Design, Fabrication and Testing of Mechanically Operated Road Sweeper PDF

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TRIBHUVAN UNIVERSITY INSTITUTE OF ENGINEERING THAPATHALI CAMPUS A project report on ‘Design, Fabrication and Testing of Mechanically Operated Road Sweeper’ Prepared by: Ashim Khanal Bhakta Bahadur Bhandari Prabin Chaudhary Anish Ghimire Durga Prasad Pandeya A PROJECT REPORT SUBMITTED TO THE DEPARTME...

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TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING THAPATHALI CAMPUS

A project report on ‘Design, Fabrication and Testing of Mechanically Operated Road Sweeper’ Prepared by: Ashim Khanal Bhakta Bahadur Bhandari Prabin Chaudhary Anish Ghimire Durga Prasad Pandeya

A PROJECT REPORT SUBMITTED TO THE DEPARTMENT OF INDUSTRIAL ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF BACHELOR IN INDUSTRIAL ENGINEERING

DEPARTMENT OF INDUSTRIAL ENGINEERING KATHMANDU, NEPAL 10 MAY, 2018

TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING THAPATHALI CAMPUS DEPARTMENT OF INDUSTRIAL ENGINEERING It is hereby certified that this paper, entitled “A Project report on Design, Fabrication and Testing of Mechanically Operated Road Sweeper” prepared by Ashim Khanal, Bhakta Bahadur Bhandari, Prabin Chaudhary, Anish Ghimire and Durga Prasad Pandeya

is an outcome of the research conducted under “Department of Industrial Engineering” The facts and ideas presented in this paper are an outcome of the student’s hard work and dedication to the project, undertaken as a partial fulfillment for requirements for degree of Bachelor in Industrial Engineering. The outcome of this project has been highly appriciated.

_____________________

_____________________

Internal Supervisor

External Evaluator

Rajan Sharma

Shailesh Sharma Design Engineer _____________________

AECPL

Head of Department Sudan Neupane APPROVAL

PAGE

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ABSTRACT Due to unassessed industrialization and unmanaged construction & development projects in developing countries like Nepal, quality of air has been significantly compromised. People are being compelled to inhale polluted air and significant amount of dust particles. Air quality has been sufficiently degraded below the standard set by World Health Organization (WHO), and this has become a serious issue. One of the major reasons is dust particles spread from road to atmosphere by vehicles plying on the road, where roads is dug up for construction purposes only to leave it uncompleted because of political, financial and personal interests of the elite groups and construction company owners. This can lead to serious health hazards like sever allergy, lung cancer and other problems related to breathing. In order to address this problem, we have designed, fabricated and tested a ‘Mechanically Operated Road Sweeper’ prototype that is financially viable and socioeconomically beneficial. This machine works on simple principle of centrifugal motion of cylindrical brush throwing dust particles from road surface in the container, uses local materials and is cheap with respect to other machines and is efficient as well. This can be used in the side area of roads where dust has been piled up in maximal amount. We have performed detailed mathematical calculation and analysis for design specification of each and every part of the machine components and made a prototype design in Solidworks. Then after we successfully fabricated using conventional fabrication tools and tested its performance. Keywords: air, pollution, dust, health, hazards, road sweeper, brush, centrifugal motion, design, calculation, analysis, testing

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ACKNOWLEDGEMENT We would like to express our sincere gratitude and honor to our project supervisor Er. Rajan Sharma, Assistant lecturer, Department of Industrial Engineering, IOE, for supervising and guiding us during our final year project entitled "Mechanically Operated Road Sweeper" as a partial fulfillment of Bachelor's degree in Industrial Engineering. It was almost impossible to complete this report without his support, suggestion and guidance. Our sincere thanks to Er. Sudan Neupane, HOD, Department of Industrial Engineering, IOE for his care and support to encourage in doing the project work. We would also like to thank Mr. Gautam Das Tuladhar, fabrication supervisor, Fabrication Workshop, Thapathali Campus for his valuable help in the fabrication processes. We are thankful to the all the teachers of the Department for helping us to reach at this level in our study.

