DESIGN AND FABRICATION OF MANUALLY OPERATED

RECIPROCTING PUMP USING FLYWHEEL

A PROJECT REPORT

Submitted in partial fulfillment for the requirements for the award

Of the degree of

BACHELOR OF TECHNOLOGY

In

(MECHANICAL ENGINEERING)

SUBMITTED By

BHOOPATHY. R 5021140012

ELAYARAJA. K 5021140023

HARISH KUMAR. K 5021140031

MARISELVAN. T 5021140053

Under the guidance of

Mr. Dinakar. N. ME.

(Asst. professor, school of Mechanical Engineering)

FACULTY OF ENGINEERING AND TECHNOLOGY

SRM UNIVERSITY VADAPALANI

DESIGN AND FABRICATION OF MANUALLY OPERATED

RECIPROCTING PUMP USING FLYWHEEL

A PROJECT REPORT

Submitted in partial fulfillment for the requirements for the award

Of the degree of

BACHELOR OF TECHNOLOGY

In

(MECHANICAL ENGINEERING)

SUBMITTED By

BHOOPATHY. R 5021140012

ELAYARAJA. K 5021140023

HARISH KUMAR. K 5021140031

MARISELVAN. T 5021140053

Under the guidance of

Mr. Dinakar. N. ME.

(Asst. professor, school of Mechanical Engineering)

FACULTY OF ENGINEERING AND TECHNOLOGY

SRM UNIVERSITY VADAPALANI

SRM UNIVERSITY

BONAFIDE CERTIFICATE

This is to certify that the project work entitled

“DESIGN AND FABRICATION OF MANUALLY OPERATED RECIPROCTING PUMP USING FLYWHEEL” is a bonafide record of project

work done by,

BHOOPATHY. R 5021140012

ELAYARAJA. K 5021140023

HARISH KUMAR. K 5021140031

MARISELVAN. T 5021140053

Towards the partial fulfillment of the requirements for the award of the degree of bachelor of technology in Mechanical Engineering in SRM university,

Chennai during the academic year 2014-2015

HEAD OF THE DEPARTMENT INTERNAL GUIDE

Mr. Dinakar. N. ME,

EXTERNAL EXAMINER INTERNAL EXAMINER

PLACE: CHENNAI

DATE:

ABSTRACT

Electrically operated pumps and immersed jet pumps are widely used in

domestic, industrial and commercial applications. The capacity of these pump

heads varies from 5Meter to 100 meter. In many places, the drinking water supplied

by the government through the pipeline is below the ground level and are collected

in sumps of residential plots.

The private agency supply the water through the water tank lorry to many

places where we have taken to multistoried building by manually.

In this project, we consider this above problem in order to deliver the water to

the tank which is above the ground level and also to overcome the during the

electricity failure time we made a manually operated reciprocating pump.

Working principle;

This manuallyoperatd reciprocating pump consists of a pair of foot pedal

,seating arrangement, chain drive , connecting rod , crank shaft, flywheel and a

reciprocating pump,

` The pump is rotated by the foot and hence the chain rotates causes the

connecting rod rotates to reciprocate the piston via connecting rod... Thus the water

is discharged to tank without using electric power.

It is used to pump the water up to10 to 20meters of total head. It could be very

useful in those areas where electricity is irregular or insufficient.

LIST OF CONTENTS

Chapter Topic Page No.

