection of the other components. Therefore
our main decisions were:

Battery packs position.

Motor selection
Power transmission selection (Type of drive)
Shaft type

Once those decisions were made, we could go on to make the remainder of our decisions:
Motor placement and mounting
Sprockets/gears
Bearings
Pins and keys

3
Orientation of Battery Pack

The position of the battery pack is important due to the limited space available. The components need to
be able to be accessed easily for installation and maintenance, as well as reducing clutter and mounting
material used

The 3 main battery pack positions that we had considered are as below;

Horizontal placement

Raised Horizontal placement

Upright Placement

Based on the pros and cons of each position, we decided to go with the upright placement. It was the most
simple, yet the most effective one. It was secure in place and would be easy to install, as well as be out of
the way of the other components. Also, the second motor could be placed on top easily, reducing the need
for additional mounting equipment.

Type of Motors

Two types of Reynold motor were considered for the power transmission in the system, The RS Gear
Motor and the WM Worm Gear Motor. The power, speed and torque required for the transmission can be
provided by both types of motors, with the WM motor being able to provide larger torques. Based on the
running time of the system, and the power needed, we decided to go with the RS motor, as it provided us
with what we needed, at a lower cost. The motor also…

One motor would be used for the vertical transmission, and one for the horizontal movement, and they
would both be powered from the battery pack independently.

Belt or Chain Drive Transmission System

Based on the accuracy and reliability requirements, the transmission options for the system are either a
chain drive or a belt drive. Both of them can drive the shafts at a synchronous speed with consistency, so
we needed to weigh up other criteria in order to make a decision. The notes on belt drives provided
included a rating of the belts based on different criteria.

Based on… we decided to go with the chain drive, due to the importance of safety and dependability.

Shaft Type

For the shaft design, the team considered two options. The designs consisted of
Continuous shaft with equal diameter
Continuous shaft with varying diameter

4
The shaft with varying diameter would save material and make the shaft more stable in the regions where
there is higher torque concentration. It is a more efficient design for bulk production and usage of the
shaft. However, the ease of manufacture will be lowered for the scale of this product, and the expense
would increase.

Further conceptual design

The other features of our design were selected to compliment the 4 main sections of our design. By
dividing our design into main sections and minor sections, we ensure compliance and the complimenting
of the entire design, allowing for a functional power transmission system of the window washer, which is
cost efficient, has high performance level, and follows necessary safety standards.

2.0 Detailed Design

Solution Description

Fig 2.0: The assembly of detailed design showcasing systematic separation of dual power transmission
system, direct connection of shafts to shafts and easy accessibility to components

The proposed solution will have two independent motors, one for the vertical motion of the cleaning mod
and the other for the horizontal motion. Due to the location of the battery/control pack, these two
independent and very different transmission systems are isolated, and it leads to a systematic orientation
of all the other components. Further description of our solution is as below
5
2.1 Vertical Motion Motor

As previously mentioned there are two separate

and independent power transmission systems. The
vertical motion is powered by the Renold RS
Series Motor, GM2D with frame size D112
coupled with the reducing gear unit, RG2D which
would allow for the specified speed being
controlled by the battery/control pack to be varied
from 0.1 to 2.5 . The power rating of the
motor is 4.00kW, with a nominal speed of 155rpm
(The actual output of motor is 1440rpm, but with Fig 2.1 Vertical GM2D Motor can connect
the standard reducing gear unit a nominal speed of directly to shaft with chain drive to power
155rpm is achieved). By changing the gear unit winches
with the RG2D reducing gear unit with exact
speed ratio of 7.842, the maximum speed that the As the GM2D motor is required to drive the shaft
cart can achieve would be 183.63rpm. The connected to the drums, the team had decided
battery/control pack coupling with this additional collectively that it was in the best interest to have
speed would ensure that the speed range of 0.1 to the motor elevated to allow as direct a connection
2.5 will be achieved consistently. as possible between the motor and shaft. The
selected solution for this was to have the motor
shaft to be directly connected on to a sprocket
using grub screws and a key.

