AUTOMATIC ROTARY CAR PARKING

SYSTEM

Submitted to: INS. ABRHA G.

Submission Date: JUNE 16TH 2017
GROUP MEMBERS
Abstract
In cities, parking of vehicles has become a major concern in crowded areas and to cope up with
this problem, we need a good parking system. Different types of vehicle parking systems are
implemented worldwide namely Multi-level Automated Car Parking, Automated Car Parking
System, Volkswagen Car Parking, etc. The present project work is aimed to design and develop a
working model of a Rotary Automated Car Parking System for parking 12 cars. This system has
been implemented to reduce the excess use of land space which is already very scarce in metro
cities. The chain and sprocket mechanism is used for driving the parking platform and a motor
shall be implemented for powering the system and indexing the platform.
Table of Contents
CHAPTER ONE ................................................................................................................................................................................... 6
1.1. Introduction................................................................................................................................................................... 6
1.2. Objective of the project ................................................................................................................................................. 6
1.3. Literature review ........................................................................................................................................................... 7
1.4. Problem statement........................................................................................................................................................ 9
1.5. Methodology/ process .................................................................................................................................................. 9
CHAPTER TWO ................................................................................................................................................................................ 10
DESIGN ANALSIS OF PARTS ........................................................................................................................................................ 10
1.1. Mathematical calculation of component .................................................................................................................... 10
1.2. Design Conveyer Chain ................................................................................................................................................ 11
1.3. Design of Power transmitting Chains .......................................................................................................................... 12
1.4. Components of Cage ................................................................................................................................................... 14
1.4.1. Pallet Design........................................................................................................................................................... 14
Design of vertical bar (Pallet hanger) ......................................................................................................................................... 17
1.4.2. Design of circular bar .............................................................................................................................................. 19
1.4.3. Design of rectangular frame ................................................................................................................................... 21
1.4.4. Design of Bolts ........................................................................................................................................................ 23
1.4.5. Design of Nut .......................................................................................................................................................... 24
1.4.6. Design of roller ....................................................................................................................................................... 25
1.5. Design of Bevel gear (gear box) ................................................................................................................................... 26
1.6. Design of shaft for bevel gear...................................................................................................................................... 30
1.7. Design of shaft ............................................................................................................................................................. 31
1.8. Design of key ............................................................................................................................................................... 32
1.9. Design of shaft coupling .............................................................................................................................................. 34
1.9.1. Design of the key .................................................................................................................................................... 35
1.9.2. Design of flange ...................................................................................................................................................... 36
1.10. Design of support ................................................................................................................................................... 37
1.11. Design of connecting bar ........................................................................................................................................ 39
1.11.1. Design of weld ........................................................................................................................................................ 39
1.12. Design of bearing .................................................................................................................................................... 40
1.13. Design of triangular plate ....................................................................................................................................... 41
1.14. Design of the roller ................................................................................................................................................. 43
1.15. Design of bolt.......................................................................................................................................................... 44
1.16. Design of small plate............................................................................................................................................... 44
CHAPTER THREE .............................................................................................................................................................................. 46
2. Drawing part..................................................................................................................................................................... 46
2.1. Part drawing ........................................................................................................................................................... 46
 2.1.1. Pallet .................................................................................................................................................................. 46
2.1.2. Pallet hanger ...................................................................................................................................................... 46
2.1.3. Rectangular bar.................................................................................................................................................. 47
2.1.4. Circular bar ........................................................................................................................................................ 47
2.1.5. Triangular plate .................................................................................................................................................. 47
2.1.6. Roller .................................................................................................................................................................. 48
2.1.7. Roller connector plate ....................................................................................................................................... 48
2.1.8. Roller connector ................................................................................................................................................ 48
2.1.9. Frame (upper support) ...................................................................................................................................... 49
2.1.10. Frame (lower support) ....................................................................................................................................... 49
2.1.11. Chain house ....................................................................................................................................................... 49
2.1.12. Shaft ................................................................................................................................................................... 50
2.1.13. Sprocket Gear .................................................................................................................................................... 50
2.1.14. Key ..................................................................................................................................................................... 50
2.2. Assembly drawing ................................................................................................................................................... 51
CHAPTER FOUR ............................................................................................................................................................................... 52
2. DESIGN AND DEVELOPMENT............................................................................................................................................ 52
2.1. OBJECTIVES OF THE PRODUCT .................................................................................................................................... 52
2.2. PRODUCT PLANNING PROCESS.................................................................................................................................... 52
2.2.1. Identify opportunities ........................................................................................................................................ 52
2.2.2. evaluate and prioritize projects ......................................................................................................................... 52
2.2.3. Allocate resource and plan timing ..................................................................................................................... 53
2.3. MISSION STATEMENT ............................................................................................................................................. 53
2.4. IDENTIFYING CUSTOMER NEEDS ............................................................................................................................ 54
2.5. PRODUCT SPECIFICATION ....................................................................................................................................... 55
2.5.1. Establish Relative Importance of Needs ............................................................................................................ 55
2.5.2. ESTABLISHING TARGET SPECIFICATIONS ........................................................................................................... 55
2.6. CONCEPT GENERATION .......................................................................................................................................... 57
2.7. CONCEPT SELECTION .............................................................................................................................................. 61
CHAPTER FIVE ................................................................................................................................................................................. 64
6. MANUFACTURING AND COST ANALSIS ............................................................................................................................ 64
6.1. Cost analysis ................................................................................................................................................................ 64
6.2. Manufacturing process ................................................................................................................................................ 65
CHAPTER SIX............................................................................................................................................................................... 66
7. Assembly and disassembly of Automated rotary car parking system ............................................................................... 66
CONCLUSION .................................................................................................................................................................................. 67
FUTURE SCOPE ................................................................................................................................................................................ 68
REFERENCES ............................................................................................................................................................................... 69
CHAPTER ONE
1.1. Introduction
The advancement and progress of nations is measured by the possibility of their use and application
of latest invented technologies in all aspects of life. For nearly one hundred years, planners,
engineers and environmentalists have wrestled with the challenge presented by the increasing
prevalence of the automobile where to put cars. Ranging from the earliest parking garages
renovated horse barns to fully automatic parking structures, innovative thinkers have attempted to
devise clever ways to park vehicles. The rapidly growing urban population is creating many
problems for the cities, vehicle parking being one of the major problems faced almost every day.
In many urban housing societies, the parking space ratio is 1:1. To avoid these problems,
recently many new technologies have been developed that help in solving the parking problems
to a great extent.
The Rotary Automated Car Parking System model is specifically designed to accommodate
multiple cars in the horizontal space of two cars. The structure can accommodate six cars
in the space of two or can even be customized to hold a greater number depending upon the
requirements of the user and can be efficiently put to use in much space crunched areas.
Although automated parking like multilevel parking has made the condition a little better
than the earlier situation, there is still scope for improvement. This is because people still face
problems of space availability, searching time and waiting time in public places like malls,
multiplexes, railway stations, shopping streets etc. With the new technology of smart parking,
majority of these issues will be solved. The vehicles parked randomly cause major problem
faced in most of the metropolitan cities and to deal with this problem, after studying all
these systems we learnt that Rotary Car.

