UNIVERSITRY OF GONDAR

INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
DESIGN AND MODELINGAUOTOMATIC WALKING
TRAILING MACHINE FOR CLINICAL TRAIL

A Thesis submitted in partial fulfillment of the requirements for the Degree of Bachelor of
Science in Mechanical Engineering.

THESIS BY:
MULUHABTTADESSE……………5787/08
ENDALEWSHIBABAW……………07758/09

ADVISOR:
MR AGERNEW MELKAMU

i
 UNIVERSITRY OF GONDAR
SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
DESIGN AND MODELING AUOTOMATIC WALKING TRAILING
MACHINE FOR CLINICAL TRAIL

THESIS BY:
MULUHABTTADESSE……………5787/08
ENDALEWSHIBABAW……………07758/09

INSTITUTE OF TECHNOLOGY
Approved by board of examiners:
---------------------- ----------------------------- ---------------------------

Chairman date signature

------------------------ ------------------------------ ---------------------------

Adviser date signature

------------------------ ------------------------------- ----------------------------

Internal examiner date signature

------------------------ ---------------------------------- ----------------------------

External examiner date signature

ii
 Declaration

this thesis work is only may original work and has been presented for a degree in any other university and that all source
of material is duly acknowledged.

Title of the Thesis: DESIGN AND MODELING AUOTOMATIC WALKING TRAILING MACHINE FOR
CLINICAL TRAIL

Thesis by:
MULUHABT TADESSE……………5787/08
ENDALEW SHIBABAW……………07758/09

Department: ________________________________________________________

Signature: __________________________________________________________

Advisor: ___________________________________________________________

Signature: __________________________________________________________

iii
 Acknowledgement

This project would not have been possible without the support and guidance of others. Our deepest thanks go to
our almighty God for giving us strength to accomplish this research work and would like to express our sincere
gratitude to our advisor Ins Agernew Melkamu and then providing his guidance, assistance and encouragement
throughout the duration of the project. We appreciate his consistent support from the first day of the project to
these concluding moments. Sincere thanks to all staff of the Mechanical Engineering Department who helped us
in many ways and providing equipment and information sources that assisted our studies and projects.

iv
 Abstract

In the past 35 years, significant research has been devoted to understanding biped locomotion. However, a sizable number
of the prototypes developed thus far have been limited to static or quasi-static gaits, and lack the ability to walk
dynamically. This inherent inability to walk dynamically leads to walking cycles that are generally quite energetically
inefficient. A large part of these inefficiencies are due to complex mechanical designs that lack a dynamic control design
that complement each other. This thesis presents a design approach that integrates both the controller and mechanical
design by designing and building a walking machine that will be used as an experimental platform to validate gait control
algorithms that induce dynamic walking. Through experimental analysis using the constructed walking machine, a
standard framework can be developed that relates both the mechanical and controller design systematically. Once
assembled, the mechanical integrity of the machine will be studied during initial experimentation and design changes will
be made to improve its complexity. Walking machines have been attempted since the beginning of the technology of
transportation machinery with the aim to overpass the limits of wheeled systems by Looking at legged solutions in nature.
But only since the last part of the 20-th century very efficient walking machines have been conceived, designed, and built
with good performances’ that are suitable for practical applications carrying significant payload with relevant flexibility
and versatility. The worldwide feasibility of walking machines is presented by discussing the activity at LARM:
Laboratory of Robotics and Mechatronics in Cession (Italy) as concerning with low-cost easy-operation solutions that can
really make the walking machines available to non-expert users for many applications

v
 Contents
Declaration .......................................................................................................................................................................... iii

Acknowledgement ................................................................................................................................................................iv

Abstract ................................................................................................................................................................................. v

Abbreviations ................................................................................................................................................................... vii

CHAPTER ONE ................................................................................................................................................................... 1

1.1 INTRODUCTION ..................................................................................................................................... 1
1.2BACKGROUND OF THE STUDY ........................................................................................................... 1
1.3PROBLEMSTATEMENT ....................................................................................................................... 1
1.4OBJECTIVES............................................................................................................................................. 2
1.4.1 GENERAL OBJECTIVES .................................................................................................................. 2
1.4.2 SPECIFIC OBJECTIVES .................................................................................................................. 2
1.5 METHODOLOGY...................................................................................................................................... 2
1.6 SIGNIFICANCE OF THE STUDY ........................................................................................................ 3
1.7DEFINITION OF THE TERMS .................................................................................................................. 3
1.8SCOPE OF THE STUDY ........................................................................................................................... 3

CHAPTER TWO................................................................................................................................................................... 4

LITERATUREREVIEW ....................................................................................................................................................... 4
2.1 INTRODUCTION ...................................................................................................................................... 4
2.2 DEFINITION TERMINOLOGY .................................................................................................................. 4

CHAPTER THREE ............................................................................................................................................................... 6

DESIGN ANALYSIS OF WALKING TRAINING MACHINE ......................................................................................... 6

3.1. FORCE ANALYSIS FOR HYDRAULIC SYSTEM ................................................................................ 6
3.1 PISTON ROD DESIGN ......................................................................................................................... 9
3.3 DESIGN OF THE PISTON HEAD .........................................................................................................10
3.4 CYLINDERDESIGN ...............................................................................................................................11
3.5 DESIGN OF BELTS .................................................................................................................................11
3.6 DESIGN OF BELT DRIVE .....................................................................................................................13
Velocity Ratio of a Belt Drive .........................................................................................................................15
3.7 V-BELT DRIVEDESIGN ...........................................................................................................................15
3.8 DESIGN OFSCREW ................................................................................................................................16
3.8.1 BUCKLING OF THE SCREW ............................................................................................................20
3.9DESIGN OF NUT ....................................................................................................................................21
3.10 DESIGN OF MAINFRAME .....................................................................................................................22
3.11 ANALYSIS AND DESIGN OF BEAM OF THE MAINF RAME ...............................................................25
3.12BEARING STRESS INCONNECTIONS .................................................................................................27
3.13 DESIGN OF LIFTINGMECHANISIM ......................................................................................................28
3.14 SPUR GEAR DESIGN ...........................................................................................................................32
3.14.1DESIGN PROCEDURE FOR SPUR GEAR .....................................................................................36
3.15 DESIGN OF THECOLUMN....................................................................................................................38
3.16 DYNAMOMOTOR ..................................................................................................................................40

RESULT AND DICUSION ................................................................................................................................................ 43

4.1 RESULT ...................................................................................................................................................43
4.2 DISCUSION .............................................................................................................................................44

CHAPTER FIVE ................................................................................................................................................................. 45

CONCLUSION AND RECOMENDATION ..................................................................................................................... 45

vi
 5.1 CONCLUSION .........................................................................................................................................45
5.2 RECOMENDATION ...................................................................................................................................46

Reference ........................................................................................................................................................................... 47

Appendix ............................................................................................................................................................................ 48
PART DRWING AND ASSEMBLY.................................................................................................................50

vii
List of figures
Figure 1-hydraulic piston rod ................................................................................................................................................ 6
Figure 2piston rod length determination ............................................................................................................................... 7
Figure 3force angle determination ........................................................................................................................................ 8
Figure 4forcedetermination ................................................................................................................................................... 8
Figure 5belts ........................................................................................................................................................................ 12
Figure 6running belt ............................................................................................................................................................ 15
Figure 7v-belt drive ............................................................................................................................................................. 16
Figure 8portion of a power screw ....................................................................................................................................... 17
Figure 9Torque required to raise the load ........................................................................................................................... 18
Figure 10 incliner leg assemble ........................................................................................................................................... 20
Figure 11running frame ....................................................................................................................................................... 23
Figure 12BEAM OF THE MAIN FRAME......................................................................................................................... 25
Figure 13shear bending moment diagram ........................................................................................................................... 26
Figure 14bearing effect diagram ......................................................................................................................................... 27
Figure 15shear in pin ........................................................................................................................................................... 28
Figure 16fixing beam .......................................................................................................................................................... 30
Figure 17bearing effect at wheel ......................................................................................................................................... 31
Figure 18spur gear ............................................................................................................................................................... 34
Figure 19 column bar cross section ..................................................................................................................................... 39
Figure 20permanent magnet dc motor performance curve ................................................................................................. 41
Figure 21schtomaticdiaram of dc motor control ................................................................................................................. 41

viii
 Abbreviations

No. Symbol Description

1. A Area
2. L Length of the key
3. D Diameter of the circle
4. B Width of the key
5. Mpa Mega Pascal
6. ay yield stress
7. au ultimate strength
8. vy yield shear stress
9. F.S Factor of safety
10. vall allowable shear stress
11. T Thickness
12. H Height
13. W Width
14. RHC RHC _Rectangular hallow cross-section
15. P Load
16. FA Force at A
17. Ac Cross-sectional area of the bar
18. V shear force
19. BM bending moment
20. I moment of inertia
21. Y distance from the neutral axis to the extreme fiber
22. ab bending stress
23. Tp Thickness of the plate
24. q density of material
25. Mu Mass of user
26. Mm Mass of the machine
27. N n- number of the columns
28. T tensile force at a single column
29. Rpm revolution per minute
30. T the maximum weight of the passenger stands the cabin base
31. Dp pin diameter
32. Su ultimate strength
33. E Young’s modulus
34. N Newton

vii
 CHAPTER ONE

1.1 INTRODUCTION
All human being can have many goals and many aims but on the way of accomplishing these goals there is many obstacle and
attacks like diseases. Thus it needs to recovers from these diseases. The ability to walk has been started to be one of the most
important goals of rehabilitation for patients. As study shown the recovery of walking ability occurs in 95% of patients within 11
weeks after strokes. The time and degree of recovery are related both to the degree of the initial loss of walking disability and to
severity of lower extremity paresis. Clinical walking training machine is one of the most important training machines for some
patient’s but not for all patients.

