CONTENT

(01.) Abstract
(02.) Introduction
(03.) Chapter – 1
(1.1) Principle
(1.2) Mechanism
(04.) Chapter – 2
(2.1) Theory of Power Transmission
(2.2) Theory of Chain & Sprocket Drive
(2.3) Bearings
(2.4) Shaft
(2.5) Electric Motor
(2.6) Motor Speed Regulator
(05.) Chapter – 3
(3.1) Machine Parts List
(3.2) Parts Details
(3.3) Cost Estimation
(06.) Chapter – 4
(4.1) Fabrication of Model
(4.2) Model Specification & Details
(07.) Chapter – 5
(5.1) Working of Automatic Separator Machine
(5.2) Applications
(08.) Chapter – 6
(6.1) Advantages
(6.2) Limitations
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(09.) Chapter – 7
(7.1) Safety
(7.2) Maintenance
(10.) Conclusion
(11.) Future Scope
(12.) Project Photographs
(13.) References

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 Abstract

The main goal is to reduce human effort and save time

using cheap & more convenient machines in constructional and other
fields where separation of waste material is required from raw materials.
Our system puts forward a automated filtering and separating system
that allows us to separate material poured in it. The separator
reciprocates and the material falls down from filter and the waste
remains in filter an removed by a slot.

This machine can be used in several fields like

constructional, agricultural and industrial fields where separation of
waste from raw material is required.

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 Introduction
A separator/filter is a mechanical machine which is used to separates
unwanted heavy & big particles from the raw material which we got.
Separator/filter machine is very efficient method for separating sand in
different sizes. This Separator/filter comes with interchangeable filters.
In construction work small size sand is used for plaster, medium size
sand for column and large size sand is used making floor. We can
separate/filter sand according to the size with same machine by changing
filer over the machine. In construction site or industry separating sand is
very time consuming to save this time and complete all construction
within given time period we can use multistage sand separator and filter.

Fig. (1) Separator machine

This filter can be used in different fields like in agricultural fields,

constructional fields and where the waste particles need to be separated
from the needed things.
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 Chapter – 1
(1.1) Principle
The machine is placed across many fields like
constructional, agricultural, industrial, etc. this helps us in separating
waste materials from raw materials like sand in constructional sites,
from grains in agricultural fields, and it can be used where separation of
waste is required. This machine is operated by an A.C. motor which is
connected to the separator through a belt drive or a chain drive. When
we start the motor the rotary motion of the motor is converted into
reciprocating motion using a link mechanism (crank shaft) and the
machine gets started and the separation work is done by the machine.

(1.2) Mechanism
Slider Crank Mechanism is used in this project to
convert rotary motion (motor’s motion) into reciprocating motion
(separator’s motion).

Slider - Crank Mechanism (or a simple crank), shown

as Fig. converts rotary to linear motion and vice versa, depending on its
application. Link AB is free to rotate 360° around the hinge while link
BC oscillates back and forth because point C is hinged to a roller which
restricts it to linear motion. Either the slider or the rotating link AB can
be the driver.

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 Fig. (1.1 - 1)

Slider-crank mechanism: This simple crank converts

the 360° rotation of driver link AB into linear motion of link BC,
causing the slider at C to reciprocate.

Fig. (1.1 - 2)

This mechanism is more familiar as the piston, connecting rod, and

crankshaft of an internal combustion engine, as illustrated in Fig2. The
piston is the slider at C, the connecting rod is link BC, and the
crankshaft is link AB. In a four-stroke engine, the piston is pulled down
the cylinder by the crankshaft, admitting

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 Chapter – 2
(2.1) Theory of Power Transmission

Power transmission devices are very commonly used to transmit

power from one shaft to another. Belts, chains and gears are used fot this
purpore. When the distance between the sahfts is large belts and ropes
are used and for intermediate distance chains can be used.

For belt drives distance an be maximum but this should not be

more than ten meters for good results. Gear drive is used for more
distances.

Type of Drives –

(1.1.1) Belt drive

(1.1.2) Chain drive
(1.1.3) Gear drive
(1.1.4) crank

(1.1.1) Belt drive –

Belt is a looped strip of flexible material used to
mechanically link two or more rotating shafts. A belt drive offers
smooth transmission of power between shafts at considerable distance.
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Belt drives are used as source of motion to transfer to efficiently
transmit power or to track relative movement.