1.2. Objective of the project

To design and develop a safe and secured car parking system which will not damage the
vehicle and the property.
It should consume less time, money and fuel.
To minimize pollution and to construct an eco-friendly system.
Designing a systematic parking system which will accommodate to any building style and
environment.
By using modern technology, to design a system which will minimize land requirement,
maximize efficiency and will be profitable in long term.
1.3. Literature review
The present parking systems such as multilevel or multistory car parking systems (non-automated),
robot car parking systems, automated multilevel car parking systems etc. It have been
implemented on a huge scale. But these systems have a major disadvantage of large space
consumption which is successfully eliminated with the use of a Rotary Car Parking System.
Moreover, the latter provides the added benefits of flexible operation without the need of an
attendant and added security and least chances of vehicle damage. Since the model makes use
of composite parts, it is easy to assemble and dismantle and is thus more convenient than the
traditional car parking systems.
PRESENT PARKING SOLUTIONS
a. Integrated Car Parking Solution
Customize application suitable for various types of
landscapes and buildings Structures available
below the ground. Ease control by soft touch on
the operation panel screen. When a vehicle stops
in front of the entrance, automatically door opens
and trolley transfers the vehicle to parking cell.
Misleading of this solution is it should be
undergrounded. By this investment increases and
lot much space utilization is to be made
b. Automated Car Parking
The driver will pull the car onto a computer- controlled
pallet, turn it off, and get out. The pallet is then
lowered into the abyss of parking spaces, much like
a freight elevator for cars, except it can also move
sideways, not just up and down. There's an array of
laser sensors that let the system know if the car doesn't
fit on the pallet (although it's big enough to fit a mid-
sized SUV),. The system retrieves the car when the
driver returns, although this might take some time
and creative manoeuvring. Cars are parked two deep
in some spots, so a specially tailored software system
has to figure out the logistics of shuffling the
various vehicles around as needed to retrieve a specific
car. And for those, like me, who find it difficult to
turn their vehicle around after pulling out of a space,
there's an underground turntable that turns the car
around before it is lifted to the surface, so the car is
facing out into the driveway, ready to go. Backing out
of garages or parking spaces is one of the most common causes of accidents
c. Multi-Level Parking
A multi-level car parking is essentially
a building with number of floors or
layers for the cars to be parked. The
different levels are accessed through
interior or exterior ramps. An automated
car parking has mechanized lifts which
transport the car to the different levels.
Therefore, these car parks need less
building volume and less ground space and
thus save on the cost of the building. It also
does away the need for employing too
many personal to monitor the place. In an
automated car parking, the cars are left at
the entrance and are further transported
inside the building by robot trolley.
Similarly, they are retrieved by the trolley and placed at the exit for the owner to drive away.
1.4. Problem statement
The rapidly growing urban population is creating many problems for the cities, vehicle parking
being one of the major problems faced almost every day.
People still face problems of space availability, searching time and waiting time in public places
like malls, multiplexes, railway stations, shopping streets etc
Lack of space availability has always been a problem in urban areas and major cities and to add to
it there are cars parked callously on the streets that further limit the space.