In the past 35 years, significant research has been devoted to understanding biped locomotion. However, a sizable number of
the prototypes developed thus far have been limited to static or quasi-static gaits, and lack the ability to walk dynamically.
This inherent inability to walk dynamically leads to walking cycles that are generally quite energetically inefficient. A large
part of these inefficiencies are due to complex mechanical designs that lack a dynamic control design that complement each
other. This thesis presents a design approach that integrates both the controller and mechanical design by designing and
building a walking machine that will be used as an experimental platform to validate gait control algorithms that induce
dynamic walking. Through experimental analysis using the constructed walking machine, a standard framework can be
developed that relates both the mechanical and controller design systematically. Once assembled, the mechanical integrity of
the machine will be studied during initial experimentation and design changes will be made to improve its complexity.

A walking training machine is a machine used to train walking for walking disabled patients who are attacked by different
diseases like nerves problem, paralyzed patients, heart problems, lung problem patients, and etc. This training enables them to
walk normally by themselves after recovery training The trainer can control the velocity of the machine as he or she want and
also can start and stop it at any time. Since the patients may not stand by her or himself it needs to have a supporting element
that can be adjusting at different level opposition. [1]

These source may be difference web site goggle face book YouTube difference design books, difference machinery
mechanisms and etc. In this chapter we have presented a survey of the variety of current solutions and prototype of walking
machines and we have illustrated fundamental characteristics and problems for their design and operation.

1.2BACKGROUND OF THE STUDY

Walking machines have been attempted since the beginning of the technology of transportation machinery with the aim to
overpass the limits of wheeled systems by Looking at legged solutions in nature. But only since the last part of the 20-th
century very efficient walking machines have been conceived, designed, and built with good performances’ that are suitable
for practical applications carrying significant payload with relevant flexibility and versatility.
The worldwide feasibility of walking machines is presented by discussing the activity at LARM: Laboratory of Robotics and
Mechatronics in Cession (Italy) as concerning with low-cost easy-operation solutions that can really make the walking
machines available to non-expert users for many applications. [2]

1.3PROBLEMSTATEMENT
Ethiopia is a developing country there is a scarcity of clinical equipment One of clinical equipment is the walking training machine.
This scarcity is because of this equipment is not manufactured in Ethiopia. There are many clinics in our country but this machine
can be found in a few clinics.
Depending on this to design this clinical walking training machine to asses to all clinics in Ethiopia by doing this to help walking
disabled patient to recover to their normal life condition and work their best in their life. This in the other hand helps Ethiopia to
increase efficient and healthy productive (working) person which enable the country to develop.
Even if this machine is available now a day it is so costly and rear Because of this is impossible to train for a patient who have
money (for only rich person).This problem should be avoided and simplified from Ethiopia within a short period of time. It should
be assessable to all clinics and for all patients at any time.

1
Involvement of the private sector in provision of health services has progressively increased in many developing countries including
Ethiopia. Promotion of the health sector involvement is also one of the elements in the health care financing strategy in Ethiopia. A
cross sectional descriptive study was done on quality of care in private clinics in Addis Ababa during the period of April, 2000.
Different levels of clinics were randomly selected and assessments were done on structural aspects, performance of health workers
in polyclinic outpatient department and patients satisfaction with the medical care given. It was found that few clinics fulfill the
requirements of the Ministry of Health (MOH) with regard to staffing, equipment and medications. Nevertheless, most clinics were
found not to fulfill the minimum requirements put in the guideline.

1.4OBJECTIVES
1.4.1 GENERAL OBJECTIVES

The general objective objectives this thesis is to design and automatic walking training machine for clinical trial

1.4.2 SPECIFIC OBJECTIVES

Some of the specific objectives
 To design part of the machine
 To model the parts of the machine using 3d modeling software
 To assemble the 3d modeling parts using software
 To show the simulation of assemble model using software

1.5 METHODOLOGY
Methodology is the systematic, theoretical analysis of the method of applied to field of study. It compressed the theoretical analysis
of the body of method and principle associated with a branch of knowledge. In general methodology in the general research is to be
undertaken and among other thing identify the method to be used it.

Methodology is the step of data collection that design automatic walking training machine. Data collection can be classified in
primary data collection and secondary data collection.

Primary data collection is the methodology of collection data from the source that are from different observation from clinics and
GYM by collecting data.

Secondary data are the data do not collect from the source data collect from internet, from text book journals, literature and which
tell about the walking machine and other source. The project methodology involves the initiative step to the finally step up to
complete the project.

The data that get from primary and secondary data source analyzed by designing different parts and by limit the problem on primary
data collection time.

In this project also use different software and make model by solid work for analyzing the effect of stresses on parts of the
machine during design, to draw the 2D and the 3D drawings, and also use matt lab to solve a complex equation if face some
complexity in the future design process.

 Collecting data by using observation, asking question and revising previously done document.

 Collecting data from the original machine GYM room at Gondar.

 Determining material properties from mechanics and strength of material books.

 Preparing standard detail drawing and manufacturing drawings.

2
 1.6 SIGNIFICANCE OF THE STUDY
The significance of the study is exercise to weight loss, for walking training, for cardio vascular strengthening exercise, to
control physically appearances, to control health patients, and for Bronchiatatic and fibrotic lung

1.7DEFINITION OF THE TERMS

A walking training machine is a machine used to train walking for walking disabled patients who are attacked by different
diseases like nerves problem, paralyzed patients, heart problems, lung problem patients, and etc.

1.8SCOPE OF THE STUDY

As it is described in the introduction walking training machine is used to exercise a patient who cannot walk alone (without
support) or help. But the machine serves for people who can try a little bit to stand by using some support and can move
their leg weakly and slowly. Since this machine is for patients it should have a supporting devices (parts) at different parts
and levels of the patient body. The speed of the rotation of the machine is adjusted by the user (patient). It is speed can be
increased or decreased and started and stop by simply a touch a button at the front. It is an electrical circuit (system).

This walking training machine is made from different part. The parts are electrical systems for controlling, starting, stopping
dynamo motor for enhancing the rotation chains supporting mechanisms, different fixtures like bolts and nuts, pins, welding, belts
which is very wide to cover the floor of machine no which the foot is stand on it …. etc.

3
 CHAPTER TWO
LITERATUREREVIEW
2.1 INTRODUCTION
Walking machines have been attempted since the beginning of the technology of transportation machinery with the aim to overpass
the limits of wheeled systems by Looking at legged solutions in nature. But only since the last part of the 20-th century very efficient
walking machines have been conceived, designed, and built with good performances’ that are suitable for practical applications
carrying significant payload with relevant flexibility and versatility.
The worldwide feasibility of walking machines is presented by discussing the activity at LARM: Laboratory of Robotics and
Mechatronics in Cession (Italy) as concerning with low-cost easy-operation solutions that can really make the walking machines
available to non-expert users for many applications.
Begnoche DM, Pitetti KH. [4] Effects of walking treatment and partial body weight walking training on the motor skills of children
with spastic cerebral palsy. A pilot study This study was designed to examine the effects of intensive traditional physical therapy
treatment methods combined with partial body weight walking training (PBWwT) on motor and ambulatory skills of children with
cerebral palsy. An intensive episode of physical therapy of reasonable frequency and duration that includes partial body weight
walking training may be effective in improving motor skills of children with spastic CP.
Birgani PM, Ashtiyani M, Rasooli A, Shahrokhnia M, Shahrokhi A, Mirbagheri MM [5] Effectiveness of walking training on gait
function in children with cerebral palsy: meta-analysis The purpose of this review was to analysis the effects of walking training on
gait function in children with cerebral palsy. Cumulative Index to Nursing and Allied Health Literature (CINAHL), Cochrane Central
Register of Controlled Trials, Physiotherapy Evidence Database (PEDro), PubMed and Web of Science were searched. Investigating
the effects of walking training on gait endurance, gait speed, limb support time, cadence, and step length in children with cerebral
palsy.
M.L. Harris-Love, R.F. Macko, J. Whitall, L.W. Forrester [6] Walking on the Moon: A randomized clinical trial on the role of lower
body positive pressure treadmill training in post-stroke gait impairmentThe study was designed as a single-blind, prospective,
randomized controlled trial (RCT) to compare the effects of LBPPSS (provided using AlterG) and TGT in patients with stroke.
Clinical and gait data of the patients were compared with those of 25 age-matched (by a frequency-matching approach) healthy
controls (HC)

2.2 DEFINITION TERMINOLOGY

An automatic walking training machine is a machine used to train walking for walking disabled patients who are attacked by
different diseases like nerves problem, paralyzed patients, heart problems, lung problem patients, and etc.
The worldwide feasibility of walking machines is presented by discussing the activity at LARM: Laboratory of Robotics and
Mechatronics in Cession (Italy) as concerning with low-cost easy-operation solutions that can really make the walking
machines available to non-expert users for many applications.
on the way of accomplishing these goals there is many obstacle and attacks like diseases. Thus it needs to recovers from these
diseases. The ability to walk has been started to be one of the most important goals of rehabilitation for patients. As study
shown the recovery of walking ability occurs in 95% of patients within 11 weeks after strokes. The time and degree of recovery
are related both to the degree of the initial loss of walking disability and to severity of lower extremity paresis. Clinical walking
training machine is one of the most important training machines for some patient’s but not for all patients.
A walking training machine is a machine used to train walking for walking disabled patients who are attacked by different
diseases like nerves problem, paralyzed patients, heart problems, lung problem patients, and etc. This training enables them to
walk normally by themselves after recovery training. The trainer can control the velocity of the machine as he or she want and
also can start and stop it at any time. Since the patients may not stand by her or himself it needs to have a supporting element
that can be adjusting at different level opposition. These source may be difference web site goggle face book YouTube
difference design books, difference machinery mechanisms and etc.

Not only this but also we can get helps from our advisor ins Agernew Geremew other teacher and partners. In this project we
also use different software for analyzing the effect of stresses on parts of the machine during design, to draw the 2D and the
3D drawings, and also we may use matt lab to solve a complex equation. if we face some complexity in the future design
process.

4
  Collecting data by using observation, asking question and Revising previously done document.

 Collecting data from the original machine GYM room at Gondar.

 Determining material properties from mechanics and strength of material books.

 Preparing standard detail drawing and manufacturing drawings.

Therefore, based on the experience we gained before in different design project and by further reading and referring
different sources we can do our final design project happy fully.

