HOLLOW BLOCK MAKING MACHINE 2004 ACKNOWLEDGMENT PDF

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HOLLOW BLOCK MAKING MACHINE 2004 Ethiopian Institute of Technology-Mekelle Department of Mechanical Engineering Final year thesis project on DESIGNE O HOLLOW BLOCK MAKING MACHINE In fulfillment of the requirement of Bsc. in Mechanical Engineering By Dahlak Hika (FST/UR 0105/2000) And Zelealem Belay ...

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HOLLOW BLOCK MAKING MACHINE 2004

Ethiopian Institute of Technology-Mekelle Department of Mechanical Engineering Final year thesis project on

DESIGNE O HOLLOW BLOCK MAKING MACHINE In fulfillment of the requirement of Bsc. in Mechanical Engineering By Dahlak Hika (FST/UR 0105/2000) And Zelealem Belay (FST/UR 181/1999)

Under the guidance of ABRHA GEBREGEYORGIS (MTECH.)

JUNE 18/2012

DAHLAK HIKA & ZELEALEM BELAY 2004 G.C

ACKNOWLEDGMENT First of all Our deep gratitude goes to the almighty GOD for everything he did to us in all the way we path through, then after for both my adviser Ato abrha and mechanical engineering department staff members for their continues and progressive support, advice and guides us to do better work and give us a reference materials and initiate us for our work and project. In addition, we would like to thank also other local companies, which participate in this block production sector and their employees for their respect, familiarity, their advice and support. In addition, we would like to thank our classmates and friends for sharing their ideas and materials with us. Finally, we would like to thank our families for understanding and helping us with all our needs.

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ABSTRACT This report presents a systematic approach to enhance the current design of hollow block machine. The design starts with data gathering from the literature review and infoBirration given by the hollow blocks maker. Product specification is then being developed and refine to the specific points. The weaknesses of the current design are being analyzed by looking at the movement waste done by the machine operator and the machine limitation is being identified. The hollow blocks are different from other noBirral blocks as it requires no mortar or cement for masonry work. This blocks interlocked with each other by means of positives and negative frogs on the top and bottom of the blocks which disallow the horizontal movement of blocks. Selection of best design is chosen from the several design concepts proposed. Finally, the drawing and detail design is produced according to standard and ready to be built by the machine developer.

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TABLE OF CONTENTS ACKNOWLEDGEMENT…………………….………………………….…………………..….. 1 ABSTRACT ……………………………………………………………………………..….….…2 LIST OF TABLES ......................................................................................................................... 7 LIST OF FIGURE……………………………………………………………….......……………9 LIST OF ABBREVIATIONS .................................................................................................. 11 LIST OF SYMBOLS

............................................................................................................ 11

LIST OF APPENDICE ................................................................................................................. 12 PROBLEM STATEMENT…………………………………………………………..…………..14 OBJECTIVE……………………………………………………………………………………. 15 SCOPE…………………………………………………………………………………………...16 CHAPTER ONE INTRODUCTION ....................................................................................... 19 1.0 Introduction. .......................................................................................................................... 19 1.1 Hollow block specification………..…………………………………………………..…20 1.1.1 Producuction of hollow block process……………………………………………...20 1.2 Introduction of block product………...………………………………………………….21 1.2.1 Concrete block.......................................................................................................... 21 1.2.2 Background .............................................................................................................. 22 1.2.3. Market& demand aspect………………………………………………….……..…23 1.2.4 Types of concrete block……………………………………………………….……23 1.2.5 Input material for cement block……………………………………………. ……..25 1.2.6 Manufacturing process of blocks…………………………………………………..26 1.3 Block making process…………………………………………………………..………..28

