Painting Device Report Content.doc

8/14/2019 Painting Device Report Content.doc

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PROJECT REPORT KJM 553 EM 220 (EMC6M1)

1.0

A mechanical wall and ceiling painting device is a desired space below a ceiling meeting

the wall. A paint applying device is removable mounted on the guide for movement along

the length of the guide and includes a roller in abutment with the wall. A railing and cord

arrangement is mounted on the guide and coupled to the paint applying device for

moving the paint applying device along the length of the guide, as desired. The moving

mechanisms are real transmission, bicycle mechanism, idler gear and bevel gear. This

mechanical wall and ceiling painting device is design considering:

The device should be suitable for local manufacturing capabilities.

The attachment should employ low-cost materials and manufacturing methods.

It should be simple to manufacture, operate, maintain and repair.

It should be as multi-purpose as possible, providing perfect painting effect during

painting process.

Standard tools used in machine shop such as drill press; small lathe and milling

machine should be adequate to fabricate the parts needed for the dual-purpose

bicycle.

It should be safe for the user because the mechanism is not using combustion.

It is also should be user friendly design and easy to assemble by the user.

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2.0

BIL CONTENT PAGES

1 Abstract 1

2 Table of content 2

3 Introduction 3

4 Literature review 4

5 Main body 5

6 Conclusion 11

7 Reference 12

8 Appendix 13

3.0

The goal of every painter is to paint neatly and quickly. This can be challenging because

painter have to stand at uncomfortable position for along time during painting. As a resultthey cannot achieve their goal to paint neatly and quickly. The new design from our

group had overcome all the constraint. The design process start with identify problem for

current painting device. Then we gather the information by brainstorming and searching

in the internet. Finally we are generating the concept for this mechanical wall and ceiling

painting device.

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The system of this mechanical wall and ceiling painting device is aspower is supplied to

the shaft by means of a chain from the bike's chain wheel (crank) to a ratcheted sprocket

on the shaft. The painter start cycle the bicycle paddle, the rotation will transmit the

human power through bevel gear. As the painter engages the forward gear, the bevel gear

will be attached to a support that is connected to the directional control system in order to

rotate the shaft forward. The roller starts to paint the wall upward. The rotating shaft has

the sprocket connected to chains that control the roller movement. In order to roller move

downward, the painter needs to engage backward gear that attached to idler gear. By

reversing the direction of the rotating shaft, the roller will move downwards. After

completed painting vertical direction the painter will move forward, the system also will

move forward. The direction and the power for the apparatus is provided by a unique

combined of bevel gear and idler gear unit whose transmit the human power to rotatingshaft that control the painting roller. The bike will be kept in a side by side position by a

railing support.

After generating the concept, we evaluate the design by making a specification and

design requirement. The specification and design requirement consist of cost,

environment, safety, materials selection, manufacturing and work schedule in order to

produce the product on time.

4.0

The main objective of this design project is to transmit human power to mechanical

system. The concept we adapt to transmit human power to mechanical system is using

bicycle mechanism and the medium to transmit power is using bevel gear, idler gear and

real transmission gear. The mechanism enables the painter to efficiently apply both arm

and leg power for motive force. Specifically the moving mechanism has oscillation shaft

and a linkage connectable to the human power through bevel gear. We had seen designs

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for devices that take power from the bicycle mechanism by means of a friction roller

pressed against it and we had doubts about the efficiency of this arrangement. In order to

improve efficiency we used roller chains, sprockets and railing.

During completing the design, we are using Pugh method in order to choose the best

concept. First concept is mechanical wall and ceiling painting device, moving

horizontally with rollers, railings, basic rear transmissions using idler gear and bevel gear

as main components. Second concept is mechanical painting device moving vertically

using transmission gear using bevel gear as its mechanism and third concept is

mechanical painting device moving vertically and horizontally using transmission gear

using chain as its mechanism. After considering all criteria in Pugh method, first concept

is the best.

Analysis also has been done for failure and strength of the gear and other component inorder to avoid failure during conducting it. The analysis calculation is using principle

stress formula and ductile failure formula.

As a result the dimension and the material selection has been decided according to

calculation guide.