2.2 Horizontal Motion Motor

The horizontal motion is powered by the Renold

RS Series Motor, GM1T with frame size D71
coupled with the reducing gear unit, RG1T which
would allow for the specified speed of 1.0 to
be achieved. The power rating of the motor is
0.75kW, with a nominal speed of 37rpm. (As
previously mentioned the actual output of motor is
1440rpm, but with the standard reducing gear unit
a nominal speed of 37rpm is achieved). By
changing the gear unit with the RG1T reducing
gear unit with exact speed ratio 30.222 , the Fig 2.2 Horizontal GM1T motor can connect
maximum speed that can be achieved is directly to driving shaft with chain drive. The
47.746rpm, which fulfils the specification of 1.0 shaft of motor is not directly above driving shaft.
constant velocity.

The team was again very interested with the A decision was also made to have the motor shaft
benefits achieved by having as direct a connection and driving roller wheel shaft to not be directly
of motor with the driving shaft as possible. We above one another, but a slight angle was taken, as
therefore decided to place the motor close to the this was specified by the manufacturer SAEKO as
driving wheel shaft. a better recommended orientation for the chain
drive for such a power transmission system.

6
2.3 Support Designs

In our design considerations, we realized that supports were necessary to be designed to allow for a
systematic and complimentary orientation of components. Our main criteria for the support was minimal
material which would lead to lower manufacturing costs and would also contribute to the aesthetics as
there would less clutter which indirectly also leads to the ease of maintenance. (For technical analysis
results, and calculations to ensure that our minimalist approach is sufficient please refer to technical
analysis and calculations section of report)

The support designs are on the page overleaf:

2.3A Battery Support

The battery support consists of four RHS cross

section of serial size 25x25mm with thickness
2.6mm of height 300mm and two mild steel
plates of dimensions 600x25x5mm welded
together.

The mild steel plates would have holes for

battery/control pack to be bolted with M8 bolts,
allowing for easy removal of the battery/control
pack. See Fig 2.3A

From Fig 2.3A it is also seen that due to the

minimalist design the space required for such
Fig 2.3A 2 RHS cross sections welded with a
support is minute.
mild steel plate. Battery pack is bolted to 2
equivalent parallel arrangements.
This would allow for versatility in orientation,
thus an optimum and systematic orientation of
other components can be achieved in conjunction
with such design
2.3B Vertical Motor Support onto the base plate, the smallest RHS section
would be sufficient to support motor and torque.
The vertical motor support consists again of the (Refer to technical analysis and calculations
minimum amount of materials. For one unit of section of report)
power carts, the support required for the vertical
motor would solely consist of 3 mild steel RHS The mild steel plate would have holes for the
sections of serial size 25x25 with thickness GM2D motor to be bolted with M12 bolts,
2.6mm and lengths 600, 240 and 820 mm. allowing for securing of the motor and easy
respectively and a 750x240x5mm mild steel removal of motor in the future. See Fig 2.3B for
plate. By having the vertical RHS section welded vertical motor support
7
 Fig 2.3B 3 RHS cross sections and a mild steel
plate welded together. GM2D motor is bolted
onto plate.

2.4 Shaft

As previously mentioned, we decided on a shaft with a continuous diameter. The selected diameter of
40mm was chosen. Through analysis, the minimum diameter required was 36mm to have a deflection of
less than 1mm on shaft. By choosing a 40mm diameter shaft the maximum deflection of shaft is 40% less.
Weighing the two factors into consideration, an extra 4mm diameter for the performance trade off in less
deflection was a more important criterion. For further information on analysis please refer to technical
analysis and calculations section of report.

2.5 Power transmission

The selected power transmission for both independent vertical and horizontal movement of power cart
was sprockets and chains on both accounts. The revolutions of the motor shaft is transferred accordingly
through a sprocket, and then to chain drives to a sprocket again allowing transmission of energy from one
point in the system to another. Sprockets used to transfer the power are secured onto the shafts with
rectangular keys and grub screws.

2.5A Horizontal power transmission

The two sprockets chosen for horizontal motion are of the same size both with 17 teeth respectively and a
pitch diameter of 69.11mm (Order ref: 08B-1/2/3 17 teeth simplex SAECO supplier). The two sprockets
are of equal dimensions due to the need of transfer of speed at a ratio of 1 to 1. For the horizontal chain
OCM 40J-SER with length of 268mm from SAECO supplier was again selected.

