FABRICATION OF DUAL SIDE WATER PUMPING

SYSTEM WITH MOBILE PHONE CHARGER

PROJECT REPORT 2014-2015

Submitted by

(Team name)

Guided by:

Submitted in partial fulfillment of the requirement for the

Award of Diploma in -----------------------------------------

By the State Board of Technical Education Government of

Tamilnadu, Chennai.

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DEPARTMENT:

COLLEGE NAME:

PLACE:

COLLEGE NAME

PLACE

DEPARTMENT

PROJECT REPORT-2014-2015

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No. ------------ Of VI Semester

class of this college.

Guide Head of the Department

Submitted for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,

TamilNadu.On -------------- (date) held at the ------------

(college name),Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED

PARENTS

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At this pleasing movement of having successfully

completed our project, we wish to convey our sincere thanks

and gratitude to the management of our college and our

beloved chairman------------------------.who provided all the

facilities to us.

We would like to express our sincere thanks to our

principal ------------------for forwarding us to do our project and

offering adequate duration in completing our project.

We are also grateful to the Head of Department

prof…………., for her/him constructive suggestions

&encouragement during our project.

With deep sense of gratitude, we extend our earnest

&sincere thanks to our guide --------------------, Department of

Mechanical for her/him kind guidance and encouragement

during this project we also express our indebt thanks to our

TEACHING staff of MECHANICAL ENGINEERING DEPARTMENT,

---------- (college Name).

FABRICATION OF DUAL SIDE WATER PUMPING

SYSTEM WITH MOBILE PHONE CHARGER

CONTENTS

CONTENTS

CHAPTER NO TITLE

SYNOPSIS

LIST OF FIGURES

1 Introduction

2 Literature review

3 Description of equipments

3.1 Dynamo

3.2 Pedal

3.3 Pneumatic cylinder

3.4 Cam

3.5 Non-return valve

3.6 Tube

3.7 Chain drive

4 Design and drawing

4.1 Machine components

4.2 Overall diagram

5 Working principle

6 Merits & demerits

7 Applications

8 List of materials

9 Cost Estimation

10 Conclusion

BIBLIOGRAPHY

PHOTOGRAPHY

LIST OF FIGURES

LIST OF FIGURES

FigureNumber Title

1 Overall diagram

SYNOPSIS

SYNOPSIS

The pedal type water pumping and mobile phone charger

system machine is a new innovative concept is mainly used to save

power. In this concept we have designed a fabrication of pedal type

water pumping system. Here we are using the mechanical energy for

pumping the water without using any other electrical energy or any

other fuel based energies and also generates the electrical power

from the dynamo by the rotation of the cam plate.

CHAPTER I

INTRODUCTION

CHAPTER I

INTRODUCTION

This invention relates to water distribution systems, and more

particularly, to water distribution systems powered by human power.

Needed in a developing country is a manually operated pump

which can be easily operated by a person for relatively long periods

of time and which lifts significant volumes of water with as little effort

as possible. Because of the high usage requirements, and because

the pump must operate as a practical device far from cities having

maintenance facilities and personnel, the pump must be both reliable

and easily repaired.

Energy is the ability to do work. While energy surrounds us in

all aspects of life, the ability to harness it and use it for constructive

ends as economically as possible is the challenge before mankind.

Alternative energy refers to energy sources which are not based on

the burning of fossil fuels or the splitting of atoms. The renewed

interest in this field of study comes from the undesirable effects of

pollution (as witnessed today) both from burning fossil fuels and from

nuclear waste byproducts. Fortunately there are many means of

harnessing energy which have less damaging impacts on our

environment.