Fig. (1.1.1 - 1) Fig (1.1.1 - 2)

(1.1.2) Chain drive –

The belt drive is not a positive drive because of
creep and slip. The chain drive is a positive drive. Like belts, chains can
be used for larger center distances. They are made of metal and due to
this, chains are heavier than the belt but they are flexible like belts. It
also requires lubrication time to time. The lubricant prevents ,chain from
rusting and reduces wear.

Advantages of Chain drives –

1. Relatively inexpensive.
2. They occupy less space in width than a belt or rope drive.
3. It gives high transmission efficiency up to 98%. That applies less
load on the shafts.
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 4. It has the ability to transmit motion to several shafts by one chain
only.
5. It transmits more power than belts.

Fig. (1.1.2-1) Chain drive

(1.1.3) Crank –
A crankshaft—related to crank—is a mechanical
part able to perform a conversion between reciprocating motion and
rotational motion. In a reciprocating engine, it translates reciprocating
motion of the piston into rotational motion; whereas in a reciprocating
compressor, it converts the rotational motion into reciprocating motion.
In order to do the conversion between two motions, the crankshaft has
"crank throws" or "crankpins", additional bearing surfaces whose axis is
offset from that of the crank, to which the "big ends" of the connecting
rods from each cylinder attach.

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 It is typically connected to a flywheel to reduce
the pulsation characteristic of the four-stroke cycle, and sometimes
a torsion or vibration damper at the opposite end, to reduce the torsional
vibrations often caused along the length of the crankshaft by the
cylinder’s farthest from the output end acting on the torsional elasticity
of the metal.

Fig. (1.4 - 1) Crank Shaft

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(2.2) Theory of Chain & Sprocket Drive

A sprocket is a toothed wheel that is used to transmit

motion and torque from one to another. Chains that are used to transmit
motion and force from one sprocket to another are called power
transmission chains. Unlike gears that have to mesh to transmit motion
and torque from one gear to another sprocket may be positioned far
apart. Sprockets are connected by a chain.

Fig. (2.2 - 1)

(2.3) Bearings

The main function of a rotating shaft is to transmit

power from one end of the line to the other. It needs a good support to
ensure stability and frictionless rotation. The support for the shaft is
known as “bearing”. The shaft has a “running fit” in a bearing. All
bearing are provided some lubrication arrangement to reduced friction
between shaft and bearing.

Fig. (2.3 – 1) Bearing

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Advantage of Bearing-

1. Low starting and running friction except at very high

speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required
while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.

Disadvantages of Bearings-

1. More noisy at very high speeds.

2. Low resistance to shock loading.
3. More initial cost.
4. Design of bearing housing complicated.

(2.4) Shaft

A shaft is an element used to transmit power and

torque, and it can support reverse bending (fatigue). Most shafts have
circular cross sections, either solid or tubular. The difference between a
shaft and an axle is that the shaft rotates to transmit power, and that it is
subjected to fatigue. An axle is just like a round cantilever beam, so it is
not subjected to fatigue.

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 Shafts have different means to transmit power and
torque. F or example, it can use gears, sprockets, pulleys, etc., and also
have some grooves to keep these elements rigid and avoid their
vibration, such as key seats, retaining ring grooves, etc. Also, to be able
to avoid vibration of the elements, and assure an efficient transmission
of power and torque, some changes in the cross-section of the shaft can
be made.

Fig. (2.4 – 1) Shafts

(2.5) Electric Motor

An electric motor is an electrical machine that

converts electrical energy into mechanical energy. The reverse of this is
the conversion of mechanical energy into electrical energy and is done
by an electric generator, which has much in common with a motor.

Most electric motors operate through the interaction

between an electric motor's magnetic field and winding currents to
generate force. In certain applications, such as in regenerative
braking with traction motors in the transportation industry, electric

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motors can also be used in reverse as generators to convert mechanical
energy into electric power

(2.6) Electric Motor Speed Regulator

A motor controller is a device or group of devices that

serves to govern in some predetermined manner the performance of
an electric motor. A motor controller might include a manual or
automatic means for starting and stopping the motor, selecting forward
or reverse rotation, selecting and regulating the speed, regulating or
limiting the torque, and protecting against overloads and faults.