2.5B Vertical power transmission

The two sprockets chosen for vertical motion are 21 teeth and pitch diameter of 127.82mm for smaller
sprocket and 24 teeth and pitch diameter of 145.95mm for larger sprocket respectively.(Order ref: 12b-
1/2/3 21 teeth and 24 teeth simplex SAECO supplier) The varying number of teeth and dimensions of
sprocket allow for the required speed ratio to be achieved, reducing the strain on the motor (reducing
scenarios where motor is running at non-nominal speeds or speeds with large variation from nominal
speed). From usage of such a configuration, a reduction ratio of 1.143 is acquired.
8
3.0 Special Features
The following will explain the notable features of our design.

3.1 Systematic orientation and compartmenting of different transmission systems

As seen from Fig 2.0 from previous section, the orientation of the battery/control pack on the support,
allows for the horizontal and vertical power transmission system to be completely separated and
independent. Such a configuration allows for an easy understanding of the system, an ease in having to
carry out maintenance of the device, and also helps isolates problematic components in the event that the
either power transmission system is faulty.

3.2 Low maintenance requirements

Even though we opted for a minimalist approach in our design in terms of materials in many aspects, we
had consistently ensured from analysis that it would not fail, thus maintaining a low cost on our end in
both aspects of materials and the need to carry out maintenance on sold/operational units.
The next maintenance aspect to consider is the chain, but since we are using the SELUBE range of chains
which are self lubricating maintenance requirements will be reduced significantly. In addition, the chain
undergoing the largest forces will be lubricated with the type II method of disk lubrication in a leak proof
casing. This would reduce the need for maintenance indefinitely.
Finally the last consideration of maintenance requirements; the bearings. The proposed maximum usage of
the power transmission system before requiring any significant maintenance would allow for a maximum
amount of revolutions in 5 years before requiring significant maintenance.(Assuming 5 hour
per day usage, 270 days per year usage at maximum speed of 2.5 ). The selected bearings on the other
hand offer a significantly larger amount of allowable revolutions to the order of to revolutions
translating to an estimated lifespan of 50 to 500 years usage due to wear and tear from loading.

3.3 Emergency braking system

In the even of some form of hardware failure, safety is a criterion we are very mindful of in designing our
product. In the event of some form of hardware failure, whether due to a short circuit or a more
mechanical natured malfunction, an emergency braking system is a necessity to prevent the 125kg
9
cleaning pod from falling uncontrollably which under worst case scenarios could claim lives and or
damage property. To overcome the shortcoming of possible malfunctions we had decided on having a
separate “detector” circuit that has an independent power source (battery). It would consist of an infrared
sensor that would measure rate of rotation of winch. If rate of rotation of winch exceeds speed of 159.15
rpm by more than 50%, a ratchet unit placed on the winch would be stopped by a lever released by a
spring in such an event locking the winch in place preventing free fall of pod. See Fig 3.0

Fig 3.0: Braking mechanism

10
4.0 List of Components
Parts List
Part No Part Part Description Quantity
1 Motor - horizontal motion GM1T, Frame D132S, RG1T 1
2 Motor - vertical motion GM2D, Frame D112, RG2D 1
3 Shaft 40mm diameter, 1500mm length, carbon steel cylinder 1
4 Bearing SKF Y-Bearing Plummer Block Units, SYK 40TR, 4
Housing SYK 40
5 Sprocket - horizontal motor shaft 17 teeth simplex order ref 08B-1/2/3 1
6 Sprocket - vertical motor shaft 21 teeth simplex order ref 12B-1/2/3 1
7 Sprocket - horizontal roller wheel shaft 17 teeth simplex order ref 08B-1/2/3 1
8 Sprocket - vertical motion shaft 24 teeth simplex order ref 12B-1/2/3 1
9 Chain - vertical motion OCM 60J-SER 466mm length 1
10 Chain - horizontal motion OCM 40J-SER 268mm length 1
11 Bolts & Nuts horizontal motor M9 Bolts 4
12 Bolts & Nuts vertical motor M12 Bolts 4
13 Bolts & Nuts M8 Bolts 12
14 Bearing Washers M12 Bolts 8
15 Grub screws Diameter 6mm 14
16 Key drums Mild steel 12x8x120 2
17 Key motor-horizontal Mild steel 8x10x45 1
18 Key motor-vertical Mild steel 8x6x50 1
19 Key in vertical shaft sprocket Mild steel 8x12x40 1
20 Key in horizontal shaft sprocket Mild steel 8x12x28 1
21 Battery pack support Mild steel Plate 600x25x5 2
22 Mild steel RHS 25x25(2.5mm thickness,300mm height) 4
23 Vertical motor support Mild steel RHS 25x25(2.5mm thickness,240mm height) 1
24 Mild steel RHS 25x25(2.5mm thickness,600mm height) 1
25 Mild steel RHS 25x25(2.5mm thickness,820mm height) 1
26 Mild steel Plate 600x25x5
27 Battery Pack 1500x600x350 1