The alternatives are,

Solar

Wind Power

Geothermal

Tides

Hydroelectric

ELECTRICITY GENERATION 

Electricity generation is the process of generating electric power from

other sources of primary energy. The fundamental principles of

electricity generation were discovered during the 1820s and early

1830s by the British scientist Michael Faraday. His basic method is

still used today: electricity is generated by the movement of a loop of

wire, or disc of copper between the poles of a magnet.[1] For electric

utilities, it is the first process in the delivery of electricity to

consumers. The other processes, electricity transmission, distribution,

and electrical power storage and recovery using pumped-

storage methods are normally carried out by the electric power

industry. Electricity is most often generated at a power station by

electromechanical generators, primarily driven by heat engines fueled

by chemical combustion ornuclear fission but also by other means

such as the kinetic energy of flowing water and wind. Other energy

sources include solar photovoltaics and geothermal power.

CHAPTER II

LITERATURE REVIEW

CHAPTER II

LITERATURE REVIEW

The history of positive displacement reciprocating pumps goes

back as far as 275 BC in Ancient Rome. In the sixteenth century,

great lift and force pumps, driven by water wheels became the

principle method for pumping water to be piped in Europe.

As late as 1987, the World Bank estimated that, throughout the

world, 1.8 billion people would need improved water supplies, and

that wells equipped with handpumps would be an appropriate choice

to meet the needs of this number of people. Most of the reciprocating

handpumps commonly used in developing countries have their

origins in designs developed during the late 19th and early 20th

Centuries in the United States and in Europe. In the United States,

about 42 million handpumps were made until 1920, when electric

pumps began to replace them. While the basic design of the

reciprocating handpump has not changed much in this century, its

typical use has changed greatly. In the early part of this century, in

the United States and Europe, the big market for pumps was for small

backyard pumps used for ten to thirty minutes per day by individual

families or farmers. In a developing country today, a single pump may

have to supply more than 500 villagers and may be in continuous

operation for ten or more hours per day.

A pump connected with a typical well is driven by pressing the

end of a lever downward and by either pulling it upward, or permitting

it to return upward due to the weight of the well. The work of lifting the

water occurs as the lever is pressed downward. The simplest type of

reciprocating pump is the suction pump, which draws water from

shallow wells by creating a partial vacuum in a suction pipe. All of the

moving parts, including a plunger moved by the lever and a suction

check valve, are located above ground; only the suction pipe extends

downward into the well. As the lever is pushed downward, the

plunger is moved upward, lifting the water above it to be discharged

through a spout, and pulling water below it upward through an open

suction check valve. As the lever is moved upward, the plunger is

moved downward, through the water below it, creating a pressure

which opens a valve in the plunger while closing the suction check

valve. Two disadvantages of this type of pump are first, it must be

primed with water before it can be used and, second, the suction

principle, depending on atmospheric pressure to lift water, limits the

usefulness of the device to wells having depths less than about seven

meters.

A number of pump configurations have been built to overcome

various of these disadvantages in the way driving forces are applied.

For example, a treadle type foot pedal drive, together with a pair of

flywheels, has been applied to a double piston pump, Model SB-115,

produced by the Water Conservancy Bureau of Shandong Province,

China. The Climax pump, manufactured by Wildon Engineering of

Worcestor, United Kingdom, and the Volanta pump, manufactured by

Jensen Venneboer BV, The Netherlands, are both pumps in which a

reciprocating motion is developed using a connecting rod driven by a

rotating crank mounted on a shaft along with a flywheel. An eccentric

rod extends from the flywheel for use as a hand crank. The Climax

pump also uses a counterweight to balance the lifting force applied

through the crank.

The usage of traditional power generation method such as

burning of coal, wood, diesel (generators) etc is continuously

depleting our natural resources such as fossil fuels, which is the

demand for power has exceed the supply due to the rising

population. In addition to this the traditional methods cause pollution,

encourage deforestation (cutting of trees) the consequences are

global warming, power shortage like we are facing in Tamilnadu.