1.5. Methodology/ process

A series of methods were followed during the design of the project. The major ones are described as
follows

 Identifying part components which are needed for the machine

 Checking availability and manufacturability of those components
 Selecting materials for each component
 Analyzing each component strength wise
 Choosing method of joining for components
 Assembling orderly
CHAPTER TWO
DESIGN ANALSIS OF PARTS
Assumption and standard detail
- Capacity: up to 10 car
- Car available dimensions
Types and Sedan (Honda Hatch Back SUV (Hummer)
Specifications Accord) (Maruti Swift)
Length 4900mm 3850mm 5300mm
Height 1450mm 1530mm 1500mm
Width 1800mm 1695mm 2300mm
Weight 1800 kg 1100 kg 3000 kg
Table 7

2.1. Mathematical calculation of component

 Motor selection
Considering width and height of pallet diameter of sprocket is D= 2400mm
 Assumptions
D=2400mm
Velocity= 6m/min = 0.1m/s
N= speed of driven sprockets
0.1𝑚
60𝑉 60∗ 𝑠
- 𝑁= = = 0.796 𝑟𝑝𝑚
𝜋𝐷 𝜋∗2.4

- Force(F)= (weight of pallet + weight of hanger rod +

weight of one vehicle) * 5/g
Weight of pallet – let the mass of the pallet is 600 kg (wp)
Weight of vehicle 2500kg (wv)
Weight of hanger rod 350 kg

- Force (F)
𝐹 = (𝑊𝑣 + 𝑊𝑟 + 𝑊𝑝) ∗ 5 ∗ 𝑔
= (2500 + 350 + 600) ∗ 5 ∗ 9.81
𝐹 = 169222.5𝑁~170000.0𝑁 = 170𝐾𝑁
 - Torque (T) 
𝐷 2400
𝑇=𝐹∗ = 170𝐾𝑁 ∗ = 204𝐾𝑁𝑚
2 2
The power needed to rotate the system is
2𝜋𝑁𝑇 204𝐾𝑁𝑚
𝑃= = 2 ∗ 𝜋 ∗ 0.796𝑟𝑝𝑚 ∗
60 60
P = 17Kw
For standardizing we take a power of 20Kw
- The power rating is 20Kw (26.81 Hp)
We can select a motor having Power p=20 Kw
Features of the motor
 Easily maintained

 Light weight

 High performance

 Less noise levels

2.1. Design Conveyer Chain

 The diameter of the sprocket is D = 2400mm
 Let the number of teeth T(Z)= 40
 Using the formula 𝐷 = 𝑃/sin 〖180/𝑇〗
180 180
𝑃 = sin ∗ 𝐷 = sin ∗ 2400
𝑇 40
P = 188.3 mm
 Center of distance for conveyor chain
- To find the center of distance
C= 38*P , this may be taken from 30 - 50 We took 38.
 Consider the height of the cage center of the conveyor to be 7
meter
 Length of the chain
〖𝑇1 − 𝑇2 )𝑝 𝑇1 − 𝑇2
𝐿 = 2𝐶 + + ∗ 𝑃²
2 4𝜋 2 𝐶
 𝟒𝟎 + 𝟒𝟎 𝟒𝟎 − 𝟒𝟎
𝑳 = 𝟐 ∗ 𝟕𝟎𝟎𝟎 + ∗ 𝟏𝟖𝟖. 𝟑 + ∗ 𝟏𝟖𝟖. 𝟑𝟐
𝟐 𝟒 ∗ 𝝅𝟐 ∗ 𝟕𝟎𝟎
𝐿 = 21532 𝑚𝑚 = 21.532𝑚
 Number of linkes (K)
𝐿 21532
𝐾= = = 115
𝑃 188.3
𝑃 20 𝐾𝑊
Load on the chain = = = 200 𝐾𝑁
𝑉 0.1

