FABRICATION OF PEDAL OPERATED

WATER PUMP

Submitted in the partial fulfillment of the requirement for the award of

“DIPLOMA IN MECHANICAL ENGINEERING”

SUBMITTED BY:

1. G.JAGADESH KUMAR 4. M.G.VISHNU 2. R.GOPINATH 5. D.MUTHUKUMARAN 3. T.NARESH 6. K.MANI

Under guidance of

Mr. Z.KHAJA MOIDEEN ,B.E

MARCH 2013.

DEPARTMENT OF MECHANICAL ENGINEERING.

SRI DURGA DEVI POLYTECHNIC COLLEGERSM NAGAR, KAVERAI PETTAI.

SRI DURGA DEVI POLYTECHNIC COLLEGERSM NAGAR, KAVERAI PETTAI

BONAFIDE CERTIFICATE

This is to certify that this Project work on

“FABRICATION OF PEDAL OPERATED WATER PUMP ”

submitted by …………………… ……………. Reg. No. ……………

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

This is the bonafide record of work carried out by him under our supervision

during the year 2013

Submitted for the Viva-voce exam held on ……………..

HOD PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. K.LAKHSMANAN,M.E encouragement and valuable

advice.

we thank our Esquired Head of Department Mr. S.JESUDASS M.E for

presenting his felicitations on us.

We are grateful on our Entourages Mr. Z.KHAJA MOIDEEN B.E,

for guiding in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the

Mechanical Department.

Ultimately, we extend our thanks to all who had rendered their co-

operation for the success of the project.

CONTENTS

CONTENTS

1. INTRODUCTION

2. SYNOPSIS

3. CONSTRUCTION DETAILS

4. WORKING PRINCIPLE

5. SPARE PARTS DRAWING

6. INTRODUCTION TO PUMP

7. APPLICATION

8. ADVANTAGES AND DISADVANTAGES

9. FEATURES OF THIS PROJECT

10. SAFTY,CARE AND MAINTENANCE

11. PAINTING AND FINISHING

12. COST ESTIMATION

13. CONCLUSION

14. BIBLIOGRAPHY

15. PHOTO VIEW

INTRODUCTION

INTRODUCTION

This is a self – assessment test on the part of the students to assess his

competency in creativity.

During the course of study, the student is put on a sound theoretical

foundation of various mechanical engineering subjects and of course, to a

satisfactory extent. Opportunities are made available to him to work on

different kinds of machines, so that he is exposed to various kinds of

manufacturing process.

As a students learn more and more his hold on production technology

becomes stronger. He attains a stage of perfection, when he himself is able

to design and fabricate a device.

This is the project work. That is the testimony for the strenuous

training, which the student had in the institute. This assures that he is no

more a student, he is an engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and

testing.

SYNPOSIS

SYNOPSIS

Hand operated pumps are widely used in

domestic, industrial and commercial applications. The capacity of

this pump varies from 5 feet to 50 feet . higher head pumps are

used for pumping drinking water in villages.

Working principle;

This pump consists of one cylinder , piston two numbers of non

return valve and hand lever. When lever is raised , the piston inside

the cylinder moves down into the cylinder causes water is sucked .

when the lever is lowered or pressed down , the water inside the

cylinder discharged to outlet point.

The pedal is rotated by the foot and hence crank rotates causes the

connect rod oscillated to the lever of the pump . Thus the water is

discharged to the outlet by pedaling the cycle pedal.

OBJECTIVE

OBJECTIVE;

To lift the water from the ground floor to first floor of the domestic

building and to avoid the painstaking staircase pot carrying option.

To save the electricity

DEFINITION OF PROBLEM

DEFINITION OF PROBLEM;

During summer season , due to water scarcity problem the people

purchasing the water from lorry by collecting the water through their

pots. These pots are carried by the men or women and getting tired when

carrying water through staircase step those who are living in flat system.

When this unit is installed in first floor of the building , the suction pipe is

put in to the water delivery pipe of lorry and water is delivered through

the flexible pipe to the required collecting point by pedaling this unit.

SCOPE OF THE PROJECT

SCOPE OF THE PROJECT;

The outstanding advantage of water discharging system from the ground floor to

first floor or discharging the water from the lorry to the collecting point by

simply pedaling this unit .

The water is carried by the flexible tube relieves the stress free painstaking

water carrying through the pot while in staircase walking.

Simple construction and less effort and costless maintenance and anybody can

work this unit.

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

less effort.

PROJECT PLANNING

PROJECT PLANNING

CONCEPT OF THE PROJECT

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

functions are 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 details 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.

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.

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.