CHAPTER III

DESCRIPTION OF EQUIPMENTS

CHAPTER III

DESCRIPTION OF EQUIPMENTS

3.1. DYNAMO

Dynamo is an electrical generator. This dynamo produces direct

current with the use of a commutator.dynamo were the first generator

capable of the power industries.The dynamo uses rotating coils of

wire and magnetic fields to convert mechanical rotation into a pulsing

direct electric current. A dynamo machine consists of a stationary

structure, called the stator, which provides a constant magnetic field,

and a set of rotating windings called the armature which turn within

that field. On small machines the constant magnetic field may be

provided by one or more permanent magnets; larger machines have

the constant magnetic field provided by one or more electromagnets,

which are usually called field coils.

The commutator was needed to produce direct current. When a

loop of wire rotates in a magnetic field, the potential induced in it

reverses with each half turn, generating an alternating current.

However, in the early days of electric experimentation, alternating

current generally had no known use. The few uses for electricity,

such as electroplating, used direct current provided by messy liquid

batteries. Dynamos were invented as a replacement for batteries.

The commutator is a set of contacts mounted on the machine's shaft,

which reverses the connection of the windings to the external circuit

when the potential reverses, so instead of alternating current, a

pulsing direct current is produced.

speed = 1000 rpm

Volts = 12 v

Watts = 18 w

If the dynamo rotates at 1000 rpm it will produce 6- 8 v

3.2 PEDAL

A pedal is the part of an equipment in this project that the

human pushes with his or her foot to propel the bicycle. It provides

the connection between the cyclist's foot or shoe and the crank

allowing the leg to turn the bottom bracket axle. 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.

3.3 PNEUMATIC CYLINDER:

All the strange names and terms around pneumatics have

evolved through about 100 years of their use in manufacturing.

Double acting, four way, quick connect are all terms that were

invented to describe (as best as could be) the difference between the

parts. Don't let the names discourage you. They're just names. I've

used quite colorful terms myself when working with pneumatics, most

of which i won't use here...

The first thing to remember is: Pneumatics are easy... really! Its all

the different names and parts that seem to be overwhelming. But

enough about that... on to the fun stuff.

Note:

This isn't the place to discuss every different kind of part that's

available - it would take hundreds of pages. But what I'd like to cover

is the basic things for a haunter to keep in mind when 'playing' with

pneumatics.

AIR CYLINDERS:

There are only two main kinds of air cylinders: Double acting,

and single acting. They come in all variations, shapes and sizes. Both

kinds are useful for haunt work. Double acting cylinders are useful

when you need to push in both directions, and single acting cylinders

are useful when only a push in one direction is needed. And,

sometimes 'in a pinch', you can adapt a double to act as a single, and

a single to act as a double.

Air cylinders are measured by three main values: "pressure rating",

the "bore", and "stroke"

PressureThis is the maximum pressure the air cylinder

can safely handle.

Bore The interior diameter of the cylinder.

Stroke The range of movement of the air cylinder's rod.

There are lots of calculations to accurately figure the power of a

cylinder, but most haunt pop-up applications can be handled by air

cylinders in the range of 3/4" to 1-1/2" bore, and 3" to 8" stroke.

Power measurements primarily take into account the air

pressure (the higher the pressure, the more power); and the bore (the

larger the bore - the more power). The power ratings are usually only

quoted at maximum pressure. So if a cylinder produces180 pounds of

'push', it will only deliver that at the maximum pressure (usually 250

psi for commerical cylinders).

Haunters should work their props to work and much, much

lower pressures. A good goal is not to exceed 60-70psi for working

props. Going much higher causes more stress on the prop and all

parts in the air system, and make your compressor run more often.

Even at lower pressures, air cylinders can still move very fast and

deliver quite a lot push, so always be very careful around pneumatics!

Double Acting means the air cylinder rod is 'pushed' out, and

'pushed' in.

A typical double acting air cylinder

Every double acting air cylinder has these basic parts. A

cylinder to hold everything together, a 'plunger' that the air pushes

against, two connections to get the air in and out, and a rod that goes

in and out. That's it. Here's a simple animation to illustrate the

motion...

As air is sent into the left connection (pressure is shown in

yellow), it pushes against the plunger and the rod goes out. At the

same time, air is released out of the right connection. To reverse the

motion, air is sent into the right connection, pushing against the

plunger on the other side and the rod is forced back in.

