Design of a mechanised pedal washing machine for rural hospitals PDF

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KYAMBOGO UNIVERSITY FACULTY OF ENGINEERING DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING BACHELOR OF ENGINEERING IN INDUSTRIAL ENGINEERING AND MANAGEMENT DESIGN OF A MECHANISED PEDAL WASHING MACHINE FOR RURAL HOSPITALS CASE STUDY: KIWOKO REFERAL HOSPITAL BY MBAZIRA PEREZ 14/U/8543/IEE/PE A PRO...

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KYAMBOGO

UNIVERSITY

FACULTY OF ENGINEERING DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING BACHELOR OF ENGINEERING IN INDUSTRIAL ENGINEERING AND MANAGEMENT

DESIGN OF A MECHANISED PEDAL WASHING MACHINE FOR RURAL HOSPITALS CASE STUDY: KIWOKO REFERAL HOSPITAL

BY MBAZIRA PEREZ 14/U/8543/IEE/PE

A PROJECT REPORT SUBMITTED TO KYAMBOGO UNIVERSITY INPARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARDOF A BACHELOR’S DEGREE OF ENGINEERING IN INDUSTRIAL ENGINEERING AND MANAGEMENT

JUNE 2018

DECLARATION I Mbazira Perez, declare that this REPORT forwarded to the Faculty of Engineering, Kyambogo University, is our own and attained from our efforts with assure explanation, it has never been presented elsewhere in any university, or any other institution of higher learning for any academic award.

Signature …..................................................

Date……………………………………

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APPROVAL This research project has been submitted for examination with my approval as University Supervisor

Signature …..................................... Date…………………………………… MISS ATIMA ROSE (UNIVERSITY SUPERVISOR)

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ACKNOWLEGMENT

First and foremost, I would like to thank the Almighty GOD for the protection, wisdom and guidance granted to me throughout these years of struggle for education. I wish to thank with gratitude my supervisor Ms. Atima Rose for the guidance, commitment and inspiration accorded to me for successive completion of this project. To my fellow colleagues in the struggle Semata Peter, Ssebaka David and others, thanks for any assistance rendered to me.

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TABLE OF CONTENT DECLARATION.......................................................................................................................i APPROVAL .............................................................................................................................ii ACKNOWLEGMENT ...........................................................................................................iii TABLE OF CONTENT..........................................................................................................iv LIST OF FIGURES ................................................................................................................vi LIST OF TABLES .................................................................................................................vii ABSTRACT...........................................................................................................................viii CHAPTER ONE: INTRODUCTION ....................................................................................1 1.1

Background of study .......................................................................................................1

1.2 Problem statement ................................................................................................................2 1.3 Objectives of study...............................................................................................................2 1.3.1 General objective ..............................................................................................................2 1.3.2 Specific objectives ............................................................................................................2 1.3.3 Research questions ............................................................................................................2 1.4 Scope of the study ................................................................................................................3 1.4.1 Content scope ....................................................................................................................3 1.4.2 Geographical scope ...........................................................................................................3 1.4.3 Time scope ........................................................................................................................3 1.5 Justification ..........................................................................................................................3 1.6 Significance of the study ......................................................................................................3 CHAPTER TWO: LITERATURE REVIEW .......................................................................4 2.1 Literature Review of a pedal Driven Washing Machine......................................................4 2.1.1 The Early washing machine ..............................................................................................4 2.1.2 Top loading washing machine: .........................................................................................5 2.1.3 Front-loading Washing machine .......................................................................................7 2.1.4 Commercial use.................................................................................................................9 2.2 Design of a pedal driven washing machine........................................................................10 2.2.2 Components of the machine............................................................................................11 2.3 Theoretical frame work ......................................................................................................17 2.4 Construction and working principle...................................................................................18 CHAPTER THREE: METHODOLOGY............................................................................19 CHAPTER FOUR: RESULTS AND DISCUSSION ..........................................................20

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4.1 Study the existing types of washing machines on the basis of design, performance, economy and applications ....................................................................................................20 4.1.1 Existing cloth washing methods......................................................................................20 4.1.2 Studying the existing laundry washing methods.............................................................20 4.1.3 Operating specifications of a convectional electric washing machine............................21 4.2 Determining the performance parameters ..........................................................................22 4.3 Select, size the material and develop a lay out...................................................................25 4.3.1 List of components ..........................................................................................................25 4.3.2 Design of sprockets and chain.........................................................................................26 4.3.3 Power transmission .........................................................................................................26 4.3.4 Sketch of the design ........................................................................................................27 4.3.5 Final lay out of the Pedal Driven washing machine .......................................................29 4.4 Cost analysis.......................................................................................................................30 4.4.1 The bill of materials ........................................................................................................30 4.4.2 Payback period ................................................................................................................30 CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS.................................32 5.1 Conclusion..........................................................................................................................32 5.2 Recommendations ..............................................................................................................32 REFERENCES.......................................................................................................................33 APPENDIX .............................................................................................................................34 Appendix i: Different components...........................................................................................34

