DESIGN AND FABRICATION OFAUTOMATI PAINTING MACHINE

ABSTRACT
The initial aim of the project is to design, develop and utensil Automatic
Wall Painting machine which helps to resolve low cost painting attachment. The
advances in machining and its wide spreading applications, interior wall painting
has shared little in research activities. The painting chemicals can cause unsafe to
the human painters such as eye and inhaling system problems. Also the nature of
painting procedure that requires repeated work and hand rising makes it boring,
time and effort consuming. When construction workers and robots are properly
combine in building tasks, the whole architecture process can be better managed
and savings in human labor and timing are obtained as a consequence. In addition,
it would offer the opportunity to reduce or eliminate human exposure to difficult
and unsafe environments, which would solve most of the problems connected with
safety when many activities occur at the same time. These factors motivate the
development of an automated robotic painting system.

The objective of this project is to design a robot for spray painting

application. This project is very useful in industries for spray painting the
components. This project is designed by following blocks Microcontroller, Object
sensor, and conveyor, pick and place arrangement, Driver circuit with relay,
Solenoid valve and Motor
 1. INTRODUCTION

Today industrial automation of spray painting is limited to high part volumes

and robot trajectories that are programmed by off-line programming and manual
teach-in this presents an approach that uses geometry of an unknown part and to
automatically generate the robot spray painting trajectories. (a geometric library
containing constraints specific for the painting application) geometric primitives
are detected in the range data. From the geometric primitives a normal vector field
is generated that enables to extract main faces. The process knowledge related to
each geometric primitive is utilized to obtain the trajectory for the paint gun.
Results of painting a car mirror and a steering column are given.
The objective of the project is to automate robot programming for painting
applications of small lot sizes with a very high number of part variants. Presently
robotic painting is economically feasible for large lot sizes, since a robot needs to
be established (using off-line programming and/or manual teach-in) for each single
part variant.
The project goal is to provide commercial capabilities for usage of robots in
painting of large part families. The goal is to reduce human programming effort by
75 percent and the human spray painting effort by 90 percent. The technical
challenge is to develop a method that can fulfill the spray painting task similar to a
human painter, who is able to paint a geometry never seen before. The project
objective is to provide commercial capabilities for usage of machines for industrial
painting tasks. As a matter of fact, economic realization hinder the application of
the currently used conventional automation technology (off-line programming
and/or manual teach-in) used for high volume production.
 CHAPTER 2

POWER SCREWS

A power screw is a mechanical device used for converting rotary motion into linear
motion and transmitting power. A power screw is also called translation screw. It
uses helical translator motion of the screw thread in transmitting power rather than
clamping the machine components.
2.1 Applications
The main applications of power screws are as follows:
(i) To raise the load, e.g. screw-jack,
(ii) To obtain accurate motion in machining operations, e.g. lead-screw of lathe,
(iii)To clamp a work piece, e.g. vice, and
(iv) To load a specimen, e.g. universal testing machine.

There are three essential parts of a power screw, viz. screw, nut and a part to hold
either the screw or the nut in its place. Depending upon the holding arrangement,
power screws operate in two different ways. In some cases, the screw rotates in its
bearing, while the nut has axial motion. The lead screw of the lathe is an example
of this category. In other applications, the nut is kept stationary and the screw
moves in axial direction. Screw-jack and machine vice are the examples of this
category.
2.2 Advantages
Power screws offer the following advantages:
(i) Power screw has large load carrying capacity.
(ii) The overall dimensions of the power screw are small, resulting in
compact construction.
(iii) Power screw is simple to design
(iv) The manufacturing of power screw is easy without requiring
specialized machinery. Square threads are turned on lathe. Trapezoidal
threads are manufactured on thread milling machine.
(v) Power screw provides large mechanical advantage. A load of 15 kN
can be raised by applying an effort as small as 400 N.Therefore, most of
the power screws used in various applications like screw-jacks, clamps,
valves and vices are usually manually operated.
2.3 Disadvantages
The disadvantages of power screws are as follows:
(i)Power screws have very poor efficiency; as low as 40%.Therefore, it is not used
in continuous power transmission in machine tools, with the exception of the lead
screw. Power screws are mainly used for intermittent motion that is occasionally
required for lifting the load or actuating the mechanism.

(ii)High friction in threads causes rapid wear of the screw or the nut. In case of
square threads, the nut is usually made of soft material and replaced when worn
out. In trapezoidal threads, a split- type of nut is used to compensate for the wear.
Therefore, wear is a serious problem in power screws.

2.4 Forms of Threads

There are two popular types of threads used for power screws viz. square
and I.S.O metric trapezoidal.

2.4.1 Advantages of square threads

The advantages of square threads over trapezoidal threads are as follows:
(i)The efficiency of square threads is more than that of trapezoidal threads.
(ii)There is no radial pressure on the nut. Since there is no side thrust, the
motion of the nut is uniform. The life of the nut is also increased.
2.4.2 Disadvantages of square threads
The disadvantages of square threads are as follows:
(i)Square threads are difficult to manufacture. They are usually turned on lathe
with single-point cutting tool. Machining with single-point cutting tool is an
expensive operation compared to machining with multi-point cutting tool.
(ii) The strength of a screw depends upon the thread thickness at the core diameter.
Square threads have less thickness at core diameter than trapezoidal threads. This
reduces the load carrying capacity of the screw.

(iii)The wear of the thread surface becomes a serious problem in the service life of
the power screw. It is not possible to compensate for wear in square threads.
Therefore, when worn out, the nut or the screw requires replacement.

2.4.3 Advantages of Trapezoidal Threads

The advantages of trapezoidal threads over square threads are as follows:
(i) Trapezoidal threads are manufactured on thread milling machine. It employs
multi-point cutting tool. Machining with multi-point cutting tool is an economic
operation compared to machining with single point-cutting tool. Therefore,
trapezoidal threads are economical to manufacture.

(ii)Trapezoidal thread has more thickness at core diameter than that of square
thread.Therfore; a screw with trapezoidal threads is stronger than equivalent screw
with square threads. Such a screw has large load carrying capacity.