5
 CHAPTER THREE
DESIGN ANALYSIS OF WALKING TRAINING MACHINE
The design analysis of our project which is walking training machine begins from the identification of each part of the
machine and the advantages of each part for the machine. Also it is basic to identify the working mechanism of the machine.
Depending on the mechanistic inter connection of the parts we can analyze the effect of the load on each parts of the
machine.
The main parts of the machine are the following: -
 Base frame
 The columns
 Dynamo motors
 Belton dynamo
 Running belt
 Running frame
 Running board
 inclination legs
 pins
 keys
 screw
 gears

3.1. FORCE ANALYSIS FOR HYDRAULIC SYSTEM

Before we go to part design we need to decompose the forces (weight) in to Fx and Fy forces which can cause bending
and buckling effects. Thus let decompose it as follow:

R
0.3m Figure 1-hydraulic piston rod
Assuming teta 1 = teta 2 =300

By using cosine law we can get ‘R’ from the other given (assumed) values as follow.

R2 = 3002 + 5002 – 2(300 * 500*cos 1200) [1]

6
R2 =90000 + 250000 – 300000 * cos 1200)

R2 = 490000

R =700mm = 0.7m

Assuming teta 1=teta2 = 00

Using again cosine law:-

R2 = 3002 + 5002 – (2 * 300 * 500 * cos 900)

R2 = 0.34m

R = 0.5831m

R=5830mm

Let us find the needed angles and some perpendicular distances as follow which enables us to find Moments as well as
Forces (transverse & axial forces).

C D

A Z2

Z1

Figure 2piston rod length determination

Cos300 = Z1
0.5m

Z1 = 0.5m * cos 300

Z1 = 0.433m

Cos 300 = Z2/0.38m

Z2 = 0.38m * cos 300

Z2 = 0.329m

‘W’ is the user (man) weight

W = 150Kg * 10m/s2

W = 1500N

7
 Fy51.8038.20 Ɵ4 D

B Fx y

Figure 3force angle determination

Using cosine law:-

(0.5m)2 = (0.3m)2 + (0.7m)2 - (2*0.3 *0.7)cosƟ3

0.25 = 0.09 + 0.49 -0.42 cosƟ3

cosƟ3 = 0.7857

Ɵ3 = 38.20

Then: Ɵ4 =21.80

x
Fy 51.80 38.20 Fx
C

Figure 4forcedetermination

sin51.80 = Fx/W
Fx = W *sin51.8

Fx = 1500N *sin51.8
Fx=1178.785N
Cos51.8=Fy/W Fy=W*cos
51.8 Fy=1500N*cos51.8
Fy=927.

8
£MA = Mc + (Fy ∗ R)

But, Mc=W*Z2

Mc=1500N*0.329m

Mc=493.5Nm

£MA=493.5NN+(927.6N∗ 0.7N)

=493.5Nm+649.3632Nm=1142.82Nm

3.1 PISTON ROD DESIGN

Let as select material for the piston rod of material stainless steel AISI 302 cold-rolled, whose properties are

𝝈u=860MP𝝈

y=520MA

E=190GPA

By using the formulas of bending stress or bulking load formula let as find the piston rod dimensions as follow

BY BENDING STRESS

Mc
𝝈all = , were 𝝈all = allowable stress [2]
I

M=Moments

C=distance from center to surface

I=Moment of inertia

F.S=Factor of safety

𝝈u=Ultimate stress

But,𝝈all=𝝈all/F.S [3]

Let us factor of safety to be two, then

860MPA
𝝈all =
2

=430MPA

Then after diameter of the piston rod can be calculated as follow

𝝈all = Mc/I [4]

Assuming c=dr/2and
πdr4
I=
64

Where, dr=rod diameter

9
 1142.82Nm∗ dr/2
430*10^6N/m2 = πr^4
64

430 * 106 = (1142.82 *

32)/πdr3dr3 = 0.000027m3

dr = 0.03m = 30mm

Take dr = 30mm for design.

By buckling formula let us check the rod dimensions as follow.

𝑆𝐹∗𝜋2∗𝐸∗𝐼
𝐹𝐸 = Where, 𝐿𝑟𝑜𝑑 =length of the rod [5]
(𝐿𝑟𝑜𝑑)2
Lcylin=length of the cylinder
Take Lrod=595mm and

Lcylin=580mm

SF=1

𝜋𝑑𝑟2 109 𝑁
1∗𝜋2 ∗190∗ 64 ∗ 2
𝑚
FE=Fx==1178.785N
(0.595𝑚)^2
Dr=0.0082m=8.2mm

Depending on these two values take the rod diameter for design as;30mm

3.3 DESIGN OF THE PISTON HEAD

Let us design the piston head by selecting the material of gray cost iron 4.5%c,ASMA-48-whose properties are:-au=
170Nea…..Ultimate tensile strength

E=69Gpa ................................................................ modulus of elasticity

Let us use bending or/and buckling formulas to get the dimension of the piston head.

By bending moment formula

σall = Mc/I

σall = (170MPa)/2

σall = 85MPa

Let assume, c = t/2 = r/2=dph/4 where, dph =piston head diameter

1142.82∗ 𝑑𝑝ℎ/4
6
Then 85 *10 = Πdp h4
64

1142.82∗ 16
85 *106 =
πdph3

dph = 0.0409m = 40.9mm = 41mm

By buckling formula

Fx = P* A where, P = is pumping pressure [6]

A = piston area Fx = force in the x-axis

10
1178.785N=15*106* π𝑑𝑝ℎ2 [7]
4

dph = 0.01m = 10mm

From these two values take the piston head diameter (dph) as 41mm for design.

Then: t = dph/2 = 20.5mm

3.4 CYLINDERDESIGN
There are two types of cylinders. These are thick shell cylinder and thin shell cylinder. Let us select thin shell cylinder and
then by using hoop stress and/or longitudinal stress formulas let us decide the dimensions as follow.

Hoop stress (circumferential stress)

Givens are:- pumping pressure (P) = 15MPa

Material property (au) = 550MPa

Lcylin = 580mm

di = dph = 41mm …..inner diameter of the cylinder

Then the thickness (t) of the cylinder can be calculated as following.

p∗ di
t= But, σall =𝝈t=𝝈u [8]
2∗ 𝝈 F.s
t

Let us take factor of safety (F.S) to be two

Then, σall=σt= 550/2 = 275MPa

15 MPa∗ 0.041m
t (thickness)= = 0.00112m = 1.12mm
2∗ 275MPa

Longitudinal stress

p∗ d 15 MPa ∗ 0.041m
i = =0.00056m = 0.56m [9]
t= 4∗ 275MPa
4∗ 𝝈t

From these two values we take the dimensions (thickness) as 1.12mm. Take the thickness for design to be 1.5mm. Then
the outer diameter (do) is:

do = di +2t

do = 41mm + 2(1.5mm)

do = 44mm

3.5 DESIGN OF BELTS

To design the belt first we need determine the dynamo speed and power based on the speed variation we need from 1km/h

– 15km/h, so from this the running belt radius can be assumed as follows.
Assumption: - Determine roller drol=7.5cm
Length of running belt = 140cm

From the center of rotation.

11
 X

RRRRTT r

Figure 5belts

From this we found the diameter of the belt and the speed variation we need is minimum speed 1km/h and maximum
speed 15km/h

Circumference of the belt can be calculated as follows:

2x + (½2prrol+ ½2prrol) = 2p rbelt

2x + 2prrol = 2prbelt

2(132.5) + 2p(3.75cm) =2prbelt

rbelt=46cm But, 140-2r =x

140-(2*3.75) =x

X=132.5cm

So, that diameter of the running belt=92cm and

Minimum speed (vmin)=1km/h=0.278m/s

Maximum speed (vmax)=15km/h=4.167m/s

V=2pN1/60, forvmax=4.167m/s

N1 =v*60/2π

N1 =4.167*60/2

N1 =39.75rpm

N1 d2
From velocity ratio formula: =
N2 d1

39.79rpm/N2=7.5cm/92cm

N2=488rpm

Where N1=rotational speed of the running belt=39.79rpm

N2=rotational speed of the roller

12
 dbelt =diameter of running belt=92cm

d1=diameter ofthe roller=7.5cm and

from velocity ratioN2/N3=d3/d2

Assumption d3=40mm

d2=120mm so,

488rpm/N3=40mm/120mm

N3=1464rpm

Where, N2=rotational speed (revolution) of the roller means is equal to the rotational speed of the boleja.

d2= diameter of the boleja on the roller

N3=rotational speed of the dynamo

d3= diameter of the dynamo shaft

From this we get the power (kw) of the dynamo

Torque=power*60/2π*N3

Power (p) = (2π*N3*T)/60

P=2π*1952rpm*225N.m/60

P=4.599kw ≈ 4.6kw≈5kw

But, T=force * radius of dynamo shaft

Torque= weight of the user*radius of dynamo shaft

T=150kg*10m/s2)*(d3/2)

T=(1500*0.04)/2 =30Nm

3.6 DESIGN OF BELT DRIVE

Belt drives are being most widely used in industries for transmission of power from one shaft to another over considerable
distances. It is successfully competing with individual drives in which the machine is directly couple to the shaft of his
own motor. The flexibility of the belt helps in arranging the shafts of the driving and the driven pulleys in any manner and
in using as many pulleys as possible. The materials of the belts to be used for transmission must be strong in tension,
flexible and pliable, durable, relatively light in weight, and have good frictional surfaces. The most commonly used
materials are:
Leather
Fabric and canvas belts
Rubber belts .

The rubber belts are made of layers of fabric impregnated with rubber composition and have a thin layer of rubber on the
faces. These belts are very flexible but are quickly destroyed if allowed to come into contact with heat, oil or grease. One
of the principle advantage of these belts is that they may be easily made endless. For this reason, we select this type of
materials Balata belts etc

Selection of a Belt Drive

13
 Following are the various important factors upon which the selection of a belt drive depends:

1. Speed of the driving and driven shafts

2. Speed reduction ratio,

3. Power to be transmitted,

4. Centre distance between the shafts,

5. Positive drive requirements,

6. Shafts layout,

7. Space available, and

8. Service conditions.

Types of Belt Drives

The belt drives are usually classified into the following three groups:

1. Light drives. These are used to transmit small powers at belt speeds up to about 10 m/s as in agricultural machines and
small machine tools.