No

Acknowledgement (i)

Abstract (ii)

List of Figures (iv)

List of Tables (v)

1 Introduction

1.1 Project planning

1.2 Operation planning

1.3 Purchase consideration

1.4 Advantages and disadvantages

1.5 Applications

2 Literature Review

2.1

2.2

2.3

3 Design and Calculations

3.1 basic designs

3.2 speed ratio

3.3 chain drive calculation

3.4 theoretical analyses

4

4.1 constructions

4.2 fabrications

4.3 assemblies

4.4 working principle

5 TESTING AND CALCULATION

5.1 formula used

5.2 trail 1

5.3 trail 2

5.4 trail 3

6 PHOTO VIEW

6.1

6.2

6.3

6.4

7 conclusions

7.1 result and discursion

7.2

7.3

LIST OF FIGURES

LIST OF TABLES

Chapter 1

INTRODUCTION

1.1 PROJECT PLANNING

CONCEPT OF THE PROJECT

Before starting every project its planning is to be done. In planning functions

is life the functions of nerves in our body. Planning a project is a very important task

and should be taken up with great care as the efficiency of the whole project largely

depends upon its planning, while planning a project each and every detail should be

worked out in anticipation should be carefully considered with all the relative

provisions aspects.

PROJECT CAPACITY

The capacity of the project must be decided considering the amount of

money which can be invested. The availability of material and machines and

usefulness of the project.

DESIGN AND DRAWING

Having decided about the project to be manufactured at must be designed.

Design work should be done very considering all the relevant factors.

After design the project detailed drawing are prepared. Detailed specification

for raw material and finished products should be decided carefully along with the

specification of the machine required for the manufacture.

MATERIAL REQUIREMENTS

The list of material required for manufacture is prepared from the

drawing. The list is known as “Bill of materials”. Availability of these materials is

surveyed and purchased from the market.

1.2 OPERATION PLANNING

Next work of planning is to “select the best method” manufacture the

product, so that the wastage of materials, labor, machines and time can be

eliminated by considering various methods. The best method is to be selected for

fabrication and other works.

The proper method and proper person and the purposes of operation,

necessity operation, proper machine planning. The best method is the developed

and is applied to fabricate the project.

MACHINE LOADING

While planning proper care should be taken to find the machining time

for the operation as correct as possible. So that arrangement of full use of machines

can be made and the machine loading program can be decided.

1.3 PURCHASE CONSIDERATION

It is difficult to manufacture all the components needed for the project in

the machine shop. In each case, we should decide whether to make or buy about a

particular item. It is decided during the planning after making a complete study of

relative merits and demerits.

EQUIPMENT PROCEDURE

Results obtained from “operation planning” and machine loading help in

calculating the equipment require Specification of the equipment should be laid

down by considering then drawings. Drawings will also help in deciding the

necessary requirement of tools and accessories.

1.4 ADVANTAGES AND DISADVANTAGES

ADVANTAGES

Compared to hydraulic and, pneumatic system, it is economical.

No extra skill is required for operating this system.

Operation is very smooth and in this system we can get more output by

applying less effort.

Single person is enough to operate this efficiently to drill the job.

Easy and efficient handling of this unit without wastage of job or damage

to unit and any other parts.

Low maintenance cost and life of equipment also increased.

Least maintenance of the equipment.

Need not require any individual work place.

Can be worked in the work spot.

Suited for pumping the water up to 10 TO 20 meter head.

DISADVANTAGES

Manual power required to operate.

The time taken for pumping the water is more when compared to electric

power unit.

It cannot be used for more than 20 meter head ...

1.5 APPLICATION;-

We can use this equipment to lift the water from ground floor to 1st floor in housing

purpose.

During rainy season we can pump the unwanted water from the required place.

Using for irrigation purposes.

It could be very useful in those areas where electricity is irregular or

insufficient.

CHAPTER 2

LITERATURE REVIEW

CHAPTER 3

DESIGN AND CALCULATION

3.1 BASIC DESIGN

Fig 3.1 Basic design of our project

3.2 SPEED RATIO CALCULATION

3.3 CHAIN DRIVE CALCULATIONS

3.4 THEORITCAL ANALYSES

4.1CONSTRUCTION

The project consist of

1. Foot Pedal

2. Chain drive

3. M.S.Frame Stand

4. Crank shaft and connecting rod

5. Flywheel

6. Reciprocating pump

7. inlet and outlet valve in pump cylinder

8. Suction and delivery pipeline with pressure gauges

9. operator seat

1. Foot pedal ;

This foot pedal is used to drive the pump by manually. A cycle pedal is the

part of a bicycle that the rider pushes with their foot to propel the bicycle. Here in

this kit, it provides the connection between the cyclist's foot or shoe and

the crank allowing the leg to turn wheel spindle and propel the crank wheel.