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CHAPTER TWO 2. 1 LITERATURE REVIE 2.1.1 Background and justification of the H.B.P.M………………………..….…….…...30 2.1.2 Hollow Concrete blocks……….………………………………………………..…...32 CHAPTER THREE 3 METHODOLOGY 3.1 Introduction………………………………………………………………………..…..34 3.1.1 Concept development phase ……………..................................................................34 3.1.2 Establishing target specifications …………………………………………………..35 3.1.3 Concept generation ………………………………………………………………...35 3.1.4 Concept selection…………………………….…………………………………….35 3.1.5 Setting final specification ………………………………………………………….35 3.1.6 Concept development….……………………………………………………………37 3.1.7 Establishing target specifications …………………………………………………..38 3.1.8 Concept generation …………………………………………………………………43 3.1.9 prblem identification………………………………………………………………...43 3.2.0 Concept selection …………………………………………………………………..50 3.2.1 Discussion ………………………………………………………………………….53 CHAPTER FOUR 4.1 DESIGN ANALYSIS .......................................................................................................... 55 4.1.1 Motor selection…………………………………….……………….…..……………...56 4.1.2 Bearing selection…………………..………………………………………………….58 4.1.3 Design of Welded joints……………………………………………………………...62 4.1.4 Design of spring……………………………………………………………………...64 4.1.5 Design of Bolt……………………………………………………………………….. 70

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4.1.6 Design of double acting cylinder………………………………………………………71 4.1.7 Design of support frame............................................................ ……………………….75 4.1.8 Design of mould base…………………………………………………………………..76 CHAPTER FIVE 5 RESULT AND DISCUSSION…………………………....... ……........................................78 5.1 Product architecture………………………………………………………………….. 78 5.2 Components analysis ……………………………………………………………….…91 5.2.1 Top Structure…………………………………………………………………….91 5.2.2 Table Structure…………………………………………………………………....93 5.2.3 Compactor Structure ………………………………………………………..…..95 5.2.2 Planar base Structure ………….…………………………………………………97 5.3 Cost analysis ……………………………………………………………………………99 5.3.1 Guideline for Calculating Bricks selling Price ………………………………….99 5.3.2 Machine component and Raw Material Cost…………………………………...102 5.3.3 Material cost estimtion…………………………………………………………..104 5.3.4 Mnufacturing cost………………………………………………………………..106 5.3.5 Product design specification …………………………………………….……...108 CHAPTER SIX 6. CONCLUSION 6.1 Introduction ……………………………………………………………….………….110 6.2 Conclusion……………..…………………………………………………………… .110 6.3 Future Development …………………………………………………………………111 DAHLAK HIKA & ZELEALEM BELAY 2004 G.C

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RECMMENDATION………………………………………………………………………….112 REFERENCES…………………………………………………………………………………113 APPENDICES …………………………………………………………………………………116

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LIST OF TABLES TITLE

PAGE

Table 1.1 Customer statement and interpretation……………………………………24 Table 3.1 interview of hallow block producers………………………………………37 Table 3.2 customer needs……………………………………………………………..42 Table 3.3 Matrix table .……………………………………………………………….42 Table 3.4 Needs-matrix table …………………………………………………………43 Table 3.5 Concept 1 description………………………………………………………44 Table 3.6 Concept 2 description………………………………………………………47 Table 3.7 Concept 3 description

……………………………………………………49

Table 3.8 Concept screening matrix ………………………………………………….51 Table 4.1.1 life of bearing for various type of machine………………………………60 Table 4.1.2 values of service factor …………………………………………………..61 Table 4.1.3 stress for welded joint……………………………………………………64 Table 4.1.4 stress concentration factor ………………………………………………64 Table 4.1.5 types of ends of spring ………………………………………………….66 Table 4.1.6 stress in helical spring ………………………………………………….66 Table 4.1.7 Material cost ……………………………………………………………104 Table 4.1.8 Screw and nuts cost ……………………………………………………105 Table 4.1.9Mechanical system and equipment cost………………………………...107

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Table 4.2. Manufacturing cost