 Break load = 106𝑃2 = 106 ∗ 188.32 = 3750.43 𝐾𝑁

𝑊𝐵 3750.43
 Factor of saftey (F.S) = = 18  SAFE
𝑊 200

2.2. Design of Power transmitting Chains

We know that the power rating is 20Kw

Let the number of teeth on drive sprocket (Z1)
Z1 =20, speed ratio = 4
So the speed of drive sprocket is 𝑁1 = 𝑁2 ∗ 4 = 0.796 𝑟𝑝𝑚 ∗ 4
𝑁1 = 3.184 𝑟𝑝𝑚
Number of teeth on drive sprocket (Z2)
 𝑍2 = 19 ∗ 4 = 76
Design power = rate power * service factor
Servic factor = Load factor (K1) * Lubrication factor (K2) * rating factor (K3)
K1 = 1.25  variable load with mild shock
K2 =1.5  Periodic lubrication
K3 = 1.25  For 16 hours per day
 Service factor (K)
K = K1 *K2 *K3 =1.25*1.5*1.25
K=2.34
Design power = 20 ∗ 2.34 = 46.8 𝐾𝑤
Now, selection of chain on basis of design power and revolution per minute of the roller sprocket
for 20 teeth pinion.
From the table 48 A-1 American standard, we get
Roller diameter = 47.625m
P=76.2mm
Width of roller= 47.35mm
Breaking load=629.32 KN
D1 (pitch circle diameter of small sprocket)
𝑃 76.2𝑚𝑚
𝑑1 = = = 487.1 𝑚𝑚
180 180
sin ( ) sin ( )
𝑇1 20
𝑃 76.2𝑚𝑚
𝑑2 = = = 1.94 𝑚
180 180
sin ( ) sin ( )
𝑇2 80
 Pitch line velocity of small pinion
(𝜋 ∗ 𝐷1 ∗ 𝑁1 ) 𝜋 ∗ 487.1 ∗ 3.184 𝑟𝑝𝑚
𝑉1 = =
60 60
𝑉1 = 0.081 𝑚/𝑠
𝑟𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 20 𝐾𝑤
 Load on the chain 𝑊 = = 𝑚
𝑝𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 0.081 𝑠

W = 246.913 𝐾𝑤
𝑊𝐵 629.32 𝐾𝑁
Factor of seftey (F.S)= = = 2.548
𝑊 246.913 𝐾𝑤

The minimum centriodal distance between the smaller and the larger sprockets should be 30 to
50 times the pitch.
 We took 40 𝐶 = 40 ∗ 𝑃 = 40 ∗ 76.2𝑚𝑚
𝐶 = 3048𝑚𝑚 = 3.04𝑚
 The nuber of chain links
𝑇1 + 𝑇2 2 ∗ 𝐶 𝑇1 + 𝑇2 𝑃
𝐾= + +( )∗
2 𝑃 2 𝐶
20 + 80 2 ∗ 3048 60 2 76.2
𝐾= + +( ) ∗
2 76.2 2∗𝜋 3048
𝐾 = 130 + 2.279
𝐾 = 132.28~133
𝐿 = 𝐾 ∗ 𝑃 = 133 ∗ 76.2 = 10.134 𝑚
 2.3. Components of Cage
Cage is used to park and hold the car while it rotates on the structure.

2.3.1. Pallet Design

 Vehicle specification
Vehicle size = 4854 mm * 2000 mm * 1476 mm
Wheel base = 3200 mm
Wheel track = 1800 mm
Maximum weight of the vehicle = 1985 – 2500 Kg
 Pallet specification
Length =5000 mm
Width = 2100 mm
Height = 1700 mm
Total load on pallet = 2500 ∗ 9.81 = 24500𝑁
Load is applied on four points on the pallet where tire of the vehicle are assumed to be rested
  Material Selection
 We selected steel for better strength, because the pallet carries a heavy load and subjected
to bending load.
 E (Elastic modules) = 210 GPa
 ρ (Desnsity) = 7.85 Kg/m3
 σt = 585 MPa
 σy = 505 MPa
 Let the distance from the support of the pallet to the wheel of the car is 1000 mm
In this structure bending moment is produced due to the weeight of the car and the pallet
 Weight on front wheel and weight in rear wheel can be calculated
𝑊𝑣𝑒ℎ𝑖𝑐𝑙𝑒 𝑊𝑝𝑎𝑙𝑙𝑒𝑡 600 2500
𝑊𝑓 = + = +
2 2 2 2
𝑊𝑓 = 1550 𝐾𝑔

𝑊𝑓 = 𝑚 ∗ 𝑔 = 1550 ∗ 9.81

𝑊𝑓 = 15205.2 𝑁 = 15.205 𝐾𝑁

 The maximum moment is 𝑀𝑚𝑎𝑥 = 𝑊𝑓 ∗ 𝐶 = 15.205 𝐾𝑁 ∗ 1000𝑚𝑚

𝑀𝑚𝑎𝑥 = 15.205 𝐾𝑁
𝑀𝐶
𝜎=
𝐼
𝑏ℎ3 𝑏𝑡 3
𝐼= =
12 12
𝑡
𝑀( )
𝜎= 2
𝑏𝑡 3
( 12 )