There are many types of starters-

1) Direct On Line (DOL)
2) Star delta starter
3) Auto transformer starter

Fig. (2.6 - 1) Speed Regulator Circuit

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 Chapter – 3
(3.1) Machine Parts List

PART NAME MATERIAL QUANTITY

SHAFTS MILD STEEL 2
SPROCKET STAINLESS STEEL 2
PULLEY CAST IRON 4
BEARING CROME – NICKLE 12
STEEL
BELT RUBBER 2
CHAIN STAINLESS STEEL 1
FRAME IRON & 1
GALVANISED IRON
FILTER GALVANISED IRON 1

(3.1 - 2) Electric Part List

MOTOR ALUMINIUM 1
WINDING
WIRE COPPER 6.5’
SWITCH PLASTIC 1
REGULATOR COPPER WINDING 1

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(3.2) Part Details

Frame-

A frame is the basic supporting structure of the entire

machine in our project. It consists 4 short rods which are joined with
each other as in rectangular shape with the help of welding.

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 or belt, or
transfer of power between the shaft and cable or belt. In the case of a
pulley supported by a frame or shell that does not transfer power to a
shaft, but is used to guide the cable or exert a force, the supporting shell
is called a block, and the pulley may be called a sheave.

A pulley may have a groove or grooves between

flanges around its circumference to locate the cable or belt. The drive
element of a pulley system can be a rope, cable, belt, or chain.

Fig. (3.2 – 1) Pulley

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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 three
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.

Fig. (3.2 – 2) Bearing

Chain and Sprocket-
A sprocket or sprocket-wheel is a profiled wheel with teeth,
or cogs, 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.

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 Fig. (3.2 - 3) Chain and Sprocket

A.C. Motor-
An AC motor is an electric motor driven by an alternating
current (AC). The AC motor commonly consists of two basic parts, an
outside stator having coils supplied with alternating current to produce a
rotating magnetic field, and an inside rotor attached to the output shaft
producing a second rotating magnetic field. The rotor magnetic field
may be produced by permanent magnets, reluctance saliency, or DC or
AC electrical windings.

Fig. (3.2 - 4) A.C. Motor

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V-Belt-

Round belts are a circular cross section belt designed to run

in a pulley with a 60-degree V-groove. Round grooves are only suitable
for idler pulleys that guide the belt, or when (soft) O-ring type belts are
used. The V-groove transmits torque through a wedging action, thus
increasing friction.

Fig. (3.2 - 5) V-Belt

Shaft-

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. The various members such as pulleys and gears are mounted on
it.

Fig. (3.2 - 6) Shaft

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Regulator-

A motor controller is a device or group of devices that serves

to govern in some predetermined manner the performance of an electric
motor. A motor controller might include a manual or automatic means
for starting and stopping the motor, selecting forward or reverse rotation,
selecting and regulating the speed, regulating or limiting the torque, and
protecting against overloads and faults.

Fig. (3.2 - 7) Regulator

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(3.2) Cost Estimation

S. No. ELEMENT QUANTITY COST

01 FRAME 1 2000
02 PULLEY 2 200
(SMALL)
03 PULLEY 2 550
(LARGE)
04 BELT 2 150
05 SHAFT 2 200
06 BEARING 12 500
07 REGULATOR 1 250
08 INCLINED 1 250
PLATE
09 SEPARATOR 2 800
10 MOTOR 1 1000
11 SPROCKET 2 150
12 CHAIN 1 100
13 NUTS & 24 200
BOLTS
14 WIRE 4m x 2 100
TOTAL 6500

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 Chapter – 4
(4.1) Fabrication of Model

1. Firstly we took a cast iron rod for making frame and chassis,
after that we cut the rod in required shape and size with the help of a
cutting tool and welded the rods with electric arc welding and made a
frame/chassis for fixing all the components.

2. Then we fixed the rollers on two sides into the frame using arc
welding which helps the separator to work smoothly.

3. Then we welded the separator into frame which is made up of

cast iron rods and a galvanized iron filter.

4. Then we mounted the A.C. motor on the frame and fixed a small
pulley into the motor’s shaft.

5. Then we fixed a simple link mechanism to the separator and

connected it to another pulley which is bigger in size.

6. Then we connected both pulleys and fixed a regulator to the

motor to control the speed of rotation.

7. We also fixed a manual mechanism to operate the machine

which helps us in operate the machine in no electricity conditions.

8. Then we fixed a tapered galvanized iron sheet using arc welding

which flow outs the separated material ready for use.