Note, sprocket bore sizes are changed therefore aren't considered as standard parts

11
5.0 Technical Analysis and Calculations
Support Calculations

Battery/control pack analysis and calculations

Stress and deflection on the power pack:

Graph:

The stress on the RHS 25.4 25.4 2.6 mm beam is :

Figure:

12
Vertical motion motor support analysis and calculations

Stress on the weld section with motor support:

Figure:

For section A and B:

For section C the force on the weld is 112N/mm, and For section D is noly10N/mm.
The weld size 4 can provide 470N/mm, so the weld section at A and C is table.

Stress on 5 mm thickness plate

Figure 1, 2

The bearing and tearing force is zero because one side of motor is against the beam.
Therefore, the plate is suitable for supporting the motor

Shaft Analysis and Calculations

Shaft torsion

13
 Figure

Maximum shear due to toque on the shaft

Figure:

Twist angle due to the toque

Shaft deflection along shaft for diameter 40 mm

Shaft Diameter/mm Shaft Area/m^2 Second Moment Of Area/m^4

40 0.001256637 1.25664E-07
Carbon Steel Properties
Young Modulus/Pa Shear Modulus/Pa Poisson's ratio Yield Stress/Pa
2.08E+11 8.10E+10 0.3 3.70E+08

XY Plane XZ Plane Total Deflection

14
Distance/m Defletion(Y)/m Deflection(Z)/m /mm
0.00 0.0000E+00 0.0000E+00 0.0000
0.02 -1.0196E-05 -1.7929E-05 0.0206
0.04 -2.0191E-05 -3.5589E-05 0.0409
0.06 -2.9786E-05 -5.2709E-05 0.0605
0.08 -3.8779E-05 -6.9020E-05 0.0792
0.10 -4.6971E-05 -8.4253E-05 0.0965
0.12 -5.4162E-05 -9.8138E-05 0.1121
0.14 -6.0150E-05 -1.1041E-04 0.1257
0.16 -6.4736E-05 -1.2079E-04 0.1370
0.18 -6.7719E-05 -1.2901E-04 0.1457
0.20 -6.8899E-05 -1.3481E-04 0.1514
0.22 -6.8138E-05 -1.3791E-04 0.1538
0.24 -6.5548E-05 -1.3804E-04 0.1528
0.26 -6.1305E-05 -1.3494E-04 0.1482
0.28 -5.5584E-05 -1.2833E-04 0.1399
0.30 -4.8558E-05 -1.1795E-04 0.1276
0.32 -4.0404E-05 -1.0353E-04 0.1111
0.34 -3.1296E-05 -8.4793E-05 0.0904
0.36 -2.1410E-05 -6.1471E-05 0.0651
0.38 -1.0919E-05 -3.3297E-05 0.0350
0.40 1.5303E-11 -2.7546E-11 0.0000
0.42 1.1181E-05 3.8478E-05 0.0401
0.44 2.2492E-05 8.1354E-05 0.0844
0.46 3.3806E-05 1.2763E-04 0.1320
0.48 4.4999E-05 1.7632E-04 0.1820
0.50 5.5947E-05 2.2641E-04 0.2332
0.52 6.6523E-05 2.7693E-04 0.2848
0.54 7.6604E-05 3.2686E-04 0.3357
0.56 8.6063E-05 3.7523E-04 0.3850
0.58 9.4777E-05 4.2102E-04 0.4316
0.60 1.0262E-04 4.6325E-04 0.4745
0.62 1.0947E-04 5.0093E-04 0.5127
0.64 1.1519E-04 5.3305E-04 0.5454
0.66 1.1968E-04 5.5862E-04 0.5713
0.68 1.2279E-04 5.7665E-04 0.5896
0.70 1.2440E-04 5.8614E-04 0.5992
0.71 1.2461E-04 5.8738E-04 0.6004