Pedals usually consist of a spindle that threads into the end of the crank and a

body, on which the foot rests or is attached, that is free to rotate on bearings with

respect to the spindle. Pedals were initially attached to cranks connecting directly to

the driven (usually front) sprocket wheel.

Fig 4.1(a) cycle pedal

2. Chain drives mechanism;

Fig 4.1(b) sprocket and chain

Chain drive is a way of transmitting mechanical power from one place to another.

It is often used to convey power to the wheels of a vehicle, particularly bicycles and

motorcycles. It is also used in a wide variety of machines besides vehicles.

Most often, the power is conveyed by a roller chain, known as the drive chain or

transmission chain, [1] passing over a sprocket gear, with the teeth of the gear

meshing with the holes in the links of the chain. The gear is turned, and this pulls

the chain putting mechanical force into the system.

Fig 4.1(c) chain drive

This chain drive is used to transmit the rotary motion from the pedal wheel to crank

wheel. The driver sprocket has 50 teeth and the driven sprocket has 12 teeth. Hence

for every rotation is multiplied to four times the rotational output to crank wheel.

This chain drive is lubricated with oil using servo 60 oil in order to eliminate the

wear and corrosion.

Fig 4.1(d) driver gear and driven gear

FABRICATION (DRIVEN GEAR)

FABRICTION – (DRIVER GEAR)

3. Frame Stand

This base frame stand made in 40 mm x 3mm M.S. material square tube and is used

to hold the entire mechanism and support the operator seat also.

First of all the frame is designed and the base is constructed by

using the welded joints and cut the material with the required size by

using hacksaw machine.

The stand frame material is used to mild steel at low cost is widely

and is used.

4. Crank and connecting rod mechanism;

A crankshaft has one (or more) offset sections where a connecting rod is attached

around it. The connecting rod moves back-and-forth (or up-and-down) ONCE for

every rotation of the crankshaft. The crank will always move in a circle, moving the

connecting rod in a smooth sine wave like motion. The power can flow in either

direction. That is, the crankshaft can drive the connecting rod, or the connecting rod

can drive the crank shaft.

5. FLYWHEEL;

Fig 4.1(e) flywheel

A rotating mechanical device that is used to store rotational energy.

It acts like a reservoir and stores the energy in mechanical form

It Supply energy when required.

o Releases it when it is more than required.

Energy is stored by the formula

E = ½ Iω2

o Where “I” is the moment of inertia and it can vary for different shapes

of wheels. For solid disk the “I=Mr2/2”.

o “Ω” is the rotational velocity and it is in (rad/sec).

• Fly wheel smoothen out variations in the speed of a shaft caused by torque

fluctuations if source of driving torque is fluctuating.

• It is also used to provide continuous energy in system.

It is also used to supply intermittent pulses of energy at transfer rates that exceed the

abilities of its energy source

Design Approach:-

There are two stages for it

• The degree at which energy is required to smoothen and its moment of inertia.

• The geometry of flywheel.

Design Parameters:-

• It depends upon acceptable changes in the speed.

Speed fluctuation:-

• The change in the shaft speed during a cycle is called the speed fluctuation

and it is given by

FL =ωmax−ωmin

Geometry of Flywheel;

• It can be a solid cylindrical disc.

• It can be like conventional wheel design.

But energy requirements and size of the flywheel increases the geometry

changes to disc of central hub and peripheral rim connected by webs and to hollow

wheels with multiple arms.

•

Fig 4.1(f) sectional view of flywheel

Applications;

Typical applications for flywheels include;

• Dynamic balancing of rotating elements.

• Energy storage in small scale electricity generator sets.