(iii)The axial wear on the surface of the trapezoidal threads can be compensated by
means of a split-type of nut. The nut is cut into two parts along the diameter. As
wear progresses, the looseness is prevented by tightening the two halves of the nut
together, the split-type nut can be used only for trapezoidal threads. It is used in
lead-screw of lathe to compensate wear at periodic intervals by tightening the two
halves.
2.4.4 Disadvantages of Trapezoidal Threads
The disadvantages of trapezoidal threads are as follows:
(i)The efficiency of trapezoidal threads is less than that of square threads.
(ii)Trapezoidal threads result in side thrust or radial pressure on the nut. The
radial pressure or bursting pressure on nut affects its performance.

There is a special type of thread called acme thread. Trapezoidal and acme threads
are identical in all respects except the thread angle. In acme thread, the thread
angle is 29° instead of 30°.The relative advantages and disadvantages of acme
threads are same as those of trapezoidal threads.
There is another type of thread called buttress thread. It combines the advantages
of square and trapezoidal threads. Buttress threads are used where heavy axial
force acts along the screw axis in one direction only.
2.4.5 Advantages of Buttress Threads
The advantages of buttress threads are as follows:
(i) It has higher efficiency compared to trapezoidal threads.

(ii) It can be economically manufactured on thread milling machine.

(iii) The axial wear at the thread surface can be compared by means of spit-type
nut.
(iv) A screw with buttress threads is stronger than equivalent screw with either
square threads or trapezoidal threads. This is because of greater thickness at the
base of the thread.

The buttress threads have one disadvantage. It can transmit power and motion only
in one direction. On the other hand, square and trapezoidal threads can transmit
force and motion in both directions.
Square threads are used for screw-jacks, presses and clamping devices.
Trapezoidal and acme threads are used for lead-screw and other power
transmission devices in machine tools. Buttress threads are used in vices, where
force is applied only in one direction. Buttress threads are ideally suited for
connecting tubular components that must carry large forces such as connecting the
barrel to the housing in anti air-craft guns.
2.5 Designation of Threads
There is a particular method of designation for square and trapezoidal threads. A
power screw with single-start square threads is designated by the letters „Sq‟
followed by the nominal diameter and the pitch expressed in millimeters and
separated by the sign „x‟. For example,
Sq 30 x 6
It indicates single-start square threads with 30mm nominal diameter and 6mm
pitch. Similarly single-start I.S.O metric trapezoidal threads are designated by
letters „Tr‟ followed by the nominal diameter and the pitch expressed in
millimeters and separated by the sign „x‟.For example,
Tr 40x7
It indicates single-start trapezoidal threads with 40mm nominal diameter and
7mm pitch.
2.5.1 Multiple Threaded Power Screws
Multiple threaded power screws are used in certain applications where higher
travelling speed is required. They are also called multiple start screws such as
double-start or triple-start screws. These screws have two or more threads cut side
by side, around the rod.

Multiple-start trapezoidal threads are designated by letters „Tr‟ followed by the

nominal diameter and the lead ,separated by sign „x‟ and in brackets the letter „P‟
followed by the pitch expressed in millimetres. For example,
Tr 40 x 14 (P7)
In above designation,
Lead=14mm pitch=7mm
Therefore, No. of starts =14/7=2

It indicates two-start trapezoidal thread with 40mm nominal diameter and 7mm
pitch. In case of left handed threads. The letters „LH‟ are added to thread
designation. For example,
Tr 40 x 14 (P7) LH
2.6 Terminology of Power Screw
The terminology of the screw thread is as follows:

(i) Pitch: The pitch is defined as the distance, measured parallel to the axis of the
screw, from a point on one thread to the corresponding point on the adjacent
thread. It is denoted by the letter„p‟.

(ii)Lead: The lead is defined as the distance, measured parallel to the axis of the
screw, that the nut will advance in one revolution of the screw. It is denoted by the
letter „l‟. For a single-threaded screw, the lead is same as the pitch, for a double-
threaded screw, the lead is twice that of the pitch, and so on.

(iii)Nominal diameter: It is the largest diameter of the screw. It is also

called major diameter. It is denoted by the letter„d‟.

(iv) Core diameter: It is the smallest diameter of the screw thread. It is also called
minor diameter. It is denoted by the letters „dc‟.

(v) Helix angle: It is defined as the angle made by the helix of the thread with a
plane perpendicular to the axis of the screw. Helix angle is related to the lead and
the mean diameter of the screw. It is also called lead angle. It is denoted by α.

From the figure,

dc = d- [ + ]

or,
dc= (d-p)
The mean diameter of the screw is denoted by dm and it is given by,
dm= [d +dc]

= [d + (d-p)]

Or, dm= (d-0.5p)

Imagine that one thread of the screw is unwound and developed for one complete
turn. The thread will become the hypotenuse of a right-angled triangle, whose base
is (πdm) and whose height is the lead (l).Considering this right-angle triangle, the
relationship between helix angle, mean diameter and lead can be expressed in the
following form,
Tan α =

where α is the helix angle of the thread.

The following conclusions can be drawn on the basis of the development of
thread: (i)The screw can be considered as an inclined plane with α as inclination.
(ii) The load W always acts in vertically downward direction. When the load W is
raised, it moves up the inclined plane. When the load W is lowered, it moves
down the inclined plane.
(iii)The load W is raised or lowered by means of an imaginary force P acting at the
mean radius of the screw. The force P multiplied by the mean radius (d m/2) gives
the torque required to raise or lower the load. Force P is perpendicular to load W.

Torque Requirement- Lifting Load

The screw is considered as an inclined plane with inclination α.When the load is
being raised, following forces act at a point on this inclined plane:
(i) Load W: It always acts in vertically downward direction.
(ii) Normal reaction N: It acts perpendicular (normal) to the inclined plane.
(iii)Frictional force μN: Frictional force acts opposite to the motion. Since the
load is moving up the inclined plane, frictional force acts along the inclined plane
in downward direction.