2. Medium drives. These are used to transmit medium powers at belt speeds over10 m/s but up to 22 m/s, as in machine
tools.

3. Heavy drives. These are used to transmit large powers at belt speeds above 22 m/s as in compressors and generators.

Types of Belts

Though there are many types of belts used these days, yet the following are important from the subject point of view:

1. Flat belt. The flat belt is mostly used in the factories and workshops, where a moderate amount of power is to be
transmitted, from one pulley to another when the two pulleys are not more than 8 meters apart.

2. V- belt. The V-belt is mostly used in the factories and workshops, where a great amount of power is to be transmitted,
from one pulley to another, when the two pulleys are very near to each other.

3. Circular belt or rope. The circular belt is mostly used in the factories and workshops, where a great amount of power is
to be transmitted, from one pulley to another, when the two pulleys are more than 8 meter apart.

Coefficient of Friction between Belt and Pulley

The coefficient of friction between the belt and the pulley depends upon the following factors:

1. The material of belt;

2. The material of pulley;

3. The slip of belt; and

4. The speed of belt.

Open belt drive.

The open belt drive, as shown is used with shafts arranged parallel and rotating in the same direction.
In this case, the driver A pulls the belt from one side (i.e. lower side RQ) and delivers it to the other side (i.e. upper side LM).
Thus the tension in the lower side belt will be more than that in the upper side belt. The lower side belt (because of more
tension) is known as tight side whereas the upper side belt (because of less tension) is known as slack side, as shown

14
 Figure 6running belt

Velocity Ratio of a Belt Drive

It is the ratio between the velocities of the driver and the follower or driven. It may be expressed, mathematically, as
discussed below:
Let d1 = Diameter of the driver,
d2 = Diameter of the follower,
N1 = Speed of the driver in r.p.m.,
N2 = Speed of the follower in rpm.,
□Length of the belt that passes over the driver, in one minute = Пd1 N1 Similarly,
length of the belt that passes over the follower, in one minute = Пd2N2
Since the length of belt that passes over the driver in one minute is equal to the length of belt that passes over the follower
in one minute, therefore
Пd1 N1 = Пd2 N2

3.7 V-BELT DRIVEDESIGN

The power of the dynamo we get by calculation is equal to 5KW
Power transmitted = 6.5hp to bucket elevator
Speed of motor = 1464 rpm; output speed = 488 rpm

Compute the design power. From Table 7-1, for a normal torque electric motor running 24 h daily driving a bucket
elevator, the service factor is 1.30. Then the design power is 1.30(6.5hp) = 8.54hp.
Compute the nominal speed ratio:
Ratio = N1/N2= 1464/488 = 3

15
 Figure 7v-belt drive

 Specify a trial center distance.

We can determine a nominal acceptable range for C:
D2<C<3(D2 + D1)
Where D2=diameter of the bodega=
D1= diameter of the of dynamo shaft
120mm < C < 3(120mm + 40mm)
120mm < C < 480mm
In the interest of conserving space, let's try C = 400mm
 . Compute the required belt length
D2–D1
L = 2C + 1.57(D2 -D1) + ( )^2 [10]
4C

120𝑚𝑚 − 40𝑚𝑚
L = 2(400mm) + 1.57(120mm - 40mm) + (
4 ∗ 400𝑚𝑚
) ^2
L=925.6mm

 Select a standard belt length from Table 7-2, and compute the resulting actual center distance
In our case, the nearest standard length is 925.6mm. Then, from Equation (7^),
B = 4L- 6.28(D2+D1)
B = 4(925.6mm) - 6.28 (120mm + 40mm)
B=2697.6mm

B + √B^2 − 32(D2 − D1)^2

𝑐=
16
2697√26972 − 32(120 − 40)^2
𝑐=
16

C=334.7mm
 Compute the angle of wrap of the belt on the small sheave.
(D2–D1)
ϴ1= 180° - 2 sin–1
2∗ C
–1 (120–40)
So, ϴ1=180° - 2 sin
2∗ 400
Then ϴ1 =174.26°
Determine the correction factors from Figures 7-14 and 7-15. For 0 – 174.26°,
C8= 0.94. For L = 100 in, CL = 0.96.
Compute the corrected rated power per belt and the number of belts required to carry the design power:
Determine the rated power for the 5V belt that we have selected at 1464 rpm, the basic rated power is 3.1 hp.
Corrected power = C8*CL*P = (0.94)(0.96)(3.1hp) = 2.7hp
Number of belts = 6.5/2.7 = 2.4 belts (Use 3 belts.)

3.8 DESIGN OFSCREW

A power screw is a device used in machinery to change angular motion into linear motion, and, usually, to transmit power.

16
Following are the three types of screw threads mostly used for power screws.
1. Square thread. A square thread is adapted for the transmission of power in either direction. This thread results in
maximum efficiency and minimum radial or bursting pressure on the nut. It is difficult to cut with taps and dies. It
is usually cut on a lathe with a single point tool and it can not be easily compensated forswear.

2. Acme or trapezoidalthread.2

3. Buttress thread.

A square-threaded power screw with single thread having a mean diameter dm, a pitch p, a lead angle λ, and a helix angle
ψ is loaded by the axial compressive force F. We wish to find an expression for the torque required to raise this load, and
another expression for the torque required to lower the load.

Figure 8portion of a power screw

Material selection
Carbon steel is selected because screw is always under tensional, bending and axial load; carbon steel is chosen due to
the strength issues.

𝝈y=400Mpa

τ =240Mpa

E=207Mpa

Material selection for Nut design

In order to reduce the friction resistance between the screw and nut a softer material is selected for the nut phosphor
bronze is proper material for nut consideration because it acts very well against wear resistance and reduces torque to
overcome friction.

𝝈u=190Mpa

𝝈y(Tension)=100Mpa

𝝈y(Compression)=90Mpa

The procedure for screw design is as follow:

- Core diameter of the screw is determined using allowable stress and the given load.
- Using the core diameter, the rest diameter and the pith will be determined from the table
- Torque will be determined using the mean diameter, coefficient of friction and the pitch.

17
 - Principal stress due to shear and the compression stress will be studied.
- The dimension for the screw is safe if and only if the maximum stresses are less than the allowable stress.
So,

𝝈c=p/(dc2/4) [11]

dc= (p/(acπ/4))½

Where p=load that are (weight of machine and user weight)

𝝈c = allowable stress of material

dc = core diameter of screw

So, dc=2200N/(π/4(400*106))=29.6mm=30mm

The next available diameter is 30mm. For dc=30mm according to the table 17.2(nominal serial) we have:
do=36mm (outer diameter)

Pitch=6mm

Then: dmean=(dc+do)/2

dmean= (30+36)/2

dmean=33mm

Torque required for raising the load

The torque required to raise the load by means of square threaded screw

RN

F α

Figure 9Torque required to raise the load

tanα =p/πd

p=pitch of screw

18
d=mean diameter of screw

α=helix angle

p=effort applied at the circumference of the screw to lift the load

W= load to be lifted

µ=coefficient of friction between screw and nut

α =tan∅ , where ∅ is the friction angle

Torque to raising the load (TR) = (p*dm/2)*((l+πµdm)/ (πdm-µl))

TR = (2200N*0.033)/((0.006+π*0.18*0.033)/(π*0.033-0.18*0.006))

TR=68Nm

Where, l=load =pitch for single thread

µ=coefficient of friction
α1=angles of helix angle
ɸ=friction

Now it is time to study principal stress due to the combined stress (compression and torsional) and see if they are in limit
for safe dimensions.

ac= load (p)/ (πdc2/4) [12]

ac=2200/((π0.0332/4))=2.57Mpa

Τ=torque (T)/ ((Πd2/4))=79.5kp

m a

𝝈max=𝜹c/2 ±1/2√(𝜹c2+4𝜏)

106 1
𝝈max= 2.57 ∗ 2 ±2√((2.57*106)2 +4*(0.795*106))

6 6
𝝈max = 1.285*10 ± 1.51*10

𝝈max=2.795Mpa and

1 √(a2 + 4τ)
𝝈 max = 2

1 √((2.57 ∗ 106)2 + 4 ∗ (0.975 ∗ 106)2)

τ max= 2

𝝈all=𝝈u/F.s
𝝈all=240Mpa/2.5
=96Mpa

19
Criteria for safe design against principal stresses

τ allowable> τmax

σallowable>σmax so, our design is safe

3.8.1 BUCKLING OF THE SCREW

Buckling is studied when the load is compressive and the unsupported length between the screw and the nut is long. when it
is short, it is short. then it is assumed a column and buckling issue dose not rise if the critical load is more than the load we
have then our design is safe and their is no chance of buckling.

𝜎𝑦
Pcritical=Ac*[ 1-4𝜋2 (1/𝑘)2 ]

Ac=Cross-sectional area of the screw core

σy =yield strength of the screw material

L=effective length of the screw (L=screw life height + 1(height of the nut)
2

C=end fixity coefficient in case of one and fix and one end free its value is 0.25kg=least radius of gyration, it is usually
taken 0.25dc

πdc2 p(0.03)2
Ac= 4 =
4

Ac =7.068*10–4m²

L=(screwliftheight+1/2(24mm))
But, from this screw lifting height
K= 0.20*Dc=0.20*0.03=0.006

Figure 10 incliner leg assemble

Length of the Leg = 60mm

20
 8=Angle of elevation assumption 10°

From right angle triangle

z
sinϴ=
l

z
sinϴ0=
60cm

z=10.4≈15cm

From this the height (lifting height) of the machine from sifting is equal to the length of the crew so, 15mm+allowance

Length of the screw=20cm

Pcritical = 282KN

Our load is 2200N so, the design is safe

Pcritical>Pload, no buckling

3.9DESIGN OF NUT
Procedures:

i. Number of threads in engagement is found

ii. Height of the nut is determined
iii. Shear stress produced at the threads of the screw at the co e diameter and at threads of the nut at the major
diameter is studied.
iv. For safe design, these shear stresses are compared with the allowable stresses
Bearing pressure is exist at surface of contact b/n two member of a machine part that are in relative motion.