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LIST OF FIGURES Figure 2.1: Early washing machine............................................................................................5 Figure 2.3: Top loading washing machine .................................................................................5 Figure 2.4: Front loading washing machine...............................................................................7 Figure 2.5: Commercial washing unit ........................................................................................9 Figure 2.6: Ball Bearing ...........................................................................................................11 Figure 2.7: Bicycle Seat ...........................................................................................................12 Figure 2.8: Spur gear................................................................................................................13 Figure 2.9: Helical gear............................................................................................................13 Figure 2.10: Worm gear ...........................................................................................................14 Figure 2.11: Bevel gear ............................................................................................................14 Figure 2.12: Plumber block......................................................................................................15 Figure 2.13: Assembly of chain, catcher and Sprocket............................................................16 Figure 2.14: Shaft.....................................................................................................................16 Figure 4.1: Pie chart showing the percentage of use of different Laundry washing methods in rural hospitals ...........................................................................................................................21 Figure 4.2: A bar graph showing the energy consumption for Electric machine ...................22 Figure 4.3: A bar graph showing power output against pedaling rate ....................................23

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LIST OF TABLES Table 3.0: Methodology and Data Instruments for each Specific Objective ...........................19 Table 4.1: Comparison of existing washing methods ..............................................................20 Table 4.2: Shows the Operating specifications of a convectional electric washing machine..21 Table 4.3: Required torque and power for each of the 3 processes .........................................24 Table 4.4: Shows the list of components required ...................................................................25 Table 4.4: Shows the specifications for sprocket and chain ....................................................26 Table 4.5: Shows the Bill of materials .....................................................................................30

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ABSTRACT The pedal driven washing machine is designed at Kiwoko Hospital to aid rural hospitals in Uganda in washing Hospital laundry. The national electrification rate in Uganda is estimated at 14% with the rural population having even a lower rate of below 7%. Power shortage remains one of the greatest obstacles in rural areas. (Web site: International Cooperation and Development visited on 10/09/2017). This challenge makes use of an electric washing machine impossible for the rural Hospitals. Hand washing the hospital laundry continues to be a challenge as the labour requirement is very high; 20 people work for 9 hours every day, these people are exposed to risk of infection from contaminated laundry. This project is aimed at providing an alternative cloth washing method which can work in the absence of electricity and relive hospitals from the high labour cost and reduce the risk of labour infections from contaminated clothes. The methods used for the design was based on the availability of material in the local market, interviews, desk research, literature reviews, questionnaires and observations. The results obtained from the research showed that the designed machine is time saving, can reduce the infection risk and save labour costs if adopted by the rural Hospitals.

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CHAPTER ONE INTRODUCTION 1.1 Background of study A washing machine is a machine that washes dirty clothes. It contains a barrel into which the clothes are placed. This barrel is filled with water, and then rotated very quickly to make the water remove dirt from the clothes. Most washing machines are made so that detergent (liquids or powders) can be put into the machine which helps make the clothes cleaner. The term is mostly applied to machines that use water as opposed to drying cleaning machines (which use alternative fluids and is performed by specialist business). Washing machine technology developed as a way to reduce the manual labour spent, providing an open basin or sealed container with pedals to automatically agitate the clothing. The earliest machines were hand operated and constructed from wood, while the later machines made of metal permitted a fire to burn below the washtub, keeping the water warm throughout the days washing (Wikipedia). Depending on the position of loading in clothes, electric washing machines are of 2 types: top loading and front loading machine. The typical electric washing machine on average will consume 500watts for 0.25hours of washing and as such, one must have access to a reliable electricity source if he is to use this machine. The national electrification rate in Uganda is estimated at 14% with the rural population having even a lower rate of below 7%. Power shortage remains one of the greatest challenges in rural areas, regardless of the government’s effort to electrify rural areas. (Web site: International Cooperation and Development visited on 10/09/2017). An electric washing machine will therefore be very expensive to operate and unreliable in most rural areas of Uganda. Among those greatly affected by this condition are the Rural Health centers. These hospitals are not in position to safely wash contaminated laundry using the electric washing machines, which is the standard for performing such a task. Kiwoko referral Hospital for example, found in Nakaseke District faces the same problem. This Hospital serves Luweero, Nakaseke and Nakasongola district, attending to over 600 patients a day (Kiwoko Hospital Audit Report 2016). Because of the large number of patients, the hospital employs 20 people working who work for 9 hours daily to hand wash the hospital laundry. 80% of the workers find this work undesirable because the operation exposes them to a high risk of infection from the contaminated laundry. This work also involves a lot of effort and time. The Hospital administration spends 8million every month on paying the workers which amounts to about 96 million a year, this is very expensive (Kiwoko Hospital Audit report 2016). 1