Shaft yielding analysis (See torque diagram on page overleaf)

Shaft Diameter/mm Shaft Area/m^2 Second Moment Of Area/m^4 S

40 0.001256637 1.26E-07
Carbon Steel Properties
Young Modulus/Pa Shear Modulus/Pa Poisson's ratio S
2.08E+11 8.10E+10 0.3

Polar Moment Of Inertia/m^4 Yield Stress/Pa

2.51327E-07 3.70E+08

XY Plane XZ Plane Normal Shear Principal

Distance/m Bending Moments/Nm Bending Moments)/Nm Sum of moments Stress/Pa Stress/Pa Stress/Pa
0.00 0 0 0 0 0 0
0.02 13.0919434 17.6177308 21.94956538 3493382 0 5240073
0.04 26.1838868 35.2354616 43.89913077 6986764 0 10480145
15
 0.06 39.2758302 52.8531924 65.84869615 10480145 0 15720218
0.08 52.3677736 70.4709232 87.79826153 13973527 0 20960291
0.10 65.459717 88.088654 109.7478269 17466909 0 26200364
0.12 78.5516604 105.7063848 131.6973923 20960291 0 31440436
0.14 91.6436038 123.3241156 153.6469577 24453673 0 36680509
0.16 104.7355472 140.9418464 175.5965231 27947055 0 41920582
0.18 117.8274906 158.5595772 197.5460885 31440436 0 47160655
0.20 130.919434 176.177308 219.4956538 34933818 0 52400727
0.22 119.4863774 193.7950388 227.6697421 36234765 19099389 59077666
0.24 108.0533208 211.4127696 237.4255237 37787446 19099389 61233748
0.26 96.6202642 229.0305004 248.5768404 39562233 19099389 63712392
0.28 85.1872076 246.6482312 260.9448415 41530661 19099389 66477282
0.30 73.754151 264.265962 274.3650369 43666552 19099389 69494103
0.32 62.3210944 281.8836928 288.6907256 45946556 19099389 72731420
0.34 50.8880378 299.5014236 303.7938366 48350291 19099389 76161079
0.36 39.4549812 317.1191544 319.564162 50860216 19099389 79758261
0.38 28.0219246 334.7368852 335.9077412 53461377 19099389 83501328
0.40 16.588868 352.354616 352.7449021 56141095 19099389 87371552
0.42 8.4236684 287.3346128 287.4580629 45750372 19099389 72452229
0.44 0.2584688 222.3146096 222.3147599 35382493 19099389 57899547
0.46 -7.9067308 157.2946064 157.4932049 25065822 19099389 44046116
0.48 -16.0719304 92.2746032 93.66381021 14907058 19099389 31681758
0.50 -24.23713 27.2546 36.47261564 5804797 19099389 22864421
0.52 -32.4023296 -37.7654032 49.76079423 7919676 19099389 24636103
0.54 -40.5675292 -102.7854064 110.5014217 17586847 19099389 34756549
0.56 -48.7327288 -167.8054096 174.7384741 27810492 19099389 47642616
0.58 -56.8979284 -232.8254128 239.6769641 38145774 19099389 61733017
0.60 -65.063128 -297.845416 304.8689923 48521407 19099389 76405824
0.62 -73.2283276 -362.8654192 370.1806321 58916077 19099389 91392608
0.64 -81.3935272 -427.8854224 435.5580799 69321221 19099389 1.07E+08
0.66 -89.5587268 -492.9054256 500.9755724 79732739 19099389 1.22E+08
0.68 -97.7239264 -557.9254288 566.4192351 90148421 19099389 1.37E+08
0.70 -105.889126 -622.945432 631.8809368 1.01E+08 19099389 1.53E+08
0.71 -109.9717258 -655.4554336 664.6168866 1.06E+08 19099389 1.6E+08

Torque diagram
Torque acting at 0<x<0.2 is 0
Torque acting at 0.2<x<0.71 is 240.01
Torque acting at 0.71<x<1.22 is -240.01
Torque acting at 1.22<x<1.4 is 0

16
6.0 Conclusions
Our design solution will be highly functional and due to the minimalist approach in terms of use of
materials it will have minimal costs, and thus be highly profitable.

Further more, due to our emphasis on systematic orientation of parts, our solution provides well
compartmentalized transmission systems, leading to a highly effective product which is simple to
manufacture

17