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Working at Project

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Project in Working Phase

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Working at Project

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Working at Project

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(4.2) Model Specification & Details

(All dimensions are in inches)

(A) Chassis Frame

Length = 50
Width = 28
Height = 36

(B) Pulley
Driver Pulley
Inner Diameter = 0.5
Outer Diameter = 3.75

Driven Pulley
Inner Diameter = 0.5
Outer Diameter =6

(C) Belt
Small Belt
Length = 40
Width = 0.5

Large Belt
Length = 42
Width = 0.5

(D) Rollers
Diameter = 1.5
Width = 0.4

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(E) A.C. Motor
RPM of motor = 1200

(F) Crank Shaft

Length = 12

(G) Flow Out Sheet

Length = 55
Width = 28
Upper Height = 30
Lower Height = 5

(H) Sprockets
Small Sprocket
Diameter =3

Large Sprocket
Diameter =8

(I) Chain
Length = 42

(J) Separator
Length = 35
Width = 23.5
Height = 2.5

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 Chapter – 5
(5.1) Working of Automatic Separator Machine

We’ll fix the machine in a plain ground place & then

plug it into electric board. Then the motor starts rotating and we
transmitted the power to pulley 1 (small) to pulley 2 (large) using a belt.
Pulley 2 (large) is connected with pulley 3 (small) using a shaft and the
pulley 3 (small) is connected with pulley 4 (large) using another belt. By
connecting all pulleys we transmitted rotary motion to pulley 4. Pulley 4
is connected with a crank using bolts which gives us rotary to
reciprocating motion.
This reciprocating motion is transmitted from crank to
the separator. Then we put the raw material in the separator and its starts
separating the waste and the needed material is filtered. Filtered material
collected using an inclined plate which is fixed in bottom of frame. Then
the sludge material which remains in filter, slides and got collected near
exit port. And we remove the sludge from the filter. It can be operated
manually.

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(5.2) Applications

1. It can be used for separating sands in different sizes.

2. It can be used for separating waste material from grains in
agricultural fields.
3. It can be used for separating wastes from raw materials in
industries.
4. It can be used in food industries to separate waste particles from
food products.
5. Project to use this in an efficient way to reduce human effort.
6. It can be used for small & wide industries, constructional works &
also for agricultural works.
7. It is used to collect remove waste particles from raw materials.

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 Chapter – 6

(6.1) ADVANTAGES

1. Production cost is very low.

2. No need to purchase special machine.
3. Its operation and maintenance is simple.
4. It is compact and portable.
5. It can be efficiently used.
6. Easy to operate.
7. No special skills required to operate this machine.
8. No need of special training to operate.
9. Interchangeable filters/separators.

(6.2) LIMITATIONS

1. It cannot be used for heavy particles.

2. It cannot works in heavy rain conditions.
3. Time required for changing filters/separators.
4. Cannot be used for full day work it can harm the electric
motor.

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 Chapter – 7

(7.1) SAFETY

Machine should be properly fixed to the floor & all the bolts,
bearings and rollers should be fixed properly than machine didn’t fail in
working and will not harm anybody.

(7.2) MAINTENANCE

1. Regular checkup required.

2. Chain/Belt would be changed if it is out of order.
3. Bearings would have to be changed if they are worn out.
4. Rollers would have to be changed when they have worn
out.
5. Filter/Separator would be changed when it is broken.
6. Regular greasing on bearings.

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 CONCLUSION

In this project the proposed concept is to replace the manual work in

constructional & other fields by and fully or automated system. Now-a-days
automation plays a vital role in all industries & other fields. So we tried to make an
automated filtering/separating system that reduces the human effort or separating
waste particles from sand in constructional field, unwanted waste from grains in
agricultural fields and it also help us in industries to separate different types of raw
materials. Sometimes it takes most of the time to separate waste particles by hand
or by using human effort and sometime it causes injuries to the people. To
overcome this problem and to reduce human effort we have undertaken this project
“AUTOMATIC SEPARATOR MACHINE” We have developed our project to
use this in efficient way to reduce the human effort in different fields as above we
told.

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 FUTURE SCOPE

1. Electrical equipment used in machine can be solar powered.

2. We can make it remote controlled.
3. We can make it with multiple separators/filters.
4. We can make it with multiple separators/filters working on different speeds.

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PROJECT PHOTOGRAPHS

Completed Project
(Automatic Separator Machine)

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 REFERENCES

Text books
 Theory of Machine Element by S. S. Ratan.
 Design of Machine by R. S. Khurmi.
 Electrical Engineering by J. B. Gupta.
 Mechanisms and Mechanical Devices by Neil Scalter.
 Mechanism Design by Kevin Russell.


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