Pb=load/area

𝑝
Pb=𝜋/4(𝑑𝑜2−𝑑𝑐2)𝑛 [13]

Pb=Bearing pressure
n=Number of threads
do= Outer diameter
dc= Core diameter
p = 2200N

Pb=2200N/ [(0.036m)2−(0.033m)2)]n=15.05MPA

n =3.9

21
We take the number of threads n=4. The height of the nut is found from following equation:

H=n*p
H = 4*7mm
H = 84mm

The nut threads are subjected to crushing and shear. To check whether crushing is expected or not,

σcrush=2200N/ [(0.036m)2−(0.033m)2)]4

σcrushing=13.53MPa
σcrushing<<σcy (bronze −90MPa)
From the above result, crushing is not expected because crushing stress is much smaller than the bronze yield stress at
compression.

p
τnut= but, t= pitch/2 [14]
π∗ do∗ π∗ t

τnut=2200/4) π*0.036m*4*0.003m
τnut=12.39MPa
τnut<<τyield(bronze −80MPa)
From the result above, the nut threads are safe against shear stress.

τscrew = 2200/ (4) π*0.033m*4*0.003m

τscrew =13.52MPa

τscrew<< σ yield(bronze-240MPa)
The screws are safe against the shear produced by the axial loading

Design of the various diameters

 Inner diameter of the nut collar(D1)

P =3.14/4[(D1)-(d0 2)] = 3.14/4[(D12) - (0.0362)]

D1 = 0.050m (50mm)

 Outer diameter of the nut collar(D2)

P= [(D2)2−(D1)2]σc

2200N =π/4[(D2)2 − (0.050m) 2]90*106 Pa

D2 = 0.56m (56mm)

3.10 DESIGN OF MAINFRAME

Welded Joint

22
A welded joint is a permanent joint which is obtained by the fusion of the edges of the two parts to be joined together,
with or without the application of pressure and a filler material. The heat required for the fusion of the material may be
obtained by burning of gas (in case of gas welding) or by an electric arc (in case of electric arc welding).

Electric Arc Welding

In electric arc welding, the work is prepared in the same manner as for gas welding. In this case the filler metal is supplied
by metal welding electrode.
The main considerations involved in the selection of weld type are:

1. The shape of the welded component required,

2. The thickness of the plates to be welded and

3. The direction of the forces applied.

Figure 11running frame

Eccentrically Loaded Welded Joints
An eccentric load may be imposed on welded joints in many ways. The stresses induced on the joint may be of different
nature or of the same nature. The induced stresses are combined depending upon the nature of stresses. When the shear
and bending stresses are simultaneously present in a joint
(see case 1), then maximum stresses are as follows:
Maximum normal stress (δmax)

σmax= 𝜹b+1√𝜹b2 + 4𝜏2 [15]

2 2
Maximum shear stress (𝜏max)
Τmax=1√δb2 + 4v2 where 𝜹b=bending stress
2

τ=shear stress
Considering T joint fixed at one end and subjected to an eccentric load at point P at distance e.

let s=size of weld

l=length of weld

t=throat length

The joint will be subjected to the following two types of stress

1. Direct stress due to the shear force P acting at the weld

2. Bending stress due to bending moment (P*e)

Area of throat =throat thickness *length of weld

23
 A=t*2*l=2t*L

For double fillet weld .t=s cos 45 =0.7075

So that A=2t*L

A=1.414*s*L

 Shear stress in weld

P P [16]
Then τ = A= 1.414∗ S∗ L

 Bending moment M=P*e.

M t∗ L^
But bending moment σb=
S∗ L^
but Z = 2
z 2
*2 =
6 4.242

𝛿𝑏 1
𝝈max= +
2 2
√𝛿𝑏2 + 4𝜏2 [17]

A weld joint as shown above is subjected to an eccentric load of a user weight 1500N.sowe get the size of the weld if the
maximum shear stress in the weld is 1ooMpa.

Assume the user weight is 1500N

Length of weld=88mm

Ande=120mm

The joint will be subjected to directed shear stress due to P=1500N and bending moment of P*e.

We know that the area of throat (A)

A=2t*L

A=1.414*S*88mm

A=124.43*S mm^2

Shear stress(𝜏)=𝑝/𝐴=1500𝑁/(124 ∗ 𝑠mm^2)

12.09N/mm^2
So 𝜏=
S
Bending moment (M) = P*e

M=1500N*120mm

M=180000N/mm^2

Section modules of the weld through the throat

Z =S∗4.242
L^2 S∗ (88) mm ^2
=
4.242
[18]

Z=1825.5*S mm^2

M
Bending stress σ b=
Z

24
 180000N/ mm 98.62N/ mm ^2
𝜹b = =
1825∗ S mm ^2 S

We know that the maximum shear stress (τmax)

1
τmax= 2 √𝜹b2+ 4𝜏2 [19]

√98.6N/mm^2 2
100Mpa=1/2( )
s

66.43
100Mpa=
S

S=6.6mm this is the size of weld

3.11 ANALYSIS AND DESIGN OF BEAM OF THE MAINF RAME

when a beam carries more than two or three concentrated load or it carries distributed load. let as consider a simple
supported beam ab carries a distributed load “w” per unit length.

RA=1ωL RB=1ωL
2 2

Figure 12beam of the main frame

From the free body diagram of the entire beam we determine the magnitude of reaction at the support.

RA=RB=1/2WL

Next we draw the shear diagram Close the end A of the beam the shear is equal to RA that is 1/2WL.

We determine the shear V at any distance X from A

In our beam AB is simply supported and carries uniformly distributed load as shown. The shear bending moment diagram
for the beam and determined the location and magnitude of the maximum normal stress due to bending.

We determine the shear V at any distance x from A. we write,

𝑥
V-VA=∫0 𝑤𝑑𝑥=-wx [20]
Ÿ

V=VA-Wx=1/2WL-Wx=W (1/2L-x)

Reaction considering the in tire beam as a free body we find,

RA=428.57N and RB=428.57N

Shear diagram form the above shear curve is thus an oblique straight line which cross the X a xise at X =L/2.Because

25
 V

1/2wL

L/2

-1/2wL

1/8WL^2

L/2 L

Figure 13shear bending moment diagram

We determine the shear V at any distance X from A

 V-VA=-∫ swdx=-wx butX=0m

0

V-428.75N=-857N*0.7

V=840N

 V=0 atx=1/2(1.4m)
 V=VA-WX at x=1.4m

V=-1/2(W*L)=-1/2(1200*1.4)

V=-840N

Considering now the bending moment first observe that MA=0.The value of the bending moment at any distance X from
A may then be obtained

M-MA=∫ sVdx
0

s 1
M=∫ w ( L − x) dx
0 2

M=1/2W(Lx-x^2)

The bending moment curve is parabola. The maximum value of the bending moment occurs when X=L/2 since V is zero
for that value of X. Substituting X=L/2 in the last equation we obtained

WL^2
Mmax =
8

In our design

 M=1/2W(Lx-x^2) when x=o

M=0

 M=1/2W(Lx-x^2 butx=1/2L=0.7m

26
 WL^2 = 1200N∗ (1.4)^2
M=
8 8

M=294Nm

 M=1/2W(Lx-x^2) when x=1.4m

M=1/2W(L^2-L^2)

M=0

3.12BEARING STRESS INCONNECTIONS

Bolts, pins and rivets create stress in the member they connect along the bearing surface or surface of contact. the bolt
exerts by the plate A Force P equal and opposite to the force F exerted by the plate on the bolts. The force P represent the
resultant of elementary force distributed on the inside surface of a half-cylinder of diameter d and length L equal to
thickness of plate. Since the distribution of this force and corresponding stress is quite complicated one use in practice an
average nominal value δb of stress Called the bearing stress.

Figure 14bearing effect diagram

In our design the running board is bolted to the main frame to be design to carry a tension force of magnitude 1500N.and
the running board will be 20mm thick plate stock.

Material selection

Grade of steel the maximum allowable stress are

σ = 175pa

τ = 100Mpa

σb= 350pa
Design the bolted running board by determining the required value of diameter of the bolt.

 The diameter of the bolt.

Since the bolt is single shear. F1=1500N

F1 [21]
so τ =
A
1500N
100Mpa = Π∗ d^2 from this d=17.6mm=20mm
4

At this point we check the bearing stress between the 20mm thick plate and the 20mm diameter bolt.

P 1500N
σb= t∗
= = 3.75Mpa
0.02∗ 0.02
d

27
Bearing stress we found is less than the material bearing stress

3.75Mpa<<350Mpa ………………………………………………..Safe design

 Dimension b at each end of running board

We consider one end portion of the running board. Recalling that thickness of steel plate is 20mm and that the average
tensile stress must not excesses 175Mpa

𝑝
, 175Mpa=750N a=17.14mm [22]
So, σb= 2
(0.02∗ a)
𝑡∗𝑎

Then b=d*2a

=20mm*2*17.14mm

b =54.28mm

3.13 DESIGN OF LIFTINGMECHANISIM

Determination of the shear stress in a connection such as a bolt, pin or rivet we first clearly show the force exert by the
various member it connection.

The pin at the tire is to be made of steel having an ultimate shearing stress of 350Mpa.so we determine the diameter of the
pin at the tire which we give the factor of safety 3.3 and also we determined the required thickness of the bracket support at
the tire that allowable shear stress of steel used in300Mpa

Material of pin steel

Ultimate shearing stress =350Mpa

Allowable shear stress = 300Mpa

Shear in pin

At this pin the force P that is the weight of the user and the weight of the machine = (1500N+700N) =2200N

Figure 15shear in pin

Assume the weight of the machine is(120kg*gravity)=1200N. But from this 70% weight is loaded in the tire.