The trick to the double acting cylinder is that you have to let air

OUT of the other side! This is an important feature of the double

acting cylinder, and an advantage that gives you great control over

the motion of the rod (but, more on that later!).

TIP: the most useful double acting cylinder I've found is one

with 1/4" connections, 6"-8" stroke, 1" bore, and end clevis mounts.

Of course, most any cylinder can be adapted for haunt use!

SINGLE ACTING CYLINDER

Single Acting means the air cylinder rod is ONLY pushed in a

single direction, either out or in. There is only one connection for air,

and a little hole in the other end to let air in and out. A spring is used

to push the rod in the opposite direction after air pressure is removed.

Single Acting Air Cylinder, with the rod normally out without pressure

Single Acting Air Cylinder, with the rod normally in without pressure

As air is pushed into the connection, the plunger begins to

move and compress the spring. Exhaust air exits out the exhaust hole

on the other end. When air is released, it exits out the connection,

and air is sucked into the exhaust hole as the spring pushes the

plunger back to its resting position. Basically, the spring is 'push'

needed to return the plunger and rod back to their starting position.

When selecting a cylinder for an application, remember that a double

acting cylinder pushes in both directions, while a single acting

cylinder only pushes in one direction.

MOUNTING

There are about as many ways to mount an air cylinder as there are

different types of air cylinders. Again, this is because of all the uses.

My personal favorite is the clevis mount. (see photo below) Clevis

mounts give the greatest amount of movement, flexibility, and ease of

mounting over other mounts.

DESIGN CALCULATION FOR PNEUMATIC CYLINDER (32 x100)

Mini pressure applied in the cylinder (p) : 2x105N/m2

Diameter of the cylinder (D) : 32 mm

Stroke length : 100 mm

Area of cylinder (A) : (3.14/4*(D2)

: (.785x.0322)

: 8.0384 x 10-4m2

Force exerted in the piston (F) : Pressures applied X area

Of cylinder

Force : (2 x 105 n /m2) (8.0384 x 10-4m2)

: 160.68 N

For lifting one kg weight, the force required is given by,

Force = m x a

= 1 x9.81

= 9.81 N

And the pressure required for one pneumatic cylinder to lift I kg is

given by,

Pressure, P =Force/ Area

= 9.81 N/8.0384 x 10-4 m2

=12203.92 N/m2

=12203.92 pa

Pressure =0.1220392 bar

Maximum load in the cylinder = Pressure*area

= 160.68 N

Total load in the cylinder = m x a

= 160.68 x9.81

= 1576.27 kg

3.4 CAM

A cam is a projecting part of a rotating wheel or shaft that

strikes a lever at one or more points on its circular path. The cam can

be a simple tooth, as is used to deliver pulses of power to a steam

hammer, for example, or an eccentric disc or other shape that

produces a smooth reciprocating (back and forth) motion in the

follower which is a lever making contact with the cam.

The reason the cam acts as a lever is because the hole is not

directly in the centre, therefore moving the cam rather than just

spinning. On the other hand, some cams are made with a hole

exactly in the centre and their sides act as cams to move the levers

touching them to move up and down or to go back and forth.

3.5 NON-RETURN VALVE:

A check valve, clack valve, non-return valve or one-way valve

is a mechanical device, a valve, which normally allows fluid (liquid or

gas) to flow through it in only one direction.

Check valves are two-port valves, meaning they have two

openings in the body, one for fluid to enter and the other for fluid to

leave. There are various types of check valves used in a wide variety

of applications. Check valves are often part of common household

items. Although they are available in a wide range of sizes and costs,

check valves generally are very small, simple, and/or cheap. Check

valves work automatically and most are not controlled by a person or

any external control; accordingly, most do not have any valve handle

or stem. The bodies (external shells) of most check valves are made

of plastic or metal.