(iv)Effort P: The effort P acts in a direction perpendicular to the load W.It may act
towards right to overcome the friction and raise the load.
For an equilibrium of horizontal forces,
P = μ N cos α + N sin α (a)
For an equilibrium of vertical forces,
W = N cos α – μ N sin α (b)
Dividing expression (a) by (b),
P=

Dividing the numerator and denominator of the right hand side by cos α,
P= (c)

The coefficient of friction μ is expressed as,

μ = tan θ (d)
where θ is the friction angle.
Substituting μ = tan θ in Eq.
(c),

P
=

or P = W tan (θ + α) (e)
The torque „T‟ required to raise the load is given by,

T=

(f
T= tan (θ + α) )
2.8 Torque Requirement- Lowering Load

When the load is being lowered, the following forces act at a point on the inclined
plane:
(i) Load W: It always acts in vertically downward direction.

(ii) Normal reaction N: It acts perpendicular (normal) to the inclined plane.

(iii) Frictional force μN: Frictional force acts opposite to the motion. Since the
load is moving down the inclined plane, frictional force acts along the inclined
plane in upward direction.

(iv) Effort P: The effort P acts in a direction perpendicular to the load W.It
should act towards left to overcome the friction and lower the load.
For an equilibrium of horizontal forces,
P = μ N cos α - N sin α (a)
For an equilibrium of vertical forces,
W = N cos α + μ N sin α (b)
Dividing expression (a) by (b),
P=

Dividing the numerator and denominator of the right hand side by cos α,
P= (c)

The coefficient of friction μ is expressed as,

μ = tan θ (d)
where θ is the friction angle.
Substituting μ = tan θ in Eq. (c),
 P=

or P = W tan (θ - α) (e)
The torque „T‟ required to raise the load is given by,
T=

T= tan (θ - α)

2.9 Self Locking Screw

The torque required to lower the load can be given by,
T= tan (θ - α)

It can be seen that

when,
θ
the torque required to lower the load is negative. It indicates a condition that
no force is required to lower the load. The load itself will begin to turn the screw
and descend down, unless a restraining torque is applied. This condition is called
„overhauling‟ of screw.
When,
θ
a positive torque is required to lower the load. Under this condition, the load will
not turn the screw and will not descend on its own unless effort P is applied. In this
case, the screw is said to be „self-locking‟. The rule for self-locking screw is as
follows:

A screw will be self-locking if the coefficient of friction ids equal to or greater

than the tangent of the helix angle.
For self locking screw,
θ>α
tan θ > tan α
μ>

Therefore, the following conclusions can be made:

(i) Self-locking of screw is not possible when the coefficient of friction (μ) is low.
The coefficient of friction between the surfaces of the screw and the nut is reduced
by lubrication. Excessive lubrication may cause the load to descend on its own.

(ii) Self-locking property of the screw is lost when the lead is large. The lead
increases with number of starts. For double-start thread, lead is twice of the pitch
and for triple threaded screw, three times of pitch. Therefore, single threaded is
better than multiple threaded screw from self-locking considerations.

Self-locking condition is essential in applications like screw-jack.

.10 Efficiency of Square Threaded Screw

Refer to the force diagram for lifting the load, illustrated in Fig. .Suppose the load
W moves from the lower end to the upper end of the inclined plane. The output
consists of raising the load. Therefore,
Work output = force x distance travelled in the direction of force
=Wxl

The input consists of rotating the screw by means of an effort P.

Work output = force x distance travelled in the direction of force
= P x (π dm)
The efficiency η of the screw is given by,
η=

= tan α
Substituting P = W tan (θ + α) in the above equation,
η=

From the above equation, it is evident that the efficiency of the square threaded
screw depends upon the helix angle α and the friction angle θ.The following figure
shows the variation of the efficiency of square threaded screw against the helix
angle for various values of coefficient of friction. The graph is applicable when the
load is lifted.

Following conclusions can be derived from the observation of these graphs,

(i)The efficiency of square threaded screw increase rapidly up to helix angle of

20°.

(ii)The efficiency is maximum when the helix angle between 40 to 45°.

(iii)The efficiency decreases after the maximum value is reached.

(iv) The efficiency decreases rapidly when the helix angle exceeds 60°
(v)The efficiency decreases as the coefficient of friction increases.

There are two ways to increase the efficiency of square threaded screws. They are
as follows:

(i) Reduce the coefficient of friction between the screw and the nut by
proper lubrication, and

(ii) Increase the helix angle up to 40 to 45° by using multiple start threads.

However, a screw with such helix angle has other disadvantages like loss of self-
locking property.

2.11 Efficiency of Self-Locking Screw

The efficiency of square threaded screw is given by,

η= (a)

For self-locking screw,

θ α
Substituting the limiting value (θ = α) in (a),
η

Substituting,

tan (2θ) =

in the above expression,

 η

Or, η [ - ]

Therefore, efficiency of self-locking square threaded power screw is less than ½ or

50%.
2.12 Efficiency of Trapezoidal and Acme Threads

The thread angle is 2θ.For isometric I.S.O metric trapezoidal thread,

2θ = 30°
For acme thread,
2θ = 29°
There is a basic difference between the force acting on the thread of square and
trapezoidal threads. In case of square threads, W is the axial load raised by the
screw. It is also the normal force acting on the thread surface. In case of
trapezoidal or acme threads, these two forces are different. The axial force on the
screw is W, while the normal force on the thread surface is (W/cos θ) or (Wsec
θ).The frictional force depends upon the normal force.Therefore; the effect of
thread angle is to increase the frictional force by a term (sec θ).This is because of
the wedging action of the threads. The coefficient of friction is taken as (μ sec θ)
instead of μ in case of trapezoidal threads and the equations derived for square
threaded screw are modified and used for trapezoidal or acme threads.
2.13 Coefficient of Friction
It has been found that the coefficient of friction (μ) at the thread surface depends
upon the workmanship in cutting the threads and on the type of the lubricant. It is
practically independent of the load, rubbing velocity or materials. An average of
0.15 can be taken for the coefficient of friction, when the screw is lubricated with
mineral oil.
2.14 Stresses in Screw and Nut
The body of a screw is subjected to an axial force W and torsional moment
(T).The direct compressive stress Fc is given by,
Fc =

The torsional shear stress is given

by, Ft =

The principal shear stress is given by,

Fs =
The threads of the screw which are engaged with the nut are subjected to
transverse shear stresses. The screw will tend to shear off the threads at the core
diameter under the action of load W.The shear area of one thread is πdc t. The
transverse shear stress in the screw is given by,
Ts =

Where,

Ts = transverse shear stress at the root of the screw (N/mm²)

t = thread thickness at the core diameter (mm)

n = number of threads in engagement with the nut.