6𝑀 6∗15.205 𝐾𝑁𝑚
The required value is thickness 𝑡 2 = =
𝑏𝜎 2.1𝑚∗585∗106 𝑃𝑎

𝑡 = 8.617 𝑚𝑚
To be more safe the thickness will be taken to be t= 10 mm
 The pallet is with t- 10 mm
W-2100 mm
L-5200 mm
 Fig6. Plate
Maximum Stress in pallet = Wa÷Z = 15205 N ×1 m ÷ Z
𝑏𝑡 2 2.1𝑚∗0.012 𝑚2
𝑍= = = 3.5 ∗ 10−5 𝑚3
6 6
𝑊𝑎 15025 𝑁𝑚
= = 434 𝑀𝑃𝑎
𝑍 3.5 ∗ 10−5 𝑚3
Deflection at Center (Max) = W * a * (3l2-4a2)
24EI
= 15025 * 1000 *[3(5200)2-4(1000)2]
24*210*109*23958.3
= 1.24*10-2
= 0.01204mm
Deflection at CAR Wheels = W*a2 * (3l-4a)
6EI
= 15025*106 * [3(5200)-4(1000)]
6*210*109*23958.3
= 7.347*10-3
= 0.007047mm
FEA analysis of plate by ANSYS workbench:-
The three dimensional model of pallet prepared in solid edge modeling software is imported in
ANSYS workbench and load is applied at the wheel resting portion and results are obtained.
Design of vertical bar (Pallet hanger)
 Material selection
 Steel, AISI 1045
 High strenght
 High corresion resistance
 σt = 585 N/mm2
 σy = 505 N/mm2
 E= 190 GPa
 Assumptions
 Weight of car 2500 Kg
 Length of the frame – 1.75 m (upper)
 Length of curved bar – 150mm
 Factor of saftey = 4
 Weight of the pallet = 600 Kg
 Consideration
 Axial stress due to length
 Bending stress due to upper length
 Direct shear on the frame
 Deformation of frame
 Analysis
 Find of the diameter of the circular frame
𝑁
505 𝑁
𝑚𝑚2
σall =σy /F.s= = 126.25
4 𝑚𝑚2

 Find the load in each frame

Nframe =4
Wcar =2500 Kg
G=9.81 m/s2
𝐹𝑡 = 𝑤 ∗ 𝑔 = 2500 ∗ 9.81 + 600 ∗ 9.81
𝐹𝑡 = 30.411 𝐾𝑁
 𝐹𝑡 30.411 𝐾𝑁
𝐹𝑒𝑎𝑐ℎ = = = 7.6013 𝐾𝑁
𝑁𝐹 4
Solve diameter due to bending moment on the circular frame
𝑀∗𝐶 𝑑
𝜎= 𝐶= 𝑀 = 𝐹 ∗ 𝐿 = 7.6013 ∗ 150 = 1140.41 𝑁𝑚
𝐼 2

𝜋𝑑 4
𝐼=
64
𝑀∗𝐶
𝜎=
𝐼
1140.41 𝑁𝑚 ∗ 32 ∗ 103
126.25 =
3.14 ∗ 𝑑3
1140.41 ∗ 32 ∗ 106
𝑑3 = = 42.02~50 𝑚𝑚
3.14 ∗ 126.25
Solve diameter due to shear stress on the frame
𝐹 4∗𝐹
𝜏= =
𝐴 𝜋 ∗ 𝑑2
4 ∗ 7.6013 𝐾𝑁
𝑑2 = = 15.12 𝑚𝑚
6.125 ∗ 𝜋
Note:- dshear is compared with dbending is small, it is concluded that it is not safe
We take dbending = 42.02 mm ͠=50 mm
check deformation (elongation)
𝑃𝐿 6.13 ∗ 103 ∗ 1.750
𝛿= = = 0.00401 𝑚𝑚
𝐸𝐴 190 ∗ 109 ∗ 1385.44
 2.3.2. Design of circular bar

- Used to connect the rectangular frame both side and used to mount the cage on to the
structure.
It is subjected to bending stress due to the load in the cage that is the load of the vehicle.
 Material selection
 Steel AISI 1045
 Yield strength – 505 MPa
 Ultimate stress – 585 MPa
 F.S=4
 Analysis
 First find the reaction force

∑ 𝐹𝑦 = 0 → 𝑅𝐴 + 𝑅𝐵 − 170 ∗ 2 = 0

𝑅𝐴 + 𝑅𝐵 = 340 𝐾𝑁
MA<⊃=0
−(0.1 ∗ 170)𝐾𝑁𝑚 − (5.1 ∗ 170)𝐾𝑁𝑚 + 5.2 ∗ 𝑅𝐵 = 0
63.7𝐾𝑁𝑚
𝑅𝐵 = = 170𝐾𝑁
5.2𝑚
∴ 𝑅𝐴 + 𝑅𝐵 = 340 𝐾𝑁
𝑅𝐴 = 170 𝐾𝑁
  Calculate the bending
moment diagram
𝑀∗𝐶 𝑑
𝜎= , 𝐶=
𝐼 2
𝑀 = 𝐹 ∗ 𝐿 = 7.6013 ∗
150 = 1140.41 𝑁𝑚
𝜋𝑑 4
𝐼=
64
𝑁
505
𝑚𝑚2
σall =σy /F.s= =
4
𝑁
126.25
𝑚𝑚2