CONSTRUCTION

CONSTRUCTION

The project consist of

1. Hand operated pump

2. M.S. . Stand

3. CONNECTING ROD

4. Crank shaft

5. Pedal with shaft

6. Seat

M.S.Stand;

This unit fabricated in M.S. square tube of size 25 x 25 mm and

having thickness 1.8 mm .the operator can pedaled in sitting

position and this seat is elevated to a height of 400 mm at right

side of stand. The pump unit is fitted at the right side of the stand .

the pedals are welded between the seat and pump at the base stand.

Connecting rod ;

The connecting rod is used to connect the pump piston and the

crankshaft.this connecting rod is made in mild steel material

having 10mm square rod to a length of 450mm.

Crankshaft;

The purpose of crankshaft is convert the rotary motion into

linear motion . here the crankshaft is made in M.S. Flat of 25mm x

6mm and rotated in pair of sleeve bearing hub on the top of the

base stand. On the other end of the crank foot pedal rod is

connected and the leg is supported on pedal shown in below figure.

BICYCLE PEDAL ;

A bicycle pedal is the part of a bicycle that the rider pushes with their 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 spindle

and propel the bicycle's wheels. 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) wheel. The safety bicycle, as it is known today, came into

being when the pedals were attached to a crank driving a sprocket that

transmitted power to the driven wheel by means of a roller chain

1.HAND OPERATED PUMP

Hand operated pumps are widely used in domestic, industrial and

commercial applications. The capacity of this pump varies from 5

feet to 50 feet . higher head pumps are used for pumping drinking

water in villages..

The Mark II is a closed-cylinder pump. The cylinder brass-lined

cast iron with the foot valve and piston assemblies made of

brass. The piston seals are double nitrile rubber cup seals.

As you can see in the figure below, the top and bottom of the

piston cylinder are “capped” with threaded reducers. The

diameter of the pump cylinder is larger than the diameter of the

riser main to which it is attached.

Maintenance on any part of the pump cylinder requires that the

riser main and the pump rod be removed from the ground.

The pump rod is galvanized steel and sections are threaded

together.

The pump cylinder is threaded onto the last section of riser main

and is removed in its entirety as the last component to come out

of the ground.

The pump cylinder can then be unscrewed from the riser main.

The top and bottom caps can be unscrewed from the cylinder

body to gain access to the foot valve, the piston valve, the piston

seals and anything else inside the cylinder body.

The Mark II water hand pumps are reliable and widely used.

However, for installation and maintenance, tools and skills are

required that may not be available at the village level.

As such, the Mark II is not considered a VLOM pump. It usually

requires a trained area technician to install and maintain a Mark II

pump.

The Mark II hand pump consists of the above-ground mechanism

which includes the pump head, pump handle, water tank, and

pump stand assemblies.

The below-ground mechanism includes the riser main, pump rods

and pump cylinder assembly.

The above-ground mechanism is constructed of welded steel

plate for strength and is hot-dip galvanized for corrosion

resistance. These parts may be locally manufactured.

A chain and quadrant mechanism of the pump handle provides

easy and accurate alignment of the connecting rod (see

illustration).

The pump handle has a high mechanical advantage. It is heavy

and is designed to counter balance the weight of the connecting

rods to reduce the pumping effort required from the user.

The handle pivot assembly (sealed ball bearings on a stainless

steel axle) makes operation easier and lowers maintenance

needs.

The pump rods are made of cold drawn bright steel bar with

threaded end couplers, electro-galvanized against corrosion.

Stainless steel rods are also available.

The pump cylinder is made from a cast iron casing with a

polished brass liner and gun metal plunger and check valve

components.

Seals (pump buckets, valve seals and cap seals) are available in

environmentally safe Nitrile rubber.

This pump can be easily adapted for shallow well, windmills and

motorized operations with minor modifications.

How Does a Hand Water Pump Work?

1. The Old Days

o Many older homes and farms have utilized the manual

hand water pump. The cast iron housing would bring water to

the surface from a hand-dug rock-lined well. It may have

taken many strokes from the long lever in order to gather just

a gallon of water from the underground source. Although the

manual hand pump may be of an old design, many are still in

use today for wells that are no deeper than 20 to 30 feet in

depth.

Leather

o The round interior of the manual water pump uses a metal

disc that is sealed against the smooth sides of the pumping

chamber. Generally, two discs are used that sandwich a

piece of leather. This leather creates a seal so a suction can

be created inside the chamber. As the handle is "pushed"

downwards, the lever action draws the disc and leather

sandwich up. The upward movement of the disc "sucks" the

liquid into the pumping chamber. When the handle is pulled

upwards the opposite lever action on the disk then forces the

water out of the chamber through a spout located at the top

of the hand pump. Generally, one full cycle of the hand

pump, a single stroke of up and down, may eject only one

glass full of water.