The transverse shear stresses in the nut are determined in a similar way. Under the
action of load W, the thread of the nut will tend to shear off at the nominal
diameter. The shear area of one thread is πdt.Therefore,
Tn =

where,
Tn = transverse shear stress at the root of the nut (N/mm²)
t = thread thickness at the root of the nut (mm).
The bearing pressure between the contacting surfaces of the screw and the nut
is an important consideration in design. The bearing area between the screw
and the nut for one thread is

[ ].Therefore,

Pb =
( )

where Pb = unit bearing pressure(N/mm²)

The permissible bearing pressure depends upon the materials of the screw and
the nut and the rubbing velocity.
2.15 Buckling of Columns

When a short member is subjected to axial compressive force, it shortens according

to the Hooke‟s law. As the load is gradually increased, the compression of the
member increases. When the compressive stress reaches the elastic limit of the
material, the failure occurs in the form of bulging.However, when the length of the
component is large compared to the cross-sectional dimensions, the component
may fail by lateral buckling. Buckling indicates elastic instability. The load at
which the buckling starts is called critical load, which is denoted by P cr. When the
axial load on the column reaches P cr, there is sudden buckling and a relatively large
lateral deflection occurs.

An important parameter affecting the critical load is the slenderness ratio. It

is defined as, Slenderness ratio =
where,
l = length of column (mm)
k = least radius of gyration of the cross-section about its axis (mm)
The radius of gyration is given by,

k=
where,
I = least moment of inertia of the cross-
section (mm4) A = area of the cross-section
(mm2)
When the slenderness ratio is less than 30, there is no effect of buckling and such
components are designed on the basis of compressive stresses. Columns, with
slenderness ratio greater than 30 are designed on the basis of critical load. There
are two methods to calculate the critical load-

Euler‟s equation and Johnson‟s

equation. According to the Euler‟s
equation,
Pcr =

where,
Pcr = critical load (N).
n = end fixity coefficient
E = modulus of elasticity (N/mm²)
A = area of cross-section (mm²)

The load carrying capacity of the column depends upon the condition of restraints
at the two ends of the column. It is accounted by means of a dimensionless
quantity called end fixity coefficient (n).

According to Johnson‟s equation,

Pcr = Syt A [1 - ]

where Syt is the yield strength of the material.

4.3.1 D.c. motor (permanent magnet)

Description of dc motor

An electric motor is a machine which converts electrical energy to mechanical

energy. Its action is based on the principle that when a current-carrying conductor
is placed in a magnetic field, it experiences a magnetic force whose direction is
given by Fleming‟s left hand rule.

When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt
wound or series wound or compound wound motors.
Fleming’s Left Hand Rule

Keep the force finger, middle finger and thumb of the left hand mutually
perpendicular to one another. If the fore finger indicates the direction of magnetic
field and middle finger indicates

direction of current in the conductor, then the thumb indicates the direction of the
motion of conductor.
Principle of Operation of Dc Motor

A uniform magnetic field in which a straight conductor carrying no current is

placed. The conductor is perpendicular to the direction of the magnetic field.
The conductor is shown as carrying a current away from the viewer, but the field
due to the N and S poles has been removed. There is no movement of the
conductor during the above two conditions. When the current carrying conductor is
placed in the magnetic field, the field due to the current in the conductor supports
the main field above the conductor, but opposes the main field below the
conductor.
Movement of
Conductor

N S

Magnetic flux current carrying Conductor

The result is to increase the flux density in to the region directly above the
conductor and to reduce the flux density in the region directly below the conductor.
It is found that a force acts on the conductor, trying to push the conductor
downwards as shown by the arrow. If the current in the conductor is reversed, the
strengthening of flux lines occurs below the conductor, and the conductor will be
pushed upwards.
Now consider a single turn coil carrying a current. In view of the reasons
given above, thone side of the coil will be forced to move downwards, whereas the
other side will be forced to move upwards. The forces acting on both the coil sides
will be of same magnitude. But their direction is opposite to one another. As the
coil is wound on the armature core which is supported by the bearings, the
armature will now rotate. The commutator periodically reverses the direction of
current flow through the armature. Therefore the armature will have a continuous
rotation.
A simplified model of such a motor is shown in figure VI. The conductors
are wound over a soft iron core. DC supply is given to the field poles for producing
flux. The conductors are connected to the DC supply through brushes
A simple 2-pole DC electric motor has 6 parts, as shown in the diagram below.
 An armature or rotor
 A commutator
 Brushes
 An axle
 A field magnet
 A DC power supply of some sort

An electric motor is all about magnets and magnetism: a motor uses magnets
to create motion. Opposites attract and likes repel.
So if there are 2 bar magnets with their ends marked north and south, then
the North end of one magnet will attract the South end of the other. On the other
hand, the North end of one magnet will repel the North end of the other (and
similarly south will repel south). Inside an electric motor these attracting and
repelling forces create rotational motion.
In the diagram above, you can see two magnets in the motor, the armature
(or rotor) is an electromagnet, while the field magnet is a permanent magnet (the
field magnet could be an electromagnet as well, but in most small motors it is not
to save power).
Electromagnets and Motors
An electromagnet is the basis of an electric motor. You can understand how
things work in the motor by imagining the following scenario. Say that you created
a simple electromagnet by wrapping 100 loops of wire around a nail and
connecting it to a battery. The nail would become a magnet and have a North and
South pole while the battery is connected.
Now say that you take your nail electromagnet, run an axle through the
middle of it, and you suspended it in the middle of a horseshoe magnet as shown in
the figure below. If you were to attach a battery to the electromagnet so that the
North end of the nail appeared as shown, the basic law of magnetism tells you
what would happen: The North end of the electromagnet would be repelled from
the north end of the horseshoe magnet and attracted to the south end of the
horseshoe magnet.
The South end of the electromagnet would be repelled in a similar way. The
nail would move about half a turn and then stop in the position shown.
You can see that this half-turn of motion is simple and obvious because of
the way
magnets naturally attractand repel one
another. The key to an electric motor
is to then go one step further so that,
at the moment that this half-turn of
motion completes, the field of the
electromagnet flips. The flip causes
the electromagnet to complete another
half-turn of motion. You flip the
magnetic field simply by changing the
direction of the electrons flowing in
the wire (you do that by flipping
the battery over). If the field of the
electromagnet flipped at just the right
moment at the end of each half-turn of
motion, the electric motor would spin
freely.
 The Armature

The armature takes the place of the nail in an electric motor.