…………………………………………………107

Table 4.2.1 Final product design specification…………………………………….109

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LIST OF FIGURES TITLE

page

Figure A Flow chart represents the scope of work…………………………….…..18 Figure 1.1 manufacturing process of block………………………………….……..20 Figure 1.2 Type of Hollow Block…………………………………………………..22 Figure 2.1 machine used for the production of H.B………….……………………32 Figure 2.2 filling in to the concrete block…………………………………………..33 Figure 2.3 cleaning the top and removing mould…………………………………..33 Figure 2.4 method of designing hollow block ……………………..………………36 Figure 3.1 Method of designing the hollow block making machine……………….36 Figure 3.2 Concept 1-Cantilever concept…………………………………… …….44 Figure 3.3 Concept 2-Cantilever concept…………………………………………..46 Figure 3.4 Concept 3-Center cylinder concept……………………………………..48 Figure 4.1.1types of bearing…………………………………………..……………59 Figure 4.1.2 ball bearing…………………………………………………………….61 Figure 4.1.3 welded lap joint ……………………………………………………….63 Figure 4.1.4 spring expression ……………………….…………………………….65 Figure 4.1.5 bolted joint……………………………………………………………..70 Figure 4.1.6 Hydraulic circuit diagram……….……………………………………..71 Figure 4.1.7 valve representation ……………………………..……………………74 Figure 4.1.8 mould base assembly …………………………………………………76 DAHLAK HIKA & ZELEALEM BELAY 2004 G.C

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Figure 4.1.9 mould assembly design…………………………………………….….79 Figure 4.2 Top structure displacement result ………………………………………80 Figure 4.2.1 churcging system ………………………………………………………81 Figure 4.2.2 inside control panel ……………………………………………………82 Figure 4.2.3 top structure stress analysis……………………………………………91 Figure 4.2.3 top structure displacement result…………………………..………….92 Figure 4.2.3 table structure stress analysis…………………………………………93 Figure 4.2.3 Compactor structure displacement result……………………………...95 Figure 4.2.3 Compactor structure stress analysis……………………………….......96 Figure 4.2.4 Compactor structure displacement result………………………………96 Figure 4.2.5 Planar Base structure stress analysis…………………………………...98 Figure 4.2.6 Planar base structure displacement result………………………..…….98 Figure Cement charging/loading

.

Figure Table assembly drawing Figure Top structure assembly drawing Figure Charging system assembly drawing Figure Table structure assembly design Figure Top structure assembly design Figure Charging system assembly design Figure Top structure stress analysis Figure Table structure stress analysis

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LIST OF ABBREVIATIONS

CAE

- Computer Aided Engineering

CATIA

- Computer Aided Three-Dimensional Interactive Application

D

- Bore Diameter

DfX

- Design for Assembly, Manufacturing, and Environment

EDM

- Electrical Discharge Machine

Kg

- Kilogram

KN

- Kilo Newton

PDS

- Product Design Specification

LIST OF SYMBOLS π

- pi (3.1415)