𝑀 ∗ 𝑑/2
𝜎=
𝜋𝑑 4
64
1140.41 𝑁𝑚 ∗ 32 ∗ 103
126.25 =
3.14 ∗ 𝑑3
1140.41 ∗ 32 ∗ 106
𝑑3 = = 46.23~50 𝑚𝑚
3.14 ∗ 126.25
Using Ansys Analyses of Bar We found that the shearing force and bending moment diagram.
The shearing force diagram.

The bending moment diagram.

 2.3.3. Design of rectangular frame
The rectangular frame is used to hold the frames from both sides. It is subjected to bending stress
due to the load.

 Material selection
 Steel AISI 1045
 Yield strength – 505 MPa
 Ultimate stress – 585 MPa
 F.S=4

 Assumption
 Length of the rectangular frame is 1800 mm
We take square (h=b)
 Analysis
 The bending moment in the rectangular frame is
𝑀 = 𝐹 ∗ 𝐿 = 170 𝑘𝑁 ∗ 0.9 𝑚 = 153𝑁𝑚
𝑀𝐶 𝑏ℎ3
𝜎= ’ 𝐼= , b=h
𝐼 12
 ℎ
𝑀∗
𝜎= 2 = 6𝑀
ℎ4 ℎ3
12
𝑁
505 𝑁
𝑚𝑚2
σall =σy /F.s= = 126.25
4 𝑚𝑚2

6𝑀 6 ∗ 153 𝐾𝑁𝑚
ℎ3 = =
ℎ3 𝐾𝑁
126.25 ∗ 103 2
𝑚
ℎ = 0.080618 𝑚 = 80.618 𝑚𝑚 = 𝑏
To be more safe h=b=100 mm
The shear force diagram for rectangular frame is shown below

The bending moment diagram

 2.3.4. Design of Bolts

Bolts are a non-permanent joint which is used to connect one component from the other. In our
design we use the bolt to connect the circular frame to the plate.
 Material selection
o Steel property class 8.8 medium carbon Q&T
o Proof strength, Sp = 600 MPa

o Tensile strength, σt = 830 MPa

o Yield strength, σy = 660 MPa
o At= 561 mm2
o As= 314 mm2

 Analysis
 M30 *2 bolts

 Length of the threaded part, Lt= 2d + 6

The bolt is subjected to shear force. So we are going calculate shear stress for the bolt.
 𝐹
Shear stress, τ =
𝐴𝑠

= 85*103
314
= 270 N/mm2

Bearing stress on the small plate,

The larger plate is thinner than the small plate, and so the largest bearing is due to the pressing
of the bolt against the larger plate. The bearing area is Ab = td = 10*30= 300mm2.

Bearing stress, σb =
𝐹
𝐴𝑏
=85*103
300
=283 MPa

2.3.5. Design of Nut

 Material selection
 Phosphor Bronze
 σyt = 126MPa
 σ yc = 112MPa
 τy = 105MPa
 Assumption
The bearing pressure is pb = 8MPa
Factor of safety = 2
 Analysis
Dimension of the nut
 Wear of the nut

F = π/4 (do2 - dc2)* pb*n ……. n= number of thread

n = 4*17000/(π*(702 - 542))*8
1.36 But the minimum number of thread is 4, and for more safety let say,
n=6
The height of the nut will be
H = p*n
= 7.5*6 = 45mm
Checking of stress strength of nut
F = τπ dont t=p/2 = 16/2
𝜏 = F/π dont
= 17000/π*70*6*8
= 1.6 MPa < τall = 52.5MPa
Therefore, the nut is quite safe

2.3.6. Design of roller

The roller is equipment which helps the cage ride on the guide. As a result it prevents the cage
from swinging while the load is moving. The material for the roller must be wear resistant and not
affected by corrosion.
General characteristics of the rolling material is
 Wear resistance
 Tear resistance
 Not ductile
 High tensile and impact strength
 Stability at high temperature
 Machineable

Assumption
Diameter of the roller, = 50mm
Material selection
- Alloy of cast iron
- Yield strength, = 60MPa
- Factor of safety, =3

Analysis
The stress on the roller can be calculate by the following formula
F = σt*A where A=πdrt
= σt *(πdrt)
𝐹
t= σt= σy/F.S
𝜋𝑑𝑟𝑡
340000
= =60/3= 20N/mm2
𝜋∗20∗50
=108.4 say
t= 120 mm