The armature is an electromagnet made by coiling thin wire
around two or more poles of a metal core. The armature has
an axle, and the commutator is attached to the axle. In the
diagram above you can see three different views of the same
armature: front, side and end-on. In the end-on view the
winding is eliminated to make the commutator more obvious.
The commutator is simply a pair of plates attached to the
axle. These plates provide the two connections for the coil of
the electromagnet.
The Commutator and brushes

The "flipping the electric field" part of an electric motor is

accomplished by two parts: the commutator and the
brushes. The diagram at the right shows how the commutator
and brushes work together to let current flow to the
electromagnet, and also to flip the direction that the electrons
are flowing at just the right moment. The contacts of the
commutator are attached to the axle of the electromagnet, so
they spin with the magnet. The brushes are just two pieces of
springy metal or carbon that make contact with the contacts
of the commutator.
Putting It All Together
When you put all of these parts together, what you have is a complete
electric motor:

In this figure, the armature winding has been left out so that it is easier to see
the commutator in action. The key thing to notice is that as the armature passes
through the horizontal position, the poles of the electromagnet flip. Because of the
flip, the North pole of the electromagnet is always above the axle so it can repel the
field magnet's North pole and attract the field magnet's South pole. If you ever take
apart an electric motor you will find that it contains the same pieces described
above: two small permanent magnets, a commutator, two brushes and an
electromagnet made by winding wire around a piece of metal. Almost always,
however, the rotor will have three poles rather than the two poles as shown in this
article. There are two good reasons for a motor to have three poles:
It causes the motor to have better dynamics. In a two-pole motor, if the
electromagnet is at the balance point, perfectly horizontal between the two
poles of the field magnet when the motor starts; you can imagine the
armature getting "stuck" there. That never happens in a three-pole motor.

Each time the commutator hits the point where it flips the field in a two-pole
motor, the commutator shorts out the battery (directly connects the positive
and negative terminals) for a moment. This shorting wastes energy and
drains the battery needlessly. A three-pole motor solves this problem as well.

It is possible to have any number of poles, depending on the size of the

motor and the specific application it is being used in.

4.3.1.1 Design of d.c. motor

Torque in a motor
By the term torque, it is meant the turning or twisting moment of a force
about an axis. It is measured by the product of the force and the radius at
which this force acts.
For an armature of a motor, to rotate about its centre, a tangential force
is necessary. This force is developed within the motor itself.
Torque (T) = ½ ( Ia / A ) BDC Z Newton
meters Using the relation,
B = φ/a
= φ/(ΠD/P)ł
= φ x P / ( Π Dł )
T = ½ x (Ia / A) x Z x φ x {P/ (ΠDł) } x Dł
= φ Z P Ia / ( 2ΠA ) Newton meters
= 0.159 x φ x Z x Ia X (P/A) Newton meters
= 0.162 x φ x Z x Ia x (P/A) Kg-m
 The torque given by the above equation is the developed torque in the
machine. But the output torque is less than the developed torque due to friction
and wind age losses.
4.3.2 Batteries
4.3.2.1 Introduction
In isolated systems away from the grid, batteries are used for storage of
excess solar energy which can be converted into electrical energy. In fact for small
units with output less than one kilowatt, batteries seem to be the only technically
and economically available storage means. Since both the photo-voltaic system and
batteries are high in capital costs, it is necessary that the overall system be
optimized with respect to available energy and local demand pattern.
To be economically attractive the storage of solar electricity requires a battery with
a particular combination of properties:
(1) Low cost
(2) Long life
(3) High reliability
(4) High overall efficiency
(5) Low discharge
(6) Minimum maintenance
(A) Ampere hour efficiency
(B) Watt hour efficiency
4.3.2.2 Lead-acid wet cell
Where high values of load current are necessary, the lead-acid cell is the
type most commonly used. The electrolyte is a dilute solution of sulfuric acid
(H₂SO₄). In the application of battery power to start the engine in an auto mobile,
for example, the load current to the starter motor is typically 200 to 400A. One cell
has a nominal output of 2.1V, but lead-acid cells are often used in a series
combination of three for a 6-V battery and six for a 12-V battery.
The lead acid cell type is a secondary cell or storage cell, which can be
recharged. The charge and discharge cycle can be repeated many times to restore
the output voltage, as long as the cell is in good physical condition. However, heat
with excessive charge and discharge currents shortens the useful life to about 3 to 5
years for an automobile battery. Of the different types of secondary cells, the lead-
acid type has the highest output voltage, which allows fewer cells for a specified
battery voltage.
4.3.2.3 Construction
Inside a lead-acid battery, the positive and negative electrodes consist of a
group of plates welded to a connecting strap. The plates are immersed in the
electrolyte, consisting of 8 parts of water to 3 parts of concentrated sulfuric acid.
Each plate is a grid or framework, made of a lead-antimony alloy. This
construction enables the active material, which is lead oxide, to be pasted into the
grid. In manufacture of the cell, a forming charge produces the positive and
negative electrodes. In the forming process, the active material in the positive plate
is changed to lead peroxide (pbo₂). The negative electrode is spongy lead (pb).
Automobile batteries are usually shipped dry from the manufacturer. The
electrolyte is put in at the time of installation, and then the battery is charged.With
maintenance-free batteries, little or no water is needed to be added in normal
service. Some types are sealed, except for a pressure vent, without provision for
adding water.
4.3.2.4 Chemical action
Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell
discharges, lead peroxide from the positive electrode combines with hydrogen ions
to form water and with sulfate ions to form lead sulfate. Combining lead on the
negative plate with sulfate ions also produces sulfate. Therefore, the net result of
discharge is to produce more water, which dilutes the electrolyte, and to form lead
sulfate on the plates.
As the discharge continues, the sulfate fills the pores of the grids, retarding
circulation of acid in the active material. Lead sulfate is the powder often seen on
the outside terminals of old batteries. When the combination of weak electrolyte
and sulfating on the plate lowers the output of the battery, charging is necessary.
 On charge, the external D.C. source reverses the current in the battery. The
reversed direction of flow of ions in the electrolyte results in a reversal of the
chemical reactions. Now the lead sulfates on the positive plate reacts with the
water and sulfate ions to produce lead peroxide and sulfuric acid. This action re-
forms the positive plates and makes the electrolyte stronger by adding sulfuric
acid.
At the same time, charging enables the lead sulfate on the negative plate to
react with hydrogen ions; this also forms sulfuric acid while reforming lead on the
negative plate to react with hydrogen ions. It also results in formation of current
which can restore the cell to full output, with lead peroxide on the positive plates,
spongy lead on the negative plate, and the required concentration of sulfuric acid in
the electrolyte.