28
 So 0.7*1200=700N is apply in the tire
𝜏 350𝑚𝑝𝑎
𝜏all= = =
𝑓.𝑠 3.3

106.5mpa

Since the pin in double shear we write

P/
Areq= 2
But P= weight of the machine and user [23]
𝜏all

𝜏all=Allowable shear stress of the material

2200N/2
A=
106.5Mpa

A=10.36*10^-5mm^2 from this we found the diameter of the pin.

πd^2
A= d = 36.3mm
4

Approximate d = 40mm

Bearing at pin using d=36.3mm, the nominal area of each bracket is (d*t ) since the force carried by each bracket is c/2

and the allowable bearing stress is 300mpa,we write

𝑐
2
Areq= [24]
𝑎𝑙𝑙

2200N/2
but, d = diameter of the pin=40mm
d*t= 106.5Mpa

So, from this t=13.5mm take t=15mm

To determine the shear stress in connection on the pin

This pin create stress in the member they connect along the bearing surface or surface of contact
Firstly at the welding point there is a fatigue loading means when the machine up or inclined there is up ward force
applied on the joint (welding) but the machine are down The welding material is 1018 steel completely reversed
load applied we determine the factor of safety of well-meant of infinite life

Material selection
Grade 1018 steel
Sut=400Mpa
Sy=250Mpa
For the E6010electrode

Sut=480Mpa

Sy=375Mpa

The fatigue stress concentration factor from table is Kfs=2.7

From table 6.2p.280 Ka=0.702. the shear area assumes the of weld are rectangular 6cm by 6cm

A=6*0.707*0.375*6=9.544cm^2

29
 From uniform shear stress on the throat kb=1

From equation (6-26) p.282 for torsion (shear)

Kc=0.59, Kd=Ke=Kf=1

From equation (6-8) p 274

Sse=0.72*1*0.59*1*1*1*0.5*400Mpa=82.76Mpa

Kfs=2.7, Fa=2200N, Fm=0

Only primary shear is present

𝑘𝑓𝑠∗𝑓𝑎 2.7∗2200𝑁
𝜏a= =9.544∗10^−4m^2=6Mpa [25]
𝑎

In the absence of midrange component the fatigue factor of safety nf is given by :

𝑆𝑠𝑒
nf= =606Mpa/87.76Mpa=4.72
𝜏𝑎

Shear and bending moment diagram

To determination of the maximum absolute value of the shear and bending moment in beam are greatly facilitated if V and M
are plotted against the distance X measured from one ends of the beam.

Figure 16fixing beam

The forces applied on the beam are the weight of the machine plus the weight of the user

(1500N+1200N)=2700N

We determined the reaction of the support from the free body diagram of the entire beam.

30
 V P

D M

M C

D B

Figure 17bearing effect at wheel

£M at a point A=0

£MA=0

2700N*0.2 - 0.6*RB=0

RB=900N

And RA=1800N

We determine the shear V at any distance X from A.

 V – VA =0 [26]

𝑥
-∫0 𝑊𝑥but, x = 0

V - 1800N = 0 V

= 1800N

 V - VA =0

𝑥
− ∫0 𝑤𝑥 6vdBut, x = 0.2m

V - 1800N = 2700N

V = 900N

 £MA=0 , x = 0m

(1800N*0m) + M1 =0

31
M1=0

£MA=0 x=0.2m

(1800N*0m)+ (2700*0.2) +M2 = 0

M2=540N

ML^2
M max =
8

In our design
1
 M= 
W(Lx-x2) when x=o
2

M=0

1 1
2
 M = W(Lx-x but x= L=0.7m [27]
2 2

ML^2 1200N∗ (1.4)^2

M= =
8 8

M=294Nm
 M=1W(Lx-x2) when, x=1.4m [28]
2

M=1W (L2-L2)
2

M=0

3.14 SPUR GEAR DESIGN

In the gear design there are some given (input) values and some assumption values. From these value power to be
transmitted, the speed of the driving gear and the driven gear (velocity ratio) and the center distance. Therefore, it is better
to find the power of the dynamo motor.
Power (P) =Torque (T)*angular speed (w)

Where N=is rotational speed (m)

Let as assume the outer diameter is be 35mm for the gear on the dynamo motor (pinion) and 45mma gear on the screw
(driven).let us also decide the output rotational speed of the screw (N2).since we need to increase the inclination slowly the
rotational speed of the screw should not be greater than 100rpm.This is the output rotational speed we need to use it to rise
and lower the machine from one side to an inclination angle of10°.
Thus ,d1=35mm
d2=56mm
N2=200rpm
N1=?
Then by using velocity ratio formula we can find the rotational speed of the motor shaft which is equal with the gear speed
on the motor (N1).Then,

N1(input gear s peed) d2(out put gear diameter)

=
N2(out put gear s peed) d1(input gear diameter)
N1 56mm
=
200rpm35mm

32
 N1=320rpm
Take the rotational speed (N1) to be 320rpm for design.
2π∗ N
Then, power=Torque* where torque=torque of the screw shaft [29]
60

2π∗ 320rpN
Power(P)=68Nm*
60

Power=2.278Kwatt
Power of the lifting motor is 2. 278Kwatt.Take power 2.5Kwatt for design which is equal to
3.3hp of power of the motor.

Gear Materials
The material used for the manufacture of gears depends upon the strength and service
conditions like wear, noise etc. The gears may be manufactured from metallic or non-
metallic materials. The metallic gears with cut teeth are commercially obtainable in cast
iron, steel and bronze. The nonmetallic materials like wood, rawhide, compressed paper and
synthetic resins like nylon are used for gears, especially for reducing noise.
The cast iron is widely used for the manufacture of gears due to its good wearing properties,
excellent mach inability and ease of producing complicated shapes by casting method. The
cast iron gears with cut teeth may be employed, where smooth action is not important.
The steel is used for high strength gears and steel may be plain carbon steel or alloy steel.
The steel gears are usually heat treated in order to combine properly the toughness and tooth
hardness.
Design Considerations for a Gear Drive
In the design of a gear drive, the following data is usually given:
 The power to be transmitted.
 The speed of the driving gear,
 The speed of the driven gear or the velocity ratio and
 The Centre distance.
The following requirements must be met in the design of a gear drive :
 The gear teeth should have sufficient strength so that they will not fail under static loading
or
 Dynamic loading during normal running conditions.
 The gear teeth should have wear characteristics so that their life is satisfactory.
 The use of space and material should be economical.
 The alignment of the gears and deflections of the shafts must be considered because they
Terms used in Gears
The following terms, which will be mostly used.
1. Pitch circle. It is an imaginary circle which by pure rolling action, would give the same motion
as the actual gear.

2. Pitch circle diameter. It is the diameter of the pitch circle. The size of the gear is
usually specified by the pitch circle diameter. It is also called as pitch diameter.
3. Pressureangleorangleofobliquity.Itistheanglebetweenthecommonnormaltotwogeart
eethatthepointofcontactandThe common tangent at the pitch point. It is usually denoted by
3/4 the standard pressure angles are 14*1/20 and 200

4. Circular pitch. It is the distance measured on the circumference of the pitch circle from a point of one tooth to the
corresponding point on the next tooth. It is usually denoted beep.
Mathematically,
A little consideration will show that the two gears will mesh together correctly, if the two wheels have the same circular pitch.

5. Module. It is the ratio of the pitch circle diameter in millimeters to the number of teeth. It is usually denoted by m.

33
 Module, m = D /T

Where, D = Diameter of the pitch circle, and

T = Number of teeth on the wheel.
6. Tooth thickness. It is the width of the tooth measured along the pitch circle

If D1 and D2 are the diameters of the two meshing gears having the teeth T1 and T2 respectively; then for them to mesh

correctly,

nD1∗ N1 nD1∗ N2
Pc= = [30]
n∗ D∗ N1 n∗ D∗ N2

D1 T1 N2
= =
D2 T2 N1

And N2=output gear speed means rotational speed of gear 2=200rpm

N1=input gear speed means that comes from dynamo=320rpm
D2=diameter of output gear=105mm
D1=diameter of input gear=75mm
Then from modules formula we get,
modulus Let us take module from Indian standard as 6
=D/T

where D = Diameter of the pitch circle, and

T = Number of teeth on the gear.

D1 75mm
So,6mm= =
T1 T1

T1= Number of teeth on the gear1=12.5=14

D2 105NN
And=6mm= =
T2 T2

T2= Number of teeth on the gear2=17.5=18

Figure 18spur gear

34
Gear geometry

DP of pinion = m*Tp =6*14 = 84mm

Dg of gear = m*Tg = 6*18= 108mm

Center distance = (DP +Dg)/ 2=(84mm+108mm)/2=96mm

Circular pitch (pc) = (π DP) /Tp = (πDg)/Tg=

3π= (π*84)/14=18.85mm

Addendum = m = 6m

Duodenum = 1.25x6 = 1.25x 6mm = 7.5mm

Clearance = 0 .25 x 6 =0 .25 x 6 = 1.5 mm

Teeth thickness = πx5/2 = 7.85 mm

Teeth space = p – teeth thickness = 15.7 – 7.85 = 7.85mm. But practical teeth thickness should be larger for purpose of
backslash to maintain lubrication in the gear operation.