5.0

5.0.1 PHASES OF DESIGN PERFORMED (PHASE I)

5.1 Identify problem:

Problem statement

- Time consuming in painting process

- Ineffective

- Messy

- Require man power

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5.2 Gather information:

- Internet

- Magazine

- Present painting device

- Discussion and brainstorming

- Lecturer guidance

5.3 Generating concept: .

Concept Ideas

a) Concept 1

Mechanical wall and ceiling painting device, moving horizontally with rollers, railings,basic rear transmissions using idler gear and bevel gear as main components.

b) Concept 2

Mechanical painting device moving vertically using transmission gear using bevel gear as

its mechanism.

c) Concept 3

Mechanical painting device moving vertically and horizontally using transmission gear

using chain as its mechanism.

5.4 Concept evaluation:

1- Pay more attention on roller, railing, and a real transmission mechanism.

2- Roller design

2.1- Roller with brush

2.2- Back-up brush to paint edged or cornered area.

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3- Real transmission mechanism.

4- Railing system to support the chain and roller and at the same time allow their

movement.

PUGH METHOD

Criteria Concept 1 Concept 2 Concept 3 Present deviceEasier mechanism to be design

(complexity)

+ _ _

Easier to manufacture + - +

Cost to manufacture + - +

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Smooth movement of the painting

process

+ + +

Uniform movement of the roller + + +

Uniform painting area during

painting

+ + +

Weight of the system - + _

Time taken for painting process + + +

Human power consumption + + +

User friendly + + +

+ 9 7 8- 1 3 2S 0 0 0

Justification

1. In Pugh method, Concept 1 has maximum summation of positive criterion

compare to concept 2 and concept 3.

2. Concept 2 is the most accurate mechanism for painting process than others but it

require high cost of manufacturing

3. Concept 3 overcome the problem statement which are time consuming in painting

process, ineffective, messy and require man power.

4. Concept 1 is the simplest concept using chain, transmission gear and railing.

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5. The complexity for Concept 2 is the most complicated design followed by

concept 1 and concept 3.

5.0.2 PHASE II

Finally, selection of the best design model is Concept 1 which is:

The Mechanical wall and ceiling painting device with rollers, railings and basic real

transmissions using idler gear and bevel gear as main components.

5.1 Product architecture

SPECIFICATION AND DESIGN REQUIREMENT

a. Costb. Environmentc. Safetyd. Materials selectione. Manufacturingf. Work schedule.

No Specification &design requirement

Item Quantity Cost (RM)

1 Cost Painter roller Chain

RailingBevel gearNormal gearBearing houseBearingSprocketShaftHollow pipeScrew

1 unit1 feet

1 feet1 unit1 unit1 unit1 unit1 unit1 feet1 feet100 gram

7.0028.00

8.00400.0021.0052.0019.008.00

17.0012.006.00

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NutBoltAdjustable rodHand pump

100 gram100 gram1 feet1 unit

6.506.501.505.00

No Specification & design requirement2 Environment Use 100% human power to move themechanism.

Involve no combustion process andtherefore produce no hazardoussubstances

Clean and environment friendly Generate less noise and vibration

3 Safety Moving mechanism enclosed insafety housing

Gear mechanism is equip with engagesystem to prevent unwantedmovement (roller drop accidentally)

Improve occupational safety ofpersonnel due to ergonomic design.

4 materials selection Gear, bearing, sprocket, pinion shaft,bevel gear, idler gear- Cast iron

Roller connection- Aluminum Shaft Steel Chain-steel Railing-aluminium Bolt & nut steel Housing mild steel Stand rod- steel Bicycle mechanism- steel

5 Manufacturing Welding Bending Sheet metal cutting Punching Turning Milling

5.2 Configuration Design

Analysis done & calculation- Gear ratio- Stress analysis

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CALCULATION OF GEAR RATIO

WALL H = 2.5 mt = 15 s

Upper sprocket

Lower sprocket

First bevel gear

Second bevel gear

=

Ordinary gear 1

Ordinary gear 2

Net distance

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Idler gear

Ordinary gear 3

= 0

Ordinary gear 4

TORQUE CALCULATION

24.5 N 24.5 N

r R = 0.035 mR = 0.035 m

;

Overall torque requires both sides.

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Toverall = 0.858(2) = 1.718Nm

Power require to rise and down the roller.

SCHEMATIC OF POWER TRANSMISSION

Force applied by the operator

Upper sprocket

20cm pedal

W = rad/sec

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Lower sprocket

Human force to raise the roller*Since the friction forces are negligible, the power transmission between input and

output are similar.

Therefore:

Power = 8.179W

=

Stress Analysis

In our project, we have decided to apply the stress analysis at the most critical part of the

system. It is at the joint shaft connecting gear system and railing part. There are 2 joining

parts, but with the same total force, torque and moment, hence we only explained one of

them.