The chemical equation for the lead-acid cell is

Charge

Pb + pbO₂ + 2H₂SO₄ 2pbSO₄ + 2H₂

Discharge
On discharge, the pb and pbo₂ combine with the SO₄ ions at the left side of the
equation to formlead sulfate (pbSO₄) and water (H₂O) at the right side of the
equation.

One battery consists of 6 cells, each having an output voltage of 2.1V, which
are connected in series to get a voltage of 12V and the same 12V battery is
connected in series, to get an 24 V battery. They are placed in the water proof iron
casing box.
4.3.2.5 Caring For Lead-Acid Batteries
Always use extreme caution when handling batteries and electrolyte. Wear
gloves, goggles and old clothes. “Battery acid” will burn skin and eyes and destroy
cotton and wool clothing.
The quickest way of ruining lead-acid batteries is to discharge them deeply
and leave them stand “dead” for an extended period of time. When they discharge,
there is a chemical change in the positive plates of the battery. They change from
lead oxide (when charged) to lead sulfate when discharged. If they remain in the
lead sulfate state for a few days, some part of the plate does not return to lead
oxide when the battery is recharged. If the battery remains in a discharged state for
a longer time, a greater amount of the positive plate will remain lead sulfate. The
parts of the plates that become “sulfate”, no longer store energy. Batteries that are
deeply discharged, and then charged partially on a regular basis can fail in less then
one year.
Check your batteries on a regular basis to be sure they are getting charged.
Use a hydrometer to check the specific gravity of your lead acid batteries. If
batteries are cycled very deeply and then recharged quickly, the specific gravity
reading will be lower than it should be because the electrolyte at the top of the
battery may not have mixed with the “charged” electrolyte.
Check the electrolyte level in the wet-cell batteries at least four times a year
and top each cell with distilled water. Do not add water to discharged batteries.
Electrolyte is absorbed when batteries are discharged. If you add water at this time,
and then recharge the battery, electrolyte will overflow and make a mess.
Keep the top of your batteries clean and check that cables are tight. Do not
tighten or remove cables while charging or discharging. Any spark around batteries
can cause a hydrogen explosion inside, and ruin one of the cells.
 On charge, with reverse current through the electrolyte, the chemical action
is reversed. Then the pb ions from the lead sulfate on the right side of the equation
re-form the lead and lead peroxide electrodes. Also the SO₄ ions combine with H₂
ions from the water to produce more sulfuric acid at the left side of the equation.
As an example, a 200 A.h battery can supply a load current of 200/8 or 25A,
used on 8h discharge. The battery can supply less current for a longer time or more
current for a shorter time. Automobile batteries may be rated for “cold cranking
power”, which is related to the job of starting the engine. A typical rating is 450A
for 30s at a temperature of 0 degree F.
The ratings for lead-acid batteries are given for a temperature range of 77 to
80ºF. Higher temperature increases the chemical reaction, but operation above
110ºF shortens the battery life.
Low temperatures reduce the current capacity and voltage output. The
ampere-hour capacity is reduced approximately 0.75% for each decreases of 1º F
below normal temperature rating. At 0ºF the available output is only 60 % of the
ampere-hour battery rating.
In cold weather, therefore, it is very important to have an automobile battery
unto full charge. In addition, the electrolyte freezes more easily when diluted by
water in the discharged condition.
4.3.2.7 Specific Gravity
Measuring the specific gravity of the electrolyte generally checks the state of
discharge for a lead-acid cell. For instance, concentrated sulfuric acid is 1.835
times as heavy as water for the same volume. Therefore, its specific gravity equals
1.835. The specific gravity of water is 1, since it is the reference.
In a fully charged automotive cell, mixture of sulfuric acid and water results
in a specific gravity of 1.280 at room temperatures of 70 to 80ºF. As the cell
discharges, more water is formed, lowering the specific gravity. When it is down to
about 1.150, the cell is completely discharged.
Specific-gravity readings are taken with a battery hydrometer.Note that the
calibrated float with the specific gravity marks will rest higher in an electrolyte of
higher specific gravity.
The importance of the specific gravity can be seen from the fact that the
open-circuit voltage of the lead-acid cell is approximately equal to
 V = Specific gravity + 0.84

For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an
example.

These values are for a fully charged battery.