2.4. Design of Bevel gear (gear box)

The bevel gears are used for transmitting power at a constant velocity ratio between two shafts
whose axes intersect at a certain angle. In our design the bevel gear is used to transfer from the
motor shaft to the reciprocating shaft.
Material selection and specification
Particular Pinion Gear
Number of teeth
Material Stainless steel Stainless steel
Brinell Hardness 200 200
Allowable stress 85 MPa 85 MPa
Speed 3.184 rpm 0.796 rpm
Tooth profile 14.5o 14.5o
ϴs 900 900
Power 20 Kw 20 Kw
Table 8
Let m= Required module in mm.
Since the shafts are at right angles, therefore pitch angle for the pinion,
1 1
𝜃𝑝1 = tan−1 ( ) = tan−1
𝑉. 𝑅 4
𝜃𝑝1 = 14°

and pitch angle for the gear,

𝜃𝑝2 = 𝜃𝑠 − 𝜃𝑝1

𝜃𝑝2 = 90 − 14 = 76°

We know that formative number of teeth for the pinion,

 𝑇𝐸𝑃 = 𝑇𝑃 ∗ sec 𝜃𝑃1 = 30 ∗ sec 14
𝑇𝐸𝑃 = 31
and formative number of teeth for the gear,
𝑇𝐸𝐺 = 𝑇𝐺 ∗ sec 𝜃𝑃2 = 120 ∗ sec 76°
𝑇𝐸𝐺 = 496
We know that tooth form factor for the pinion,
0.684
 For tooth profile of 14.50 
𝑌𝑝′ = 0.124 − = 0.102
𝑇𝐸𝑃

and tooth form factor for the gear,

0.684
For tooth profile of 14.50 
𝑌𝐺′ = 0.124 − = 0.122
𝑇𝐸𝐺

∴ 𝜎𝑜𝑝 ∗ 𝑌𝑝′ = 85 ∗ 0.102 = 8.62

𝜎𝑜𝐺 ∗ 𝑌𝐺′ = 85 ∗ 0.122 = 10.2

Since the product 𝜎𝑜𝐺 ∗ 𝑌𝐺′ is less than 𝜎𝑜𝑝 ∗ 𝑌𝑝′ , therefore the gear is weaker. Thus, the design
should be based upon the gear.
We know that torque on the gear,
𝑃 ∗ 60 20 𝐾𝑊 ∗ 60
𝑇= = = 240 𝐾𝑁𝑚
2𝜋𝑁𝐺 2𝜋0.796
∴Tangential load on the gear,
𝑇 2𝑇 2 ∗ 240 𝐾𝑁𝑚
𝑊𝑇 = = = = 800 𝑁
𝐷𝐺 𝑚𝑇𝐺 5 𝑚𝑚 ∗ 120
2
𝑇𝐺 𝑁𝐺 0.796
We know that pitch line velocity, 𝑉 = 𝜋 ∗ 𝑚 ∗ = 𝜋 ∗ 5 ∗ 120 ∗
60 60

𝑉 = 0.024 𝑚/𝑠
6 6
Taking velocity factor,𝐶𝑣 = = = 0.996
6+𝑣 6+0.024
𝑚∗𝑇𝐺
We know that length of pitch cone element, 𝐿 = = 0.309 𝑚
2∗sin 76

We know that tangential load on the gear,

𝑊𝑇 = 𝜎𝑂𝐺 ∗ 𝐶𝑣 ∗ 𝑏𝜋𝑚𝑌𝐺′ (𝐿 − 𝑏)/𝐿
800 𝑁 = 85 ∗ 0.996 ∗ 𝑏 ∗ 𝜋 ∗ 0.005 ∗ 0.122 ∗ (0.309 − 𝑏)0.309
Solving the quadratic equation we get 𝑏 = 290 𝑚𝑚
Gear diameters
𝐷𝑃 = 𝑚 ∗ 𝑇𝑃 = 0.005 ∗ 30 = 0.15 𝑚
We know that pitch diameter for the pinion,
and pitch circle diameter for the gear,
𝐷𝐺 = 𝑚 ∗ 𝑇𝐺 = 0.005 ∗ 120 = 0.6 𝑚
Check for dynamic load
We know that pitch line velocity,𝑣 = 0.024 𝑚/𝑠
and tangential tooth load on the gear,𝑊𝑇 = 800 𝑁
From Gupta book Table 28.7, we find that tooth error action for first class commercial gears
having module 5 mm is e = 0.055 mm
Taking K= 0.107 for 14 .5º composite teeth, EP= 210 × 103N/mm2; and EG= 210 × 103N/mm2,
we have
𝐾∗𝑒 0.107∗0.055
Deformation or dynamic factor, 𝐶 = 1 1 = 2 = 617.925 ∗ 103 𝑁/𝑚
+
𝐸𝑃 𝐸𝐺 210∗103