• Automotive applications such as clutches.

6. Reciprocating pump;

Fig 4.1(h) block diagram of reciprocating pump

• Pushing of liquid by a piston that executes a reciprocating motion in a closed

fitting cylinder.

• Crankshaft-connecting rod mechanism

• Conversion of rotary to reciprocating motion.

• Entry and exit of fluid

7. Inlet and outlet valve in pump cylinder

During the suction stroke the inlet valve is used to allow water into the

cylinder and at the same time the delivery valve is closed. During the delivery stroke

when piston moves in opposite direction and the outlet valve is used to allow the

water from the cylinder to outlet pipe line and at the same time the suction valve is

closed. The functions of inlet and outlet valves are shown in figure.

8. Suction and delivery pipeline with pressure gauges;

Here 18MM DIA flexible PVC pipe line is connected at suction and delivery

pipe line in order to deliver the water from sump to tank. To show the

pressure a vacuum gauge is connected at the suction side and pressure gauge

is connected at the discharge side.

4.2 FABRICATION

FABRICTION - (FITTING)

FABRICTION-(PRESSURE & VACCUM GAUGE)

4.3 ASSEMBLIES

9. Operator seat;

A bicycle seat, unlike a bicycle saddle, is designed to support the rider's

buttocks and back, usually in a semi-reclined position. Arthur Graford is credited

with inventing the padded bicycle seat in 1892, and they are now usually found

on recumbent bicycles.

10. BEARINGS;

A bearing is a machine element that constrains relative motion between moving

parts to only the desired motion. The design of the bearing may, for example,

provide for free linear movement of the moving part or for free rotation around a

fixed axis; or, it may prevent a motion by controlling the vectors of normal forces

that bear on the moving parts. Bearings are classified broadly according to the type

of operation, the motions allowed, or to the directions of the loads (forces) applied

to the parts.

A journal bearing consists of an approximately cylindrical body around a

rotating shaft. This journal bearing is used either for supporting a radial load, or

simply as a guide for smooth transmission of torque. Most common applications of

bearings are the plain circular bearings type (with a 360 degrees arc). Lubrication

usage, on the other hand, range from a simple inlet hole to axial, circumferential,

and helical grooves for efficient lubrication distribution.

The plain bearing applications include reciprocating sliders, rotating or oscillating

cylindrical members sliding in annular sleeves, and rotating or rotationally

oscillating disks sliding on mating disks.

The advantages of plain bearings are as follows:

- lower first cost

- simple design

- small radial space required

- quiet operation

- not so sensitive to dust or grit

- less likely to be subjected to fatigue failure

- easy to replace

Materials:

Plain bearings must be made from a material that is durable, low friction, low wear

to the bearing and shaft, resistant to elevated temperatures, and corrosion resistant.

#Babbitt (metal)

#Bronzes

#Graphite

#Plastic-Solid plastic plain bearings are now increasingly popular due to dry-

running lubrication-free behavior. Solid polymer plain bearings are low weight,

corrosion resistant, and maintenance free.

4.4 WORKING PRICIPLE

To function the pump, the operator sits on the seat and pedal

continuously. The foot pedal is used to drive the pump by manually. By

pedaling, the driver sprocket transmits rotary power to driven sprocket

though the chains drive. This chain drive is used to transmit the rotary motion

from the pedal wheel to crank wheel. The crank wheel converts the rotary motion

into linear motion of piston inside the cylinder. During the suction stroke the inlet

valve is used to allow water into the cylinder and at the same time the delivery valve

is closed. During the delivery stroke when piston moves in opposite direction and

the outlet valve is used to allow the water from the cylinder to outlet pipe line and

at the same time the suction valve is closed.

Thus the water is discharged to tank without using electric power.