4.3.2.8 Charging the Lead-Acid Battery
An external D.C. voltage source is necessary to produce current in one
direction. Also, the charging voltage must be more than the battery e.m.f.
Approximately 2.5 per cell are enough to produce current opposite to the direction
of discharge current.
Note that the reversal of current is obtained just by connecting the battery
VB and charging source VG with + to + and –to. The charging current is reversed
because the battery effectively becomes a load resistance for VG when it higher
than VB. In this example, the net voltage available to produce charging currents is
15-12=3V.
A commercial charger for automobile batteries is essentially a D.C. power
supply, rectifying input from the AC power line to provide D.C. output for
charging batteries.
Float charging refers to a method in which the charger and the battery are
always connected to each other for supplying current to the load. In figure the
charger provides current for the load and the current necessary to keep the battery
fully charged. The battery here is an auxiliary source for D.C. power.
It may be of interest to note that an automobile battery is in a floating-charge
circuit. The battery charger is an AC generator or alternator with rectifier diodes,
driven by a belt from the engine.When you start the car, the battery supplies the
cranking power. Once the engine is running, the alternator charges the battery. It is
not necessary for the car to be moving. A voltage regulator is used in this system to
maintain the output at approximately 13 to 15 V.It is a good idea to equalize
charge when some cells show a variation of 0.05 specific gravity from each other.
With proper care, lead-acid batteries will have a long service life and work very
well in almost any power system.
WORKING PRINCIPLE

D.C. MOTOR
Almost every mechanical movement that we see around us is accomplished
by an electric motor. Motors take electrical energy and produce mechanical energy.
Electric motors are used to power hundreds of devices we use in everyday life.
Motors come in various sizes. In most cases, regardless of type, electric motors
consist of a stator (stationary field) and a rotor (the rotating field or armature) and
operate through the interaction of magnetic flux and electric current to produce
rotational speed and torque. In our systems 1 HP motor is used.
B WARM GEAR
The warm and warm wheel gear uses two spur gears one of small size and
another larger size to achieve the speed reduction ratio. Most of the industrial
systems uses the warm gear to achieve the speed reduction. The rotational speed
from the D.C. motor is reduced to 30 RPM by this warm gear.
C CHAINS AND SPROKET
The shaft is attached to warm gear and sprocket. The rotation of gear will
rotates the sprocket. The chain which is meshed with sprocket moves along the
rotation of sprocket. The sprocket and chain moves with same speed as the gear
speed.
SPRAY GUN
The table which is attached to the chains moves in vertical direction along
with movement of chain. The sprayer is mounted on table. The movement of the
table helps the sprayer to move along the path to paint all the area of the wall. The
sprayer works with the help of blower to spray paint on wall surface.
E BLOWER
The helps the sprayer to spray the paint with its high velocity air. The blower
works the power supply of230V. Most of spraying applications uses compressor or
blower as the main source. Here as well we use blower as main source to spray
connected by flexible hose230V. Most of spraying applications uses compressor or
blower as the main source. Here as well we use blower as main source to spray
connected by flexible hose

2. REVIEW OF LITERATURE
Mohamed Abdellatif
In this paper author describe the design and working of an automatic wall
painting robot machine. The visionary design of a movable painting robot to be
used for painting interior walls of residential building had been described. The
robot uses roller fed with liquid paint and keeps contact with the wall surface. The
robot enables the roller to scan vertically as well as horizontally to the painted
walls. The robot can maneuver to adjust itself in front of the wall.

Dhaval Thakar
This paper gives basic information about small and medium scale industries
manufacturing
components have to paint for protecting from rusting so the spray application
consumes maximum time and paint which required the skilled worker emerged
with the application. They cannot manage robotic arrangement for higher
efficiency so the rise of the such process have to be made which is affordable,
gives better accuracy, consumes minimum time for coating so objective has to
developed such mechanism which coat the object with the dipping technique
having semi-automatic arrangement which is suitable for our requirement and
which can be valuable for small and medium scale industries.

P.Keerthanaa They research that automatically paint the wall surface of

given importance has been designed and accompanist in massive manner. The
approach uses Infrared transmitter and flaming receiver to identify the appearance
of wall. The microcontroller unit to regulate the movement of the DC motor. The
robot wipes out the risky caused due to the painting chemicals to the human
painters and also the nature of painting techniques that require imitated work and
hand rising makes it dull, time consuming. The robot is cost effective, reduces
work force or labors, reduces time consumption. The drawback of the project is
that the robot continues painting later the end of the wall so it can be eliminated by
adding some indicating objects such as alarms.

Berardo Naticchia In this paper, they shown that mechanized painting can
be not only aimed at upgrade productivity, but also quality checking. A robot arm
with high precision is required. An automated system to convert the normalized
coordinates of the liquid colors to be reproduced into the movement speed of the
robot end tool and valve opening end of the mixing board. Most of the work will
be probably necessary to achieve high resolution.

Because of the shape of full scale robots, probably also the resolution of the
human scale robot will be lower. Another particularity of the small scale
arrangement is of course the ability to access some hard places of buildings
under construction, where human range robots could not be allowed.

Takuya Gokyu They have shared that construction of Wall-Surface

Operation Robot plan to automate and increasethe efficiency a series of restoration
works by adding, changing of an attachment, new task for cleaning. Tile
departure perceive and repair work to the initial functions of picture painting in a
single and multiple colors is also done. The analysis of this example was
introduced as a periodic inspection of the 10th year for the office building
concerned. And, high profitability is expected because of presence of many similar
structures.

Pal Johan In this paper, they present a technique for increasing the speed at
which a standard industrial manipulator can paint a wall surface. The approach is
based on the perception that a small error in the direction of the end effecter does
not influence the quality of the paint job. It is far more important to maintain
constant velocity throughout the orbit. In doing this, they cast the problem of
finding the optimal orientation at each time step into a convex minimized problem
that can be solved efficiently and in real time.