Project members, Ashim Khanal Bhakta Bahadur Bhandari Prabin Chaudhary Anish Ghimire Durga Prasad Pandeya

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TABLE OF CONTENTS ABSTRACT................................................................................................................... 3 ACKNOWLEDGEMENT ............................................................................................. 4 LIST OF TABLES ......................................................................................................... 7 LIST OF FIGURES ....................................................................................................... 8 LIST OF ABBREVIATIONS ........................................................................................ 9 CHAPTER ONE: INTRODUCTION ......................................................................... 10 1.1

Background ................................................................................................... 10

1.2

Dust Control Methods ................................................................................... 11

1.3

Objectives ...................................................................................................... 12

1.3.1

General Objective .................................................................................. 12

1.3.2

Specific Objectives ................................................................................ 12

1.4

Details of the Project ..................................................................................... 12

1.4.1

Problem Statement ................................................................................. 12

1.4.2

Concept Generation ............................................................................... 15

CHAPTER TWO: LITERATURE REVIEW ............................................................. 16 CHAPTER THREE: METHODOLOGY .................................................................... 20 3.1

Data collection............................................................................................... 22

3.1.1

Primary data collection .......................................................................... 22

3.1.2

Secondary data collection ...................................................................... 22

CHAPTER FOUR: RESULTS AND DISCUSSION ................................................. 23 4.1

Solution concepts .......................................................................................... 23

4.2

Design Selection:........................................................................................... 24

4.3

Design details ................................................................................................ 25

4.3.1

Chassis: .................................................................................................. 25 5

4.3.2

Wheel ..................................................................................................... 26

4.3.3

Handle .................................................................................................... 27

4.3.4

Brush ...................................................................................................... 28

4.3.5

Sprockets ................................................................................................ 30

4.3.6

Chain ...................................................................................................... 31

4.3.7

Spur Gear ............................................................................................... 35

4.3.8

Shaft ....................................................................................................... 36

4.3.9

Container: ............................................................................................... 42

4.4

Working principle and operation................................................................... 45

4.5

Economic analysis ......................................................................................... 47

4.6

Financial analysis .......................................................................................... 50

CHAPTER FIVE: RESULT AND CONCLUSION .................................................... 52 5.1

Conclusion..................................................................................................... 52

5.2

Future Modification of the Project ................................................................ 52

REFERENCES ............................................................................................................ 53 Annexes........................................................................................................................ 99 Annex A: Designs ........................................................................................................ 99 Annex B: Calculations ................................................................................................. 99 Annex C: Fabrication ................................................................................................. 120 Annex D: Charts and Graphs ..................................................................................... 121 Annex F: Installation and performance...................................................................... 123

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LIST OF TABLES Table 4.1: Factor rating method ................................................................................... 24 Table 4.2: Specification of chassis............................................................................... 25 Table 4.3: Spefication of wheel ................................................................................... 26 Table 4.4: Specification of handle ............................................................................... 27 Table 4.5: Spefications of brush .................................................................................. 29 Table 4.6: Spefication of sprockets .............................................................................. 31 Table 4.7: Spefication of chain drive 1 ........................................................................ 33 Table 4.8: Spefication of chain drive 2 ........................................................................ 34 Table 4.9: Specification of chain drive 3 ..................................................................... 35 Table 4.10: Spefication of spur gear ............................................................................ 36 Table 4.11: Specification of shaft 1 ............................................................................. 37 Table 4.12: Specification of shaft 2 ............................................................................. 38 Table 4.13: Specification of shaft 3 ............................................................................. 39 Table 4.14: Specification of shaft 4 ............................................................................. 40 Table 4.15: Specification of shaft 5 ............................................................................. 42 Table 4.16: Specification of front tire .......................................................................... 44 Table 4.17: Financial analysis...................................................................................... 50

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LIST OF FIGURES Figure 1.1: Air pollution .............................................................................................. 11 Figure 1.2: Kathmandu Air Pollution: Real-time Air Quality Index (AQI) ................ 14 Figure 1.3: P.M at Ratna Park ...................................................................................... 14 Figure 1.4: Sources of air pollution in Kathmandu valley ........................................... 14 Figure 3.1: Flow process for methodology .................................................................. 20 Figure 3.2: Survey of road for dust accumulation ....................................................... 22 Figure 4.1: Chassis ....................................................................................................... 25 Figure 4.2: Wheel......................................................................................................... 26 Figure 4.3: Handle ....................................................................................................... 27 Figure 4.5: Brush ......................................................................................................... 28 Figure 4.6: Larger sprockets ........................................................................................ 30 Figure 4.7: Smaller sprockets ...................................................................................... 30 Figure 4.8: Chain drive 1 ............................................................................................. 32 Figure 4.9: Chain drive 2 ............................................................................................. 33 Figure 4.10: Chain drive 3 ........................................................................................... 34 Figure 4.11: Spur Gear ................................................................................................. 35 Figure 4.12: Shaft 1...................................................................................................... 36 Figure 4.13: Shaft 2...................................................................................................... 38 Figure 4.14: Shaft 3...................................................................................................... 39 Figure 4.15: Shaft 4...................................................................................................... 40 Figure 4.16: Shaft 5...................................................................................................... 41 Figure 4.17: Container ................................................................................................. 43 Figure 4.18 : Front tire ................................................................................................. 43 Figure 4.19: Displacement analysis of Front wheel..................................................... 44 Figure 4.20: Stress analysis of Front wheel ................................................................. 44 Figure 4.21: Principle of Operation ............................................................................. 45 Figure 4.22: Solid Model for Road Sweeper ............................................................... 46