The pedal driven washing machine does not need electricity to operate and as such, can be used in rural areas with no electricity supply. This machine generates power through human pedaling and with the drive mechanism, converts the pedaling motion into required rotary motion of the drum. With the help of compound gear system, the machine achieves the desired speed for different purposes like washing, rinsing and drying. Its innovation lies in its simple design and use of inexpensive parts. This project makes laundry washing safe by reducing workers’ contact with the contaminated laundry which is apparently exposing them to a high risk of infection from the clothing, reduce human effort and save time. The hospital can also save labor costs as this operation only needs 4 people working 4 hours a day, instead of 20 people. 1.2 Problem statement Because of Power shortage in rural areas of Uganda, Kiwoko Hospital found in Kiwoko Village employs 20 people who work for 9 hours every day to hand wash Hospital laundry, this is time consuming. Therefore in the absence of electricity, a mechanized Pedal washing machine provides a faster alternative for performing this task which only needs 4 people working 4 hours a day 1.3 Objectives of study 1.3.1 General objective To design a driven washing machine 1.3.2 i.

Specific objectives To study the existing types of washing machines on the basis of design, performance, economy and applications

ii.

To determine the machine parameters

iii.

To select, size the material and develop a lay out.

iv.

To carry out a cost analysis of developing a unit of pedal powered washing machine

1.3.3

Research questions

i.

What are the different types of existing washing machines?

ii.

What are the machine parameters?

iii.

Which materials are appropriate for the design and what are the component sizes?

iv.

What is the cost of developing a unit of pedal powered washing machine?

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1.4 Scope of the study 1.4.1 Content scope The study concentrated on studying existing laundry washing methods in rural Hospitals in Uganda with their associated time, costs, risks and required man power, with the major emphasis on developing a pedal driven washing machine which could be used by the rural Hospitals to save time, cut labour costs, and reduce workers’ risk of infection due contact with contaminated clothing. 1.4.2 Geographical scope The study was carried out in Uganda at different Rural Hospitals and major at Kiwoko Referral Hospital. The Hospital is located in Nakaseke District, Kiwoko Town Council. 1.4.3 Time scope The study took a period of Seven months that is from November to May 2018. 1.5 Justification There is a great need for designing a pedal driven washing machine for Rural Hospitals because; i.

The present electric washing machines have a high power consumption, 500watts for 0.25 washing hours and yet there is electricity shortage in rural areas.

ii.

The present hand washing method exposes the people involved to a high risk of infection from contaminated laundry

iii.

Hand washing is time wasting, 20 people work for 9 hours every day to finish the wash.

iv.

The cost of purchasing a commercial electric washing machine is high, between $800 $2700 (Washing machine catalog 2017). Most rural hospitals cannot afford this.

1.6 Significance of the study If this project is implemented, Rural Hospitals will; i.

Reduction in the labour requirement from 20 people to 4 people which lowers the labour expenses from 36m to 10m a year.

ii.

Make cloth washing safe by reducing workers’ contact with contaminated laundry which reduces the risk of infection.

iii.

Increased Hospital sanitation due to a constant supply of clean clothing brought about by a faster rate of washing.

iv.

Higher hospital capacity hence more patients can be handled. This is because the machine has a higher efficiency than man. 3

CHAPTER TWO LITERATURE REVIEW 2.1 Literature Review of a pedal Driven Washing Machine A washing machine is a machine that washes dirty clothes. It contains a barrel into which the clothes are placed. This barrel is filled with water, and then rotated very quickly to make the water remove dirt from the clothes. Most washing machines are made so that detergent (liquids or powders) can be put into the machines which help make the clothes cleaner. The term is mostly applied to machines that use water as oppose...