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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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
* 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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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
PAINTING DEVICE 22
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_gears8/14/2019 Painting Device Report Content.doc
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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
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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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
b) Concept 2
Mechanical painting device moving
vertically with transmission gear using
bevel gear as its mechanism.
-idea: Mohd Faizal & Mohd Hazwan
No ISSUES ACTION DUE DATE PICTURE
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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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
No ISSUES ACTION DUE DATE PICTURE
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
ATTENDANCE: ALL MEMBERS
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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
No ISSUES ACTION DUE DATE PICTURE
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
DATE: 20th SEPT 2008
ATTENDANCE: ALL MEMBERS
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PROJECT REPORT KJM 553 EM 220 (EMC6M1)
No ISSUES ACTION DUE DATE PICTURE
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
DATE: 25th SEPT 2008
ATTENDANCE: ALL MEMBERS
No ISSUES ACTION DUE DATE PICTURE
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PROJECT REPORT KJM 553 EM 220 (EMC6M1)