Height of teeth = 2.25 x 6 = 2.25 x 6mm = 16.5mm

Whole depth (minimum) = Ht =2.25(6) = 16.5 mm

Work depth = Hk = 2m = 2x6mm =16mm

Width of top land = to= 0.25 (6) = 1.5mm

Outer diameter of pinion = Dop=Dp +2addendum = 84+ 2*6=96mm

Outer diameter of gear = Dog = Dg+2adendem = 1081+2*6 =120mm

Base circle of pinion = Dbp = DP-2didendum = 84 – 2*6 = 72mm

Base circle of gear = Dbg = Dg – 2didendum = 108 – 2*6 = 96mm

Causes of Gear Tooth Failure

The different modes of failure of gear teeth and their possible remedies to avoid the failure, are as follows :

1. Bending failure. Every gear tooth acts as a cantilever. If the total repetitive dynamic load acting on the gear tooth is
greater than the beam strength of the gear tooth, then the gear tooth will fail in bending, i.e. the gear tooth will break.
In order to avoid such failure, the module and face width of the gear is adjusted so that the beam strength is greater than
the dynamic load.
2. Pitting. It is the surface fatigue failure which occurs due to many repetition of Hertz contact stresses. The failure occurs
when the surface contact stresses are higher than the endurance limit of the material. The failure starts with the formation
of pits which continue to grow resulting in the rupture of the tooth surface.
In order to avoid the pitting, the dynamic load between the gear tooth should be less than the wear strength of the gear
tooth.
3. Scoring. The excessive heat is generated when there is an excessive surface pressure, high speed or supply of lubricant
fails. It is a stick-slip phenomenon in which alternate shearing and welding takes place rapidly at high spots.
This type of failure can be avoided by properly designing the parameters such as speed, pressure and proper flow of the
lubricant, so that the temperature at the rubbing faces is within the permissible limits.
4. Abrasive wear. The foreign particles in the lubricants such as dirt, dust or burr enter between the tooth and damage the
form of tooth. This type of failure can be avoided by providing filters for the lubricating oil or by using high viscosity
lubricant oil which enables the formation of thicker oil film and hence permits easy passage of such particles without
damaging the gear surface.
5. Corrosive wear. The corrosion of the tooth surfaces is mainly caused due to the presence of

35
corrosive elements such as additives present in the lubricating oils. In order to avoid this type of wear, proper anti-
corrosive additives should be used.
3.14.1DESIGN PROCEDURE FOR SPUR GEAR
1. First of all the design tangential tooth load is obtained from the power transmitted and the peach line velocity by using
the following relation.

P
WT= *cs, where, p=power transmitted in watts=2.5kw
V
[31]

2.5kw
WT= *1.54 WT=permissible tangential tooth lod in Newton.
5.6

π∗ D∗ π∗ 75mm∗ 320rpN
WT= 687.5N v=pitch line velocity in m/s=
N 60
= =5.6m/s
60

D=pitch circle diameter in meter =75mm

Cs=serves’ factor means from (table 28.10) type of load light

Shock and continuous 24 hours per day the values of Cs=1.54

The diameter of gear=75mm

2, calculating the dynamic load (WO) on the tooth by using bucking ham equation i.e.

WD=WT+ WI where b=75.4mm, v=5.6m/s WD=Wt+1640=3665.07N

WI=increment load due to dynamic load

WT=steady load due to transmitted load

The face width (b) may be taken as 3 pcto 4 pc(or 9.5 m to 12.5 m) for cut teeth and 2 pcto 3 pc(or 6.5 m
to 9.5 m) fore cast teeth.
So, b=3*pc (circular pitch) =3*18.85=75.4mm

3, Calculate the dynamic load (WD) on the tooth by using Buckingham equation, i.e.
WD = WT + WI
21∗ v(b∗ c+MT)
WD =WT +
21∗ v√(𝑏𝑐𝑊𝑇)

Where, WD = Total dynamic load in new tons, WT =

Steady transmitted load in nektons, v = Pitch
line velocity in m/s,
b = Face width of gears in mm, and
C = A deformation or dynamic factor in N/mm. from table 28.5=114N-m

21∗ 6.5(75.8∗ 114+MT)

WD=687.5N+
21∗ 6.5√(7.5 ∗ 114 + 𝑊𝑇)

WD=687.5+1260850.5/13118.9

WD=783.12N

4. Find the static tooth load (i.e. beam strength or the endurance strength of the tooth) by using
the relation,
0.912
WS=σe.b.pc.y=σe.bπm.y y= 0.154– For20°full depth involute system. ButT=14
T

WS=252Mpa*75mm*18.5*0.151 where Flexural endurance limit (σe) from table 28.8=252Mpa

WS=53146.8N
36
 5. Finally, find the wear tooth load by using the relation,

Ww=DP.b.Qk where Q = Ratio factor

K = Load-stress factor (also known as material combination factor) 1.32N/mm2.

WW=84mm*75mm*1.5*1.32
Ww=12474N

The wear load (Ww) should not be less than the dynamic load (WD).
DESIGN OFKEY
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect these together in order
to prevent relative motion between them. It is always inserted parallel to the axis of the shaft.
Keys are used as temporary fastenings and are subjected to considerable crushing and shearing stresses. A keyway is a slot
or recess in a shaft and hub of the pulley to accommodate a key.
Types of Keys
The following types of keys are important from the subject point of view:
Sunk keys,
 Saddle keys,
 Tangent keys,
 Round keys and
 Splines
Sunk Keys
The Sunk keys are provided half in the keyway of the shaft and half in the keyway of the hub or boss of the pulley. The
sunk keys are of the following types:-
1. Rectangle key
2. Square key
3. Parallel key
Square sunk key: The only difference between a rectangular sunk key and a square sunk key is that its width and
thickness are equal i.e.
w = t = d /4
For this design we select square sunk key
Forces acting on a Sunk Key
When a key is used in transmitting torque from a shaft to a rotor or hub, the following two types of forces act on the key:
1. Forces (F1) due to fit of the key in its keyway, as in a tight fitting straight key or in a tapered Key driven in place. These
forces produce compressive stresses in the key which are difficult to determine in magnitude.
2. Forces (F) due to the torque transmitted by the shaft. These forces produce shearing and Compressive (or crushing)
stresses in the key.
The distribution of the forces along the length of the key is not uniform because the forces are Concentrated near the
torque-input end. The non-uniformity of distribution is caused by the twisting of the shaft within the hub.
In designing a key, forces due to fit of the key are neglected and it is assumed that the distribution of forces along the
length of key is uniform.
The forces acting on a key for a clockwise torque being transmitted from a shaft to a hub are shown in Fig.
Select a material of key
SteelAISI NO 1020 HR Sult = 380 Mpa
Sy = 210 Mpa
Sf = 1.65
τ = 63.9Mpa
 Considering shearing of the key the tangential shearing of force at the circumference of the screw shaft.

37
 Force(F) = Area resisting shearing *shearing stress= (l*w) * τ

Torque transmitted by screw shaft=Force*d/2

Considering crushing of the key,

F= Area resisting crushing*crushing stress=l*t/2*σc
Where, T= Torque transmitted by screw shaft
F= tangential of force at the circumference of the screw shaft
d=diameter of the screw shaft
l=length of the key
w=width of the key
t=thickness of the key
τ and σ = are shear and crushing stress for the material of key
Screw shaft and pinion key
The maximum torque transmitted by the shaft and key on input shaft is
Assumption
Width of the key(w)=thickness of the key(t) = 4mm
π π
T= ∗ τmaxd3= ∗ 63.952 ∗ 363
16 16

T = 585.85Nm Where d=diameter of screw shaft=36mm

Let us consider failure of key due to shearing

T = l w τ*d/2
585.85∗ 2
L= =12.7mm 14mm
4∗ 36∗ 63.952
According to haft More the shaft strength factor
w t
e = 1 - 0.2 ( d ) - 1.1 ( ) = 0.744
2d

π
Strength of the shaft with key way = ∗ τ max∗ d3* e
16

=435.24 Nm and
Shear strength of key = l*w * τ*d/2
= 644.6Nm

𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 644.6

𝑛𝑓 = == = 1.48 … … … . . 𝑠𝑎𝑓𝑒
𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠ℎ𝑎𝑓𝑡 435.24

 Due to crushing
T = l * t/2 * Sy/sf*d/2
435.24Nm = l* 4/2 * 210/1.65 *36/2
W=t = 4mm
L= 9.5mm
Take larger one from 9.5 and 14 mm
Say, l = 14 mm
3.15 DESIGN OF THECOLUMN
A column is a structural member that carries an axial compressive load and that tends to fail by elastic instability, or
buckling, rather than by crushing the material. Elastic instability is the condition of failure in which the shape of the
column is insufficiently rigid to hold it straight under load.The tendency for a column to buckle is dependent on the

38
1. The cross sectional area, A.
2. The moment of inertia of the cross section, /, with respect to the axis about which the value of / is minimum.
3. The least value of the radius of gyration of the cross section r.

Procedure for Analyzing Straight, Centrally Loaded Columns

1. For the given column, compute its actual slenderness ratio.
2. Compute the value of Cc
3. Compare Cc with KL/r. Because Cc represents the value of the slenderness ratio that separates a long column from a
short one, the result of the comparison indicates which type of analysis should be used.
4. If the actual KL/r is greater than Cc the column is long.
5. If KL/r is less than Cc the column is short
Material selection:
AISI 1020 cold-drawn steel.
E=207Gpa
Sy=209Mpa
Hallow rectangular cross section: B- 40mm mm; H= 100mm; L = 1500 mm.
The bottom of column is pinned; the top is free

Figure 19 column bar cross section

Compute the slenderness ratio. The radius of gyration must be computed about the axis that gives the least value. This is
the y-y axis, for which
B
So, r = = 11.54mm
√12

The column has a pinned-free end fixity for which K = 2.1. Then
2.1∗ 150CN
KL/r = where,L = actual length of the column between supports
11.54
=272.8 K = constant dependent on the end fixity,

Compute the transition slenderness ratio. For the AISI 1040 hot-rolled steel,

E = 207GPa and Sy = 290 MPa.

√2 ∗ π2 ∗ E Sy = yield strength of the material

𝐶𝑐 =
sy
where E=modulus of elasticity of the material of the column
√2 ∗ π2 ∗ E
𝐶𝑐 =
sy

Cc=119
Assume the column is long
Compute

I=Npa(KL)2, Euler’s formula

π2E
3∗ 250N∗ (2.1∗ 1.5N)2
I=
π2207∗ 109pa

39
 I= 3.64*10–9

Then KL/r ≫ Cc thus the column is long. Euler's equation formula to compute the critical load:

Where, Pa = allowable load, usually set equal to the actual maximum expected load
Pcr= critical buckling load
Pa = allowable load=1500N
P = actual applied load
N = design factor
Then: Pa =P/N
The actual applied load, P, must be less than
π2∗ 207Gpa∗ A
Pcr= 272∗ 1500mm =121
(11.54)

Where, area (A) = (100mm*40mm)-(90mm*30mm) because hallow and thickness=10mm

A=1300mm^2
Pcr =121
At this load, the column should just begin to buckle. A safe load would be a reduced value, found by applying the design
factor to the critical load. Let's use N = 3 to compute the allowable load, Pcr = Pa/N;
The safe load on the column.