Check Valve

o A check valve or a one-way valve is generally used to

keep the suction pipe full of water. The check valve is located

at the bottom of the pipe and inside the well. This suction

pipe is attached to the bottom of the hand pump and is what

conducts the well water to the surface. If a check valve is not

used, the water that in the pipe can drain back into the well.

In order for the hand pump to be used, it must be kept in a

closed circuit of water. If air is allowed to enter the pumping

chamber it must be removed by priming the pump. Priming

the pump can be achieved by filling the pump chamber and

perhaps even the suction pipe with water. This can be

accomplished by pouring water through the exit spout of the

hand pump while stroking the handle up and down. This will

allow the water to fill in the chamber and suction pipe to

remove any unwanted air.

Still In Use

o Many homes in rural areas that use a private well for their

source of water may still employ a hand pump as a backup

device. These reliable pumps can be attached mechanically

to a small windmill or a solar powered motor and be used as

an emergency backup whenever the electrical power may be

disrupted. Even with modern technology, the same basic

design is still used today in the construction and operation of

a manual hand water pump.

2. 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)

#Bronze

#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.

3. Crank rod;

CRANK is a mechanical number. It is connect to the

through follower .Links to hand lever for pump. The crank is

rotated by the cycle pedal . . When the cycle pedal is rotated, the

rotory motion of crank is converted to reciprogating motion of

connecting rod

3.FRAME STAND

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

WORKING PRINCIPLE

WORKING PRINCIPLE

The project consist of

1.Hand operated pump

2.M.S. . Stand

3.CONNECTING ROD

4.Crank shaft

5.Pedal with shaft

6.Seat

1.HAND OPERATED PUMP

Hand operated pumps are widely used in domestic, industrial and

commercial applications. The capacity of this pump varies from 5

feet to 50 feet . higher head pumps are used for pumping drinking

water in villages.

Working principle;

This pump consists of one cylinder , piston two numbers of non

return valve and hand lever. When lever is raised , the piston inside

the cylinder moves down into the cylinder causes water is sucked .

when the lever is lowered or pressed down , the water inside the

cylinder discharged to outlet point.

The pedal is rotated by the foot and hence crank rotates causes the

connect rod oscillated to the lever of the pump . Thus the water is

discharged to the outlet by pedaling the cycle pedal.

SPARE PARTS AND ASSEMBLY DRAWING

ADVANTAGES

ADVANTAGES

1. Single person is enough to operate this efficiently to pump the water

from the sump..

2. Easy and efficient handling of this unit without wastage of water or

damage to unit, pump and to any other parts.

3. low maintenance cost and life of equipment also increased..

4. Least maintenance of the equipment.

5. Need not require any individual work place.

6. Can be worked in the work spot.

7. Suited for pumping water for 15 feet to 20 feet depth .

DISADVANTAGES

DISADVANTAGES

Manual power required to operate .

The time taken for discharging the water is more when

compared to power unit.

It cannot be used for more than 50 feet depth ...

APPLICATION

APPLICATIONS

1.By using this device , the water can be pumped up to 20 feet height.

2.used as exercise kit.

PAINTING AND FINISHING

FINISHING AND PAINTING

JOB PREPARATION

Before welding, remove any bend in the L angle with the sludge

hammer on the anvil block. Then it is cut to the required length with the

hacksaw blade and fabricated to required dimensional shape with arc

welding.

FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the

chipping hammer and cleaned with the metal wire brush. Then all the

surfaces are rubbed with the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the

metal primer, the second coating is applied with the paint.

SAFETY,CARE AND MAINTENANCE

SAFETY,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 piston in the unit.

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

operation of pumping.

(4) Check the leakage of water and pipeline in the unit.

(5) sit carefully while pumping the water .

FEATURES OF THIS PROJECT

FEATURES 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..

RESULT AND DISCUSSION

RESULT AND DISCUSSION

The various type of pumps are used for pumping the water

from a sump to tank. This is also one of the hand operated pump

which is now operated through the cycle pedal .The operation and

mechanism of this unit and its function have been studied.

At the end, the machine is assembled.

This machine is more advantages of other types of hand pump

since it has more easier to operate comfortable seating

arrangement and good exercise to our body and also less time

consumption, easy handling etc.

COST ESTIMATION

COST ESTIMATION

1. suction pipe line and connector--------------------200.00

2. Hand pump unit 2800.00

3. Crank rod 600.00

4.M.S. Fabricated BASE unit 1600.00

5. PEDAL & SEAT UNIT 600.00

6. transport cost 200.00

TOTAL COST 6000.00

CONCLUSION

CONCLUSION

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 welding

work at our Institute.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY -HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY -R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY -S.S.MANIAN

4. JIG AND FIXTURE DESIGN - R.K.JAIN

5.FLUID POWER BY -E.SUNDRAMOORTHY

PHOTO VIEW

PHOTO VIEW