P

- Pressure

ᵒC

- Degree Celsius

ᵒF

- Degree Fahrenheit

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LIST OF APPENDICES TITLE

page

A-1

Machine assembly drawing

116

A-2

Mold assembly drawing

117

A-3

Table assembly drawing

118

A-4

Top structure assembly drawing

119

A-5

Charging system assembly drawing

120

A-6

Block pusher drawing

121

A-7

Charger drawing

122

A-8

Compactor drawing

123

A-9

Container drawing

124

A-10

Cover drawing

125

A-11

Hinge drawing

126

A-12

Middle bar drawing

127

A-13

Mold drawing

128

A-14

Movable base drawing

129

A-15

Planar base drawing

126

A-16

Horizontal plate structure drawing

130

A-17

Pusher base drawing

131

A-18

Pusher shaft drawing

132

A-19

Rod drawing

133

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A-20

Slider base drawing

134

A-21

Slider compactor drawing

135

A-22

Slider pusher drawing

136

A-23

Structure table 1 drawing

137

A-25

Structure base drawing

138

A-24

Structure table 2 drawing

139

A-26

Table structure drawing

140

A-27

Top mold drawing

141

A-28

Top structure 1 drawing

142

A-29

Top structure 2 drawing

143

B-1

Hydraulic cylinder

144

B-4

Vibration motor

145

C-1

Socket hex cap screw

146

C-2

Bolt, washer and nut

147

C-3

Bearing bush

148

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PROBLEM STATEMENT Today in our country the problems of homeless have been increasing gradually and it appear to be continue the main reason for the cause will be higher cost of construction raw materials, poverty, low income and lack of new technology Since the government of Ethiopia focus to build thousands of low cost house throughout the country, to meet the millennium development goals and achieve significant reduction in poverty the introduction of compacted block making machine must be essential. Nowadays providing house to our community at an affordable price is a major task being carried out by our government and real state organizations. Hollow blocks and burnt blocks are a colossal input for the construction of those low cost houses, but the currently in use hollow block and burned block construction materials in our country are expensive and take long time to manufacture and construct, which makes the selling price of those hoses expensive and take long time to manufacture and construct, which makes the selling price of those hoses expensive and take long time to manufacture and construct, which makes the selling price of those hoses expensive and unaffordable for the medium income society. In addition to this those construction materials has the following drawbacks: 

high moisture penetration



low theBirral efficiency



difficulties for electric & plumbing jobs insects



cost inefficiency bad finishes





it is difficult to produce on site



water absorption



higher cost & time consuming



higher unit weight low control over quality

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OBJECTIVE OF THE PROJECT General objective The main objective of this project is to design a new blocks making machine with new features and simplifying the machine for one man operation in order to reduce operational cost and maximize the production rate. FurtheBirrore, the purpose of this is to design the hollowblocks making machine that suitable for SME entrepreneurs.

Specific objective  To bring building construction of low cost houses effective, easier and faster using the CBMM  To achieve superior finishes and compatible for almost all types of construction.  To have on site production to reduce transportation cost and to minimize ecological imbalance caused due to burnt blocks.  General it aims high strength and technical superiority over conventional methods.  To achieve lighter than conventional masonry and hollow blocks save no mortar & plaster cost.

Problem Identification Current machine design unable to increase productivity, this is mainly due to;

i.

Time wasting by doing the cement charging, loading and leveling, (Time required 50 seconds).

ii.

Manually obtaining the lower mold plate as operator needs the device to turn the block (Time required 45 seconds).

iii.

The load applied several time on the hollow block (Time required: 15 seconds)

iv.

Operator need to manually pick-up the block one by one after compaction process before start the new process cycle (Time required: 20 seconds).

v.

The mold lower plates are manually inserted one by one (Time required 45 seconds).

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Expected results and Scope From the above interview, we conclude that customer’s needs are  High production rate,  Minimum 3 blocks per cycle,  One-man operation,  Simple operation,

 Comes with auto arrange block system,  Comes with cement charging system,  Comes with cooling system,  Fool proof operation,  Automated function,

 UnifoBirr pressure distribution,  Can be easily maintainable.  Safe to handle,

 Low cost machine,

 Marketable machine,

 Comes with alert system And also The high aesthetic value, faster, theBirrally efficient, structurally durable, eco-friendly, and low cost block will be identified for the production of low cost house in the country. The analysis of this project is limited to the manufacturing of compacted block making machine for producing blocks with dimensions (21*10*15cm) by applying 4.5 Mpa of compressing pressure between the compressing mould of the machine at low cost. N:B the compressive strength of both hollow blocks and hollow clay burned blocks range from 2Mpa up to 7Mpa it is acceptable in the Ethiopian standards for load bearing walls .(ESC.D4.026),(ESC D3 301). With system pressure of compacting 9-10 Mpa, cement content of 5-8% clay silt content of 10&50% a typical block can be made with a compression strength ranging from 4-7 Mpa this compression strength for load bearing walls in the Ethiopian standard will be acceptable.

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With over all dimension of the machine (120*150*147cm) and 

Motor driven two hydraulic units with 7.5 Mpa.



Capacity 1500 blocks/12 hours



Power 4 kw



Net weight 300 kg

The main task to be done on the design of hollow block making machine Is to design machine that can produce 1. Three block wit L=400mm, W=200mm, t=20mm 2. Four block with L=400mm, W=150mm, t=20mm 3. Five block with L=400mm, W=100mm, t=20mm

1.2 Scope of project The scope of project is clearly define the specific field of the research and ensure that the entire content of this thesis is confined the scope. This project is start with the literature review on product specification in order to satisfy the project objectives. After obtaining...