Free Body Diagram

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Both point A and B are welded areas on hollow shaft. The material used for the shaft is

mild steel with Yield Strength, y = 250 Mpa and Young Modulus, E = 210 Gpa.

F = 40 N

A M = 0.5 Nm

B

0.25 m T = 0.5 Nm

0.10 m z

y

x

Force F is obtained from total weight of upper system acting on the shaft, consists

of roller, paint tray, chain, etc.

Moment and Torque are produced by the vibration of gear movement and cyclingaction on the shaft.

For welded area, maximum Yield Strength allowed, all = 0.60 y

Hence,

all = 0.60 (250)

all = 150 Mpa (Ans)

Shaft Dimension

External diameter, do = 0.030 m

Internal diameter, di = 0.024 m

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* wall thickness of 3 mm

I = do 4 - di4

64

= (0.030)4 - (0.024)4

64

I = 2.347 x 10-8 m4 (Ans)

J = do 4 - di4

32

= (0.030)4 - (0.024)4

32

J = 4.695 x 10-8 m4 (Ans)

Consider Element A

y

xy

x x

xy

y

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Stresses Calculation

x = Mx . c where c = r = 0.015 m

I

= 40 (0.25) (0.015)

2.347 x 10-8

x = 6.39 Mpa (Ans)

y = My . c

I

= 0.5 (0.015)

2.347 x 10-8

y = 0.32 Mpa (Ans)

xy = T . r

J

= 40 (0.1) + 0.5 (0.015)

4.695 x 10-8

xy = 1.44 Mpa (Ans)

Consider Element B

y

xy

x x

xy

y

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Stresses Calculation

x = Mx . c where c = r = 0.015 m

I

= (0.5) (0.015)

2.347 x 10-8

x = 0.32 Mpa (Ans)

y = My . c

I

= 40 (0.10) (0.015)

2.347 x 10-8

y = 2.56 Mpa (Ans)

xy = T . r

J

= (0.5) (0.015)

4.695 x 10-8

xy = 0.16 Mpa (Ans)

Principle Stresses of Element A

1,2 = x + y x - y 2 + xy2

2 2

= 6.39 + 0.32 6.39 0.32 2 + (1.44)2

2 2

= 3.355 3.359

max = 6.714 Mpa min = - 0.004 Mpa (Ans)

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Principle Stresses of Element B

1,2 = x + y x - y 2 + xy2

2 2

= 0.32 + 2.56 0.32 2.56 2 + (0.16)2

2 2

= 1.13 1.44

max = 2.57 Mpa min = - 0.31 Mpa (Ans)

Safety Factor will be calculated based on 3 Theorems for Ductile Material;

a) Maximum Normal Stress Theorem (MNST)

b) Maximum Shear Stress Theorem (MSST)

c) Distortion Energy Theorem (DET)

Safety Factor of Element A

A = 12 + 22

= (6.714)2 + (-0.004)2

A = 6.714 Mpa

i) Maximum Normal Stress Theorem (MNST)

P = Px2 + Py 2 = (150)2 + (-29)2

P = 152.78 Mpa

SF = P = 152.78

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A 6.714

SF = 22.8

ii) Maximum Shear Stress Theorem (MSST)

Q = Qx2 + Qy 2 = (125)2 + (-25)2

Q = 127.48 Mpa

SF = Q = 127.48

A 6.714

SF = 19.0

iii) Distortion Energy Theorem (DET)

R = R x2 + Ry 2 = (138)2 + (-27)2

R = 140.62 Mpa

SF = R = 140.62

A 6.714

SF = 20.9

Safety Factor of Element B

B = 12 + 22

= (2.57)2 + (-0.31)2

B = 2.589 Mpa

i) Maximum Normal Stress Theorem (MNST)

P = Px2 + Py 2 = (150)2 + (-29)2

P = 152.78 Mpa

SF = P = 152.78

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B 2.589

SF = 59.0

ii) Maximum Shear Stress Theorem (MSST)

Q = Qx2 + Qy 2 = (127)2 + (-24)2

Q = 129.25 Mpa

SF = Q = 129.25

B 2.589

SF = 49.9

iii) Distortion Energy Theorem (DET)

R = R x2 + Ry 2 = (137)2 + (-27)2

R = 139.64 Mpa

SF = R = 139.64

B 2.589

SF = 53.9

5.0.3 PHASE 3

BLUE PRINT-Assembly drawing-Production drawing

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6.0

As a conclusion, we manage to complete the design project successfully with Mr Afzan

guide and all group members. This project is very challenging because we had just

learned CATIA software. We spent lot of time to draw the model. Even though it is

difficult, we manage to finish it. This KJM 533 subject is very relevant subject to train us

expose to designing field. The chapters introduce in this subject guide us to proceed with

the design project.