5. TESTING AND CALCULATION

5.1FORMULA USED

FORMULA USED FOR RECIPROCATING PUMP

SUCTION HEAD

Hs = ps*sm/1000

Hs = suction head (m of water)

Ps = suction pressure (mm of Hg)

Sm= specific gravity of Hg = 13.6

DELIVERY HEAD

Hd = Pd * 104/ ρ

Hd = Delivery head (m of water)

Pd = Delivery pressure (kg/cm2)

P = unit weight of water = 1000kg/m3

COLLECTING HEAD = 0.13m (constant)

TOTAL HEAD

H=Hs+Hd+Hc (m of water)

DISCHARGE

Q= lby/t1 (m3/s)

Q = discharge (m3/s)

L = length of collecting tank (m)

Y = rise of water in collecting tank (m)

Y = 0.1m

t = time taken for ‘y’ rise of water/sec

OUTPUT POWER

OP = ρgQH/1000 (kW)

ρ = unit weight of water 1000 kg/m3

g = specific gravity 9.81 m/s2

Q = discharge (m3/s)

H = total head (m of water)

INPUT POWER

IP = 2πNT/60

Torque = force × radius

Force = mass × acceleration

F = m × a (or) m × g

T = m × g × r

M = flywheel mass

g = specific gravity 9.81 m/s2

r = flywheel radius

OVERALL EFFICIENCY

η = OP/IP %

COLLECTING TANK DETAILS(using in FM lab)

l = 0.5m

b = 0.5m

Hc =0.13m (constant)

CALCULATION

TRAIL 1

TRAIL 1

TRAIL 2

TRAIL 2

TRAIL 3

TRAIL 3

TABULATION

TRIAL 1

TRIAL 2

TRAIL 3

5.5 COMPARISIONS

PHOTO VIEW

6.1 FRONT VIEW

6.2 TOP VIEW

6.3 SIDE VIEW

7.1RESULT AND DISCUSSION

Hand operated portable drilling as well as electrically operated drilling

machines are widely used in domestic, industrial and commercial applications.

The capacity of this drilling varies from 1mm to 25mm dia hole. This pedal

operated drill is fitted with a drill bit, used for drilling holes in various

materials

. This is also one of the pedal operated drilling machines which are now

operated through the cycle pedal .The operation and mechanism of this unit

and its function has been studied.

At the end, the machine is assembled.

This machine is more advantages of other types of power drilling since it

has easier to operate computable seating arrangement and good exercise to our

body and also less time consumption, easy handling etc.

7.2FEATURES OF THIS PROJECT

It is compact in size

It can be move

No electrical power consumption

It can be utilized at our work shop

It is simple in construction

Low cost

Less weight and easy to handle

It reduces the man power

It is simple in operation.

7.3SAFETY, CARE AND MAINTENANCE

Before using the machine, some of the points to be noted for safety purpose,

1. Before starting the operation, check the following items

(1) Check the mechanism for proper operation.

(2) Check the alignment of connecting rod and piston in the unit.

(3) Don’t insert the any material or object between the during

operation of flywheel.

(4) Check the lubrication of chain drive and bearing in the unit.

(5) Sit carefully while driving the pedal.

7.4CONCLUSION

We make this project entirely different from other projects. Since

concepts involved in our project is entirely different that a single unit is

used to various purposes, which is not developed by any of other team

members.

By doing this project we gained the knowledge of fabrication work

and how the welding is doing and material selection for particular

components etc.

It is concluded that any fabrication work can be done with the help

of welding.

We have successfully completed the project work on using pedaling

pump work at our Institute.

Once again we express our sincere thanks to our staff members

7.3SAFETY, CARE AND MAINTENANCE

Before using the machine, some of the points to be noted for safety purpose,

2. Before starting the operation, check the following items

(1) Check the mechanism for proper operation.

(2) Check the alignment of connecting rod and piston in the unit.

(3) Don’t insert the any material or object between the during

operation of flywheel.

(4) Check the lubrication of chain drive and bearing in the unit.

(5) Sit carefully while driving the pedal.

COST ESTIMATION

BIBLIOGRAPHY