An important concept in check valves is the cracking pressure

which is the minimum upstream pressure at which the valve will

operate. Typically the check valve is designed for and can therefore

be specified for a specific cracking pressure.

3.6 TUBE:

A hose is a hollow tube designed to carry fluids or air from one

location to another. Hoses are also sometimes called tube or pipes

(the word pipe usually refers to a rigid tube, whereas a hose is

usually a flexible one), or more generally tubing. The shape of a hose

is usually cylindrical (having a circular cross section).

Hose design is based on a combination of application and

performance. Common factors are Size, Pressure Rating, Weight,

Length, Straight hose or Coilhose and Chemical Compatabiltiy.

Hoses are made from one or a combination of many different

materials. Applications mostly use nylon, polyurethane, polyethylene,

PVC, or synthetic or natural rubbers, based on the environment and

pressure rating needed. In recent years, hoses can also be

manufactured from special grades of polyethylene (LDPE and

especially LLDPE). Other hose materials include PTFE (Teflon),

stainless steel and other metals.

3.7 CHAIN DRIVE

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. The power is conveyed by a

roller chain, known as the drive chain, 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.

DESIGN PROCEDURE

Chain drive design is done by following this procedure and referring to the

DESIGN DATA

1. Calculate the drive ratio R (velocity ratio) given the input RPM and

output RPM.

Drive ratio=N1/N2 = T2/T1

VELOCITY RATIO = N1/N2

So,

N1/N2 = T1/T2

N1= 30

N2= ?

T1= 44

T2 = 18

N1/N2 = T1/T2

30/N2 = 44/18

N2 = (30) / (44/18)

N2 = (30)/2.44

N2 = 12.30 RPM

Velocity ratio = N1/N2

= 30/12.30

Velocity ratio =2.44

2. Determine the number of teeth of the sprockets.

Minimum number of teeth on the sprocket = 18

3. Number of teeth on the larger sprocket

Number of teeth on the larger sprocket = 44

4. Determine the design power by using the service factor, such that

Design power = Rated power x Service factor(Ks)

= 0.25 x Service factor (Ks)

= 0.25 x ( (Load factor(K1) x (Lubrication factor (K2) x

Rating factor (K3)

= 0.25 x (1.5 x 2.44 x 1.25)

Design power = 1.143kW

5. Choose the type of chain, number of strands for the design power and

RPM of the smaller sprocket

Types of chain = simple roller chain (06B)

Power rating (in kW) = 0.25

Speed of smaller sprocket or pinion (RPM) = 30

6. Note down the parameters of the chain, such as pitch, roller diameter,

minimum width of roller.

ISO chain number = 06B

Pitch (mm) = 9.525

Roller diameter (mm) = 6.535

Minimum width (mm) = 5.72

Braking load (simple type roller chain) in kN = 8.9

7. Find the velocity.

Velocity, v = (π D N)/60

(3.14×0.0065×30)/60

0.0102 m/s

8. Find the pitch circle diameter and pitch line velocity of the smaller

sprocket

Pitch circle diameter (D) = p / (sin (180/T))

= 9.525 /(sin (180/18))

= 9.525 / (sin (7.5))

= 9.525/0.173648

Pitch circle diameter (D) in mm = 54.852

CHAPTER IV

DESIGN AND DRAWING

CHAPTER IV

DESIGN AND DRAWING

4.1 MACHINE COMPONENTS:

The fabrication of dual side water pumping system with mobile

charger consists of the following components to full fill the

requirements of complete operation of the machine.