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LIST OF SYMBOLS g d Eff KN KW 𝑣 MPa m m/s mm

Acceleration due to gravity Diameter Efficiency Kilo newton Kilowatt Linear velocity Mega Pascal Meter Meter per second Millimeter

N Nm z ppm 𝜋 α Wr r R rpm N sqrt 𝜎 Ft T t τ W

Newton Newton meter Number of teeth Particulates per million Pi Pressure angle Radial weight Radius Rating Rotations per minute Speed in rev/min Square root Stress Tangential Load Tension Thickness Torque Weight

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LIST OF ABBREVIATIONS BM

Bending moment

BMD

Bending moment diagram

CAD

Computer Aided Drawing

CSMFR

Central Institute of Mining and Fuel Research

FBD

Free body diagram

MS

Mild Steel

SFD

Shear force diagram

WHO

World Health Organization

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1 1.1

CHAPTER ONE: INTRODUCTION

Background

Air is the element that has made life possible in this beautiful planet earth. Had there not been air none of the living species that we know exists today might not be here. We not only humans but all other living beings need air for their survival. Air is the most essential component for living being’s survival on this planet earth. We may even survive for a week without food, couple of days without water but is it possible for us to be alive in the absence of air for a couple of minutes. The answer would be a big NO. Air is what we need 24/7 for survival but the air that we breathe in sometimes causes some serious health hazards. The reason for our illness is polluted air. Polluted air has negative impacts on respiratory system of our body. So, do we stop breathing now? That choice might cost our life. So, the only possible choice that we are left with is to clean the air. The pollutants of air must be removed to make the air clean and harmless. The air pollution has been the major problem since the last decade in world. Kathmandu being one of the most polluted cities in Asia has to be customized to get rid of the pollution. Pollution caused by dust and particles, poses grave danger to children, older people and people with respiratory illness. For this purpose, we the students of Industrial engineering approached to build Road Sweeper for dust removal. Dust has evolved as a serious problem in Kathmandu city which has occurred due to road expansion, electrical and electronic installation in roads, Melamchi water project and settlement of dust from air pollution. Therefore, Road Sweeper can play a vital role for maintenance and keeping the city clean.

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Figure 1.1: Air pollution (Adhikary, 1996) Most of the air pollution is caused by the burning of fossil fuels, such as coal, oil, natural gas. Dust is generated by the undergoing road reconstruction, drinking water pipeline project and electrical installations and is piled up in the edge of the road. Dust and pollution particles mix in the atmosphere and can travel for days across long distance before settling on the ground surface. Dust are also produced from agricultural field operations, parking lots, waste cleanup sites, industrial facilities, construction activities, demolition activities, etc. 1.2

Dust Control Methods

Dust emissions can be prevented by limiting the creation of dust sized particles, reduce wind speed at ground level, etc. The majority of mechanical sweepers are mobile units that use a vacuum system to collect the waste materials. Generally, the suction action is complemented by one or more rotating brushes for dislodging residues that adhere to the surface of the road. There is a wide range of mechanical sweepers. They vary in size from very small units controlled by a pedestrian, to large mechanical sweepers mounted on a vehicular chassis. The large mechanical sweepers generally are equipped with an auxiliary engine to generate the vacuum and, in some cases, are fitted with a hose that can be controlled by an operator to pick up refuse from areas that are difficult to reach (i.e., dry leaves from drainage ditches). Mechanical sweepers are efficient for the collection of light litter, fine dust, and sand from roadways. The conditions typically found in economically developing countries limit the role of mechanical sweepers to that of simply supplementing manual sweeping. Mechanical 11

sweepers normally are found in the large metropolitan areas of developing countries. The degree to which mechanical sweepers are utilized for a specific application should be based on thorough analyses of advantages and disadvantages, as well as the costs associated with usi...