The mechanical wall and ceiling painting device is design to improve current painting

device. The concept we adapt to transmit human power to mechanical system is using

bicycle mechanism and the medium to transmit power is using bevel gear, idler gear and

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real transmission gear. The mechanism enables the painter to efficiently apply both arm

and leg power for motive force. Specifically the moving mechanism has oscillation shaft

and a linkage connectable to the human power through bevel gear.

This mechanical wall and ceiling painting device we have been design consist of many

parts. This is because the moving mechanism is the major parts. In order to reduce the

parts and minimize the human power, we need to combine with motor as the moving

mechanism.

7.0

http://www.technologyforthepoor.com/PedalPowerReport/PedalPowerReport.htm

http://www.ncl.ac.uk/gears/services/transmission/index.htm

http://auto.howstuffworks.com/transmission1.htm

http://adventure.howstuffworks.com/bicycle4.htmhttp://www.calculatoredge.com/

file:///E:/Pedel%20Power%20Report.htm

http://en.wikipedia.org/wiki/Gear#Bevel_gears

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http://www.technologyforthepoor.com/PedalPowerReport/PedalPowerReport.htmhttp://www.ncl.ac.uk/gears/services/transmission/index.htmhttp://auto.howstuffworks.com/transmission1.htmhttp://adventure.howstuffworks.com/bicycle4.htmhttp://www.calculatoredge.com/http://e/Pedel%20Power%20Report.htmhttp://en.wikipedia.org/wiki/Gear#Bevel_gearshttp://www.technologyforthepoor.com/PedalPowerReport/PedalPowerReport.htmhttp://www.ncl.ac.uk/gears/services/transmission/index.htmhttp://auto.howstuffworks.com/transmission1.htmhttp://adventure.howstuffworks.com/bicycle4.htmhttp://www.calculatoredge.com/http://e/Pedel%20Power%20Report.htmhttp://en.wikipedia.org/wiki/Gear#Bevel_gears


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8.0 APPENDIX (MINUTE MEETING AND RELEVANT DOCUMENTS OR INFORMATION)

MINUTE OF MEETING

DATE: 11th Sept 2008

ATTENDANCE: ALL MEMBERS

No ISSUES ACTION DUE DATE PICTURE

1 Discuss the design concept all

members give an idea before the best

concept was selected.

Concept Ideas

a) Concept 1

Mechanical wall and ceiling painting

device moving horizontally with

rollers, railings, transmission gear and

bavel gear as main components.

-idea: Noor Idayu ,Ummi Zulaikha &

Faizal Mohd

7/11/08

-as attached in Appendix I

-as attached in Appendix II

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b) Concept 2

Mechanical painting device moving

vertically with transmission gear using

bevel gear as its mechanism.

-idea: Mohd Faizal & Mohd Hazwan


c) Concept 3

Mechanical painting device moving

vertically and horizontally using

transmission gear using chain as its

mechanism.-idea: Shadila

-as attached in Appendix III

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Concept 2

1- Pay more attention on roller, railing

using transmission gear using bevelgear as its mechanism

2- Roller design

2.1- Roller with brush

2.2- Back-up brush

3- Chain mechanism.

4- Railing system to support the chain

and roller and at the same time allow

their movement.

DATE: 18th SEPT 2008


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1 The mechanism designing.

1- Upper and lower support design

idea.

-idea: Syadilla

2- The adjustable rod is suggested to beused.

- idea: Ummi Zulaikha

3- Use transmission gear as moving

mechanism.

-idea: Noor Idayu

4- Bevel gear as moving mechanism

-idea: Mohd Faizal

5- Bicycle mechanism to transmit

human power to moving mechanism

-idea: Mohd Hazwan

7/11/08



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1 New concept 1- Concept of using gear mechanism

2- All members generate ideas to this

new concept design.

3- All discussion more towards the

disadvantages rather than the

advantages of this concept, such as:

- The designing of this concept faced

difficulty for roller to move upward

and downward continuously

- Difficulty in solving moving

transmission gear.

7/11/08




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Painting Device Report Content.doc