1. DYNAMO

2. PNEUMATIC CYLINDER

3. PEDAL

4. CAM

5. CHAIN DRIVE

6. NON RETURN VALVE

7. TANK

4.2 DRAWING FOR FABRICATION OF DUAL SIDE

WATER PUMPING SYSTEM WITH MOBILE PHONE

CHARGER

CHAPTER V

WORKING PRINCIPLE

CHAPTER V

WORKING PRINCIPLE

In this concept we have design the gym based system is the

simple mechanism for water pumping and generate the electrical

power with the help of pedaling operation. It system also consists of

one more advantage, the pedaling operation just acts like an exercise

to the human being. Here the pedaling arrangement is coupled with

the cam. So whenever we operate the chain drive to pedal it’s rotated

the cam mechanism which makes the pedaling operation easier to

pump the water. The output from the pedaling system is coupled with

the pneumatic cylinder. Here we are converting the rotary motion in to

the linear motion for pumping the water. The pressure pushes the

piston for the stroke. At the end of the stroke pressure reaches the

rear end of the cylinder block. The pressure remains the same but the

area is less due to the presence of the piston rod. This exerts greater

pressure on the piston pushing it at a faster rate thus enabling faster

return stroke. The outlet of the cylinder is connected with the tank on

one side and the same to discharge the water with help of a T joint.

When the piston of the cylinder actuates it sucks the water in the tank

due to the vacuum produced in the cylinder. Here the dynamo is

coupled with the cam plate; the dynamo’s output power is used to

charge the mobile phone.

CHAPTER VI

MERITS & DEMERIT

CHAPTER VI

MERITS & DEMERIT

MERITS

Power is not required

Low maintains

Cost is less compared to other pumping devices

DEMERIT

It does not operate through long time.

CHAPTER VII

APPLICATIONS

CHAPTER VII

APPLICATIONS

It is used in gym and home uses.

CHAPTER VIII

LIST OF MATERIALS

CHAPTER VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.

1.PROPERTIES

The material selected must posses the necessary properties for

the proposed application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials

decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific

gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue

resistance, impact resistance, eleastic limit, endurance limit, and

modulus of elasticity, hardness, wear resistance and sliding

properties.

The various properties concerned from the manufacturing point

of view are,

Cast ability

Weld ability

Surface properties

Shrinkage

Deep drawing etc.

2. MANUFACTURING CASE

Sometimes the demand for lowest possible manufacturing cost or

surface qualities obtainable by the application of suitable coating

substances may demand the use of special materials.

3. QUALITY REQUIRED

This generally affects the manufacturing process and ultimately

the material. For example, it would never be desirable to go casting of

a less number of components which can be fabricated much more

economically by welding or hand forging the steel.

4. AVAILABILITY OF MATERIAL

Some materials may be scarce or in short supply, it then

becomes obligatory for the designer to use some other material which

though may not be a perfect substitute for the material designed. The

delivery of materials and the delivery date of product should also be

kept in mind.

5. SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the

forces involved are high and space limitations are there.

6. COST

As in any other problem, in selection of material the cost of

material plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of

proper materials.

CHAPTER IX

COST ESTIMATION

CHAPTER IX

COST ESTIMATION

1.MATERIAL COST

2. LABOUR COST

Lathe, drilling, welding, drilling, power hacksaw, gas cutting cost

3. OVERGHEAD CHARGES

The overhead charges are arrived by” manufacturing cost”

Manufacturing Cost =Material Cost + Labour Cost

=

=

Overhead Charges =20%of the manufacturing cost

=

4.TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

=

=

Total cost for this project =

CHAPTER X

CONCLUSION

CHAPTER X

CONCLUSION

This project is made with pre planning, that it provides flexibility

in operation.

The comparative gain that can be accomplished is the

utilization of pedal. This innovation has made the more desirable

This project “FABRICATION OF DUAL SIDE WATER

PUMPING SYSTEM WITH MOBILE PHONE CHARGER” is designed

with the hope that it is very much economical and help full to many

people’s on their needs.

This project helped us to know the periodic steps in completing

a project work. Thus we have completed the project successfully.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. Design data book -P.S.G.Tech.

2. Pneumatic handbook -R.H.warrning

3. Machine tool design handbook –Central machine tool Institute,

Bangalore.

4. Strength of Materials -R.S.Kurmi

5. Manufaturing Technology -M.Haslehurst.

6.Design of machine elements- R.s.Kurumi

PHOTOGRAPHY