2. OBECTIVE

 To minimize time requirement for painting work multi spray gun and auto
filling system is used.
 To obtain work by a machine it is not required to move the machine
manually to paint the other wall.
 To minimize the paint requirement spray gun is used.
 To minimize human efforts the machine is automated and operated by
electric supply.
 To obtain smooth cleaning surface air sprayer is used.
 To minimize the paint requirement spray gun is used.
3. 2-D MODEL
5. ACTUAL MODEL
6. WORKING

The construction of paint paths is apart into the following steps: outlining of
the painting process, planning of encounter free spray gun motions. Specifies a
trajectory of the spray gun, which satisfies the desired paint quality. In this module
only spray gun motions are considered in relation to process quality. machine are
made and collisions between the spray gun and its background are not considered.
The system uses the “Geometry Library” and the “Procedure Library” in order to
plan this trajectory. The arithmetic library specifies for each arithmetic primary or
more painting scheme, which may be e applied for painting that particular type of
geometric primitive. The painting procedure specifies how to apply spray gun
motions to the surfaces in order to achieve a satisfactory process quality.
The procedure library is established through experimental work. The basic
idea is to enable outlining of paint strokes that continue everywhere the parts even
though different geometric primitives must be covered along the surface and even
though continuous robot motions cannot follow the surface.
The system will attempt to approximate the triangular patches of the surface
model by larger plane regions (virtual surfaces), which are oriented in a few main
directions. DP/DT switch has an central OFF position, when operated to one of the
ON position, the motor will rotate in clockwise direction , operating the worm gear
box and thereby the pinion shaft. The pinion rotates to rotate the gear and thereby
the main shaft and stand in clockwise direction taking the stand to close position.
When other ON position is operated the motor will rotate in counter clockwise
direction , operating the worm gearbox and thereby the pinion shaft. The pinion
rotates to rotate the gear and thereby the main shaft and stand in counter clockwise
direction taking the stand to open position.

7. SPECIFICATION OF COMPONENT
Sr. No. Name of Component Specification
1 Threaded Rod Length:1 m
Diameter:12 mm
2 Spray Gun Max. delivery rate:0.26
Lts/min Operating Voltage:220/230V
3 Motor RPM:100
Operating Voltage:12V
DC
4 Wheel Diameter:6 inch
5 Switch 2 way
6 Connecting wires For Remote & Chassis
7 Battery Operating Voltage:12V, 7 Amp
8 Electric Spray Gun Operating Voltage:230V DC
9 Fixture Diameter:12 mm

7.1 COST OF SETUP

TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost +cost
of Purchased Parts +Overheads
= Rs 11043

ADVANTAGES

 Low power consumption

 Easy to operate
 Reduces the manual work
 Low skilled operator is sufficient
 Minimizes the working time
 Easy material handling

DISADVANTAGES

 Separate compressor required to operate

 Initial cost is high

8. ADVANTAGES
 The painting process is virtually impossible without the painting robot set
up.
 The painting robot saves on time required for painting.
 The painting robot saves on the labor cost.
 As robot is automatic, it reduces human effort.
 Easy to maintain.
9. CONCLUSION

A method has been advance for mechanize spray painting of unknown parts.
This machine is very useful for painting of any shape with very time period less
closeness of this machine is more as compared to manually painting .It also saves
the labor cost and the total cost of painting the any jobs.

11. REFERENCES
[1]. Mohamed Abdellatif “Design of an Autonomous Wall Painting Robot”
Mechatronic and Robotic Dept. Egypt-
Japan University of Science and Technology, Alexandria, Egypt, 7 February 2016.
[2]. Dhaval Thakar, Chetan P. Vora “A Review on Design and Development of
Semi-Automatic Painting Machine’’
Int. Journal of Engineering Research and Applications, ISSN : 2248-9622, Vol. 4,
Issue 4( Version 7), April 2014.
[3]. P.Keerthanaa1, K.Jeevitha2, V.Navina3, G.Indira4, S.Jayamani5 “Automatic
Wall Painting Robot” International
Journal of Innovative Research in Science, Engineering and Technology Vol. 2,
Issue 7, July 2013
[4]. Berardo Naticchia, Alberto Giretti and Alessandro Carbonari “Set Up of an
Automated Multicolour System for
Interior Wall Painting” International Journal of Advanced Robotic Systems, Vol. 4,
No. 4 (2007),ISSN 1729-8806,
pp. 407-416
[5]. Takuya Gokyu, Masayuki Takasu, Sumio Fukuda “Development of Wall
Painting Robot” Tokyu Construction
Co. Ltd. 1-16-14 Shibuya-ku , Tokyo, Japan.
[6]. Pal Johan & Jan Tommy Gravdahl “A Real-Time Algorithm for Determining
the OptimalPaint Gun Orientation
in Spray Paint Applications” IEEE transactions on automation science and
engineering, vol. 7, no. 4, october 2010.
[7]. Praneet Singh, Deepanshu Suneja, Prachi, Jitendra Kumar“Android Based,
Arduino Powered Automated Wall”
Praneet Singh et al, / (IJCSIT) International Journal of Computer Science and
Information Technologies, Vol. 5 (3) ,
2014, 4490-4491
[8] I. Aris, A. K. Parvez Iqbal, A. R. Ramli and S. Shamsuddin. “Design and
development of a programmable
painting robot for houses and buildings.,” Jurnal Teknologi, Universiti Teknologi
Malaysia, vol. 42(A), pp. 27-48,
2005.
[9] B. Kahane, Y. Rosenfeld: “Balancing human-and-robot integration in building
task,” Computer-Aided Civil and
Infrastructure Engineering, vol.19, pp. 393-410, 2004.
[10] Warszawsky, Y. Rosenfeld: “Robot for interior finishing works in building:
feasibility analysis,” ASCE Journal
of Construction Engineering and Management, vol.120 (1), pp. 132-151, 1994.
Vol-4 Issue-2 2018 IJARIIE-ISSN(O)-2395-4396
7676 www.ijariie.com 1393
BIOGRAPHIES (Not Essential)
Author Photo-1
Prof. A. R. Raghatate
Lecturer Datta Meghe Institute of Engineering
Technology and Research, Sawangi (M), Wardha
Author Photo-2
Jayant R. Sawarkar
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi (M),
Wardha
Author Photo-3
Rupesh D. Belkhade
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi (M),
Wardha
Author Photo-4
Vivek G. Dalal
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi (M),
Wardha
Author Photo-5
Sanket M. Fulmali
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi (M),
Wardha
Vol-4 Issue-2 2018 IJARIIE-ISSN(O)-2395-4396
7676 www.ijariie.com 1394
Author Photo-6
Chetan D. Ghode
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi
(M), Wardha
Author Photo-7
Shubham L. Maskar
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi
(M), Wardha
Author Photo-8
Shubham B. Shelki
Final year student at Datta Meghe Institute of
Engineering Technology and Research , Sawangi
(M), Wardha