3.16 DYNAMOMOTOR
The electric motor is widely used for providing the prime power to industrial machinery, consumer products, and business
equipment.
The primary factors to be considered in selecting a motor include the following:
• Operating torque, operating speed, and power rating. Note that these are related by the equation
Power = torque x speed
• Starting torque.
• Load variations expected and corresponding speed variations that can be tolerated.
• Current limitations during the running and starting phases of operation.
• Duty cycle: how frequently the motor is to be started and stopped.
• Environmental factors: temperature, presence of corrosive or explosive atmospheres, exposure to weather or to liquids,
availability of cooling air, and soon.
• Voltage variations expected:
• Shaft loading, particularly side loads and this loads that can affect the life of shaft bearings.
DCMOTORS
DC motors have electric windings in the rotor, and each coil has two connections to the commentator on the shaft. The
commentator is a series of copper segments through which the electric power is transferred to the rotor. The current path
from the stationary part of the motor to the commentator is through a pair of brushes, usually made of carbon, which are
held against the commentator by light coil or leaf springs.
The advantages of direct current motors are summarized here:
• The speed is adjustable by use of a simple rheostat to adjust the voltage applied to the motor.
• The direction of rotation is reversible by switching the polarity of the voltage applied to the motor.
• Automatic control of speed is simple to provide for matching of the speeds of two or more motors or to program a
variation of speed as a function of time.
• Acceleration and deceleration can be controlled to provide the desired response time or to decrease jerk.

40
• Torque can be controlled by varying the current applied to the motor. This is desirable in tension control applications,
such as the winding of film on as pool.
• Dynamic braking can be obtained by reversing the polarity of the power while the motor is rotating. The reversed
effective torque slows the motor without the need for mechanical braking.
• DC motors typically have quick response, accelerating quickly when voltage is changed, because they have a small rotor
diameter, giving them a high ratio of torque to inertia.
DC Motor Types
Four commonly used DC motor types are the shunt-wound, series-wound, compound wound, and permanent magnet
motors. They are described in terms of their speed/torque curves.
Permanent Magnet DC Motors:- Instead of using electromagnets, the permanent magnet DC motor uses permanent
magnets to provide the field for the armature. The direct current passes through the armature. The field is nearly constant
at all times and results in a linear speed/torque curve. Current draw also varies linearly with torque.

Figure 20 permanent magnet dc motor performance curve

DC MOTOR CONTROL
Speed control is provided by variation of the resistance in the lines containing the armature or the field of the motor. The
details depend on whether the motor is a series, shunt, or compound type. The variable-resistance device, sometimes
called a rheostat, can provide either stepwise variation in resistance or continuously varying resistance.

Figure 21 schtomatic diaram of dc motor contro

41
 MACHINE PARTS COST ANALYSIS TABLE

No. Name of material Quantity Price in birr

1 Lifting/elevator dynamo 1 3000

2 V-belts 1 1000

3 Spur Gear 2 3000

4 Front roller shaft 1 600

5 Main frame 1 2500

6 Up right tube unit/column 2 2000

7 Screw 1 1000

8 Nut 1 500

9 Key 2 150

10 Running board 1 800

11 Running belt 1 3000

12 Rear roller shaft 1 600

13 Monitoring case/control system 1 5500

14 Pin/cushion 22 500

15 Motor 1 4000

16 Hydraulic system component 1 600

17 Motor cover 1 300

18 Anti-slip side bar 2 500

19 Total cost 52000 Birr

42
CHAPTER FOUR
RESULT AND DICUSION
4.1 RESULT

Part Formula Result

Piston rod 𝜋𝑑𝑟 4 Dr=30mm

𝐼=
64

Cylinder
𝑝 ∗ 𝑑𝑖 t=1.12mm
𝑡=
4 ∗ 𝜎𝑡

𝑝∗𝑑𝑖 t2=0.56mm
t 2=
4∗𝜎𝑡

Dc=(p/(acπ/4))1/2 dc=30mm
Screw

Dmean=(dc+do)/2 dmean=33mm

Main frame 𝜏=(12.09N/mm2)/s S=6.6mm

𝜏=20mm
𝜏=F1/A
Bearing 𝝈b=3.75Mpa
𝝈b=p/t*d
b=54.28mm
b=d*2a

B R=11.54mm
𝒓=
Column √12

√2𝜋2
Cc= Cc=119
𝑠𝑦

V belt L = 2C + 1.57(D2 -D1) + (d2-d1/4c)2 L=925.6mm

43
4.2 DISCUSION
From the above result is important to this technical project either to modify, continue or finish the project we have design cylinder,
piston rod, cylinder, screw, main frame, bearing column belt and base.As we see from the above result , the maximum bending
moment at the end of the bearing the material. A most suitable bolt and nut is selected by calculating the basic dynamic load that
is applied on the bolt. The preferable length is calculated by taking the shear stress and bending stress induced in accordance to
design. By using the maximum principal stress and maximum shear stress theories the maximum bending(tensile) and maximum
shear stress induced in the base is checked by comparing with the allowable bending and shear stress. the width and thickness of
base calculatedand its length is calculated by considering the shearing and crushing strength material.

In general All of these components are designed and selected by using optimized concept and appropriate formula reduce the
failure which may cause by design error and poor material selection hence the adequate design and proper material selection is
well performed.The result of this project shows all the designed and selected components are efficient and safe to apply
practically.

44
 CHAPTER FIVE
CONCLUSION AND RECOMENDATION

5.1 CONCLUSION
This automatic walking training machine is mainly designed for the clinical training purpose that is training ordered by the
doctors in the hospitals and clinics. Patients who are affected by diseases like Bronchiatatic and Fibrotic lung disease
cardio vascular and overweight effected peoples are ordered to take exercise in the hospitals (clinics) or at home. This
exercise is taken by this machine. For this purpose, this machine should be available in every clinic (health center).to do
available materials we tried to design the machine and we want to be manufactured in our country by ourselves. This also
can crate work opportunity for others and have many other advantages. Our machine haves many parts like base frame,
walking frame, running board, belts, and dynamo motors gears (drive and followers), screw, bolts and nuts, pine, wheels,
electronic dash board; patients tightening mechanism, hydraulic system assembly and etc. For this all parts we tried to
design their dimensions by using some assumptions and appropriate formulas. the design we used the free body diagrams
to show the force, torque, shear and other effects on the part to be designed.

45
5.2 RECOMENDATION

In the design process of our project on automatic walking training machine we used some assumption values that used us
to decide the dimensions of each parts. These values may be upper limit or lower limit. If we take the user weight as an
example, we take a maximum of 150kg. Thus the machine parts are designed by taking this mass value as an input value.
Because of this & others the users need to take care of this kinds of specifications. It is forbidden to use this machine two
or more people at the same time on one machine. The users mass value added may exceed 150kg. This may leads the
machine to fail. The other recommendation we have to the uses is that every person need to tighten himself by the
suspended belts & adjust the inclined bar which is operated by the hydraulic system to the user person’s height. Then
after the user can start the running belt to run to run at the needed speed of revolution by simply touch button. And we
recommend our design is useful for developing country it is important and low cost for clinic and hospitals.

46
 Reference

[1] https //reliefweb.int ethiopia

[2] http://www.larmlaboratory.net/
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47
 Appendix

Table: .1 coefficient of friction between belt and pulley

Pulley material
Cast iron, steel
Belt material Wood Compressed Leather Rubber
Dry Wet Greasy paper face face

1. Leather oak tanned 0.25 0.2 0.3 0.33 0.38 0.40

0.15
2. Leather chrome tanned 0.35 0.32 0.4 0.45 0.48 0.50
0.22
3. Canvases-stitched 0.20 0.15 0.12 0.23 0.25 0.27 0.30

4. Cotton woven 0.22 0.15 0.25 0.28 0.27 0.30

0.12
5. Rubber 0.30 0.18 0.35 0.40 0.42

6. Balata 0.20 0.40 0.42

Table.2 the standard proportions in module (m)

S. No. Particulars 1°14/2 composite system full 20°dipth 20stup depth

involute system involute system involute
1 Addendum 1m 1m 0.8m
2 Addendum 1.25m 1.25m 1m
3 Working depth 2m 2m 1.60m
4 Minimum total depth 2.25m 2.25m 1.80m
5 Tooth thickness 1.5708m 1.5708m 1.57m
6 Minimum clearance 0.25m 0.25m 0.2m
7 Fillet radius at root 0.4m 0.4m 0.4m

Table. 3 values of deformation factor (C)

Material Values of deformation factor (C) in N-mm

Involute Tooth error in action(e) in mm

Tooth
Pinion Gear

Form
0.01 0.02 0.04 0.06 0.08

Cast iron Cast iron 14 1/2° 55 110 220 330 440

steel Cast iron 76 152 304 456 608

Steel Steel 110 220 440 660 880

Cast iron Cast iron 57 114 228 342 456

steel Cast iron 20°full 79 158 316 374 632

Steel Steel Depth 114 228 456 684 912

Cast iron Cast iron 20° stub 59 118 236 354 472

48
 Steel Cast iron 81 162 324 486 648

Steel Steel 119 238 476 714 952

Table.4 value of flexural endurance limit

Material of pinion andgear Brinell hardness Flexural endurance limits
number(B.H.N) (ae) in Mpa
Grey cast iron 160 84
Semi-steel 200 126
Phosphor bronze
100 168
Steel
150 252

200 350

240 420

280 490

300 525

320 560

350 595

360 630

400 and above 700

49
 PART DRWING AND ASSEMBLY

1 piston rod and piston head

2 cylinder

3 belt

4 belt drive

4 power screw

50
4 running frame

5 shear in pin

6 fixing beam

51
7 bearing effect at wheel

8 spur gear

9 nut

10 column

52
11 column and frame

12 screw shaft

13 final auotomatic walking training machine assembly

53
54