21∗𝑣(𝑏𝑐+𝑊𝑇 )
We know that dynamic load on the gear, 𝑊𝐷 = 𝑊𝑇 +
21∗𝑣+√(𝑏∗𝑐+𝑊𝑇 )

21 ∗ 0.024 ∗ (290 ∗ 617.925 + 800)

𝑊𝐷 = 800 + = 802.034 𝑁
21 ∗ 0.024 + √(290 ∗ 617.925 + 800)
From Table 28.8, we find that flexural endurance limit (σe) for the gear material which is grey
cast iron having B.H.N. = 160, is σe =126 MPa
We know that the static tooth load or endurance strength of the tooth,
WS=σe .b.π m. y’G= 126 × 290 × 𝜋 × 5 × 0.122 = 70024.2 𝑁
Since WS is greater than that WD, therefore the design is satisfactory from the standpoint of
dynamic load.
Check for wear load
From Table 28.9, we find that for a gear of grey cast iron having B.H.N. = 160, the surface
endurance limit is, σes = 630 MPa = 630 N/mm2
(𝜎𝑒𝑠 )2 ∗sin ∅ 1 1 6302 ∗sin 14.5 2
∴Load-stress factor, 𝐾 = ∗( + )= ∗( )
1.4 𝐸𝑃 𝐸𝐺 1.4 210∗103

𝐾 = 0.676 𝑀𝑃𝑎
2𝑇𝐸𝐺 2∗496
and ratio factor, 𝑄 = = = 1.882
𝑇𝐸𝐺 +𝑇𝐸𝑝 496+31
We know that maximum or limiting load for wear, 𝑊𝑤 = 𝐷𝑃 ∗ 𝑏 ∗ 𝑄 ∗ 𝐾
𝑊𝑤 = 0.15 ∗ 0.29 ∗ 1.882 ∗ 0.676 ∗ 106 = 55342.092 𝑁
Since Ww is greater than WD, therefore the design is satisfactory from the standpoint of wear.
∴ 𝑊𝑆 > 𝑊𝑅 > 𝑊𝐷
2.5. Design of shaft for bevel gear
Specification for Shaft from bevel gear
Power 20 KW
Torque 60 KNm
Speed of pinion 3.18 rpm
Length of pitch cone element 309 mm
Face width 290 mm
Pitch angle for pinion 140
Material Steel AISI 1045
Yield stress 505 MPa
Ultimate stress 585 Mpa
Young’s Modulus 210 GPa
Pinion over hang 150 mm

The tangential force (WT) acting at the mean radius (Rm) of the pinion.
𝑏 0.290
𝑅𝑚 = (𝐿 − ) ∗ sin 𝜃𝑃1 = (0.309 − ) ∗ sin 14
2 2
𝑅𝑚 = 0.0494 𝑚
𝑇 60 𝐾𝑁𝑚
𝑊𝑇 = = = 1212.782 𝐾𝑁
𝑅𝑚 0.0494 𝑚
Now find the axial and radial forces (i.e. WRH and WRV) acting on the pinion shaft
𝑊𝑅 = 𝑊𝑇 𝑡𝑎𝑛 𝜑 = 1212.782 𝐾𝑁 ∗ tan 14.5° = 310 𝐾𝑁
𝑊𝑅𝐻 = 𝑊𝑅 ∗ sin 𝜃𝑝1 = 310 ∗ sin 14 = 77.61 𝐾𝑁

𝑊𝑅𝑉 = 𝑊𝑅 ∗ cos 𝜃𝑝1 = 310 ∗ cos 14 = 300.79 𝐾𝑁

The bending moment on the pinion shaft as follows :

The bending moment due to WRH and WRV is given by
𝑀1 = 𝑊𝑅𝑉 ∗ 𝑜𝑣𝑒𝑟 ℎ𝑎𝑛𝑔 − 𝑊𝑅𝐻 ∗ 𝑅𝑚
𝑀1 = 300.79 ∗ 0.15 − 77.67 ∗ 0.0494 = 41.298 𝐾𝑁𝑚
and bending moment due to WT
 𝑀2 = 𝑊𝑇 ∗ 𝑜𝑣𝑒𝑟 ℎ𝑎𝑛𝑔 = 1212.782 ∗ 0.15 = 181.9 𝐾𝑁𝑚
∴Resultant bending moment,

𝑀 = √𝑀12 + 𝑀22 = √41.2982 + 181.92 = 186.54 𝐾𝑁𝑚

Since the shaft is subjected to twisting moment (T) and resultant bending moment (M), therefore
equivalent twisting moment,

𝑇𝑒 = √𝑇 2 + 𝑀2 = √602 + 186.542 = 196 𝐾𝑁𝑚

Now the diameter of the pinion shaft may be obtained by using the torsion equation. We know
that
 Let the factor of safety for the shaft to be 2, 𝑠𝑠𝑦 = 0.577 ∗ 𝑠𝑢𝑡 = 0.577 ∗ 585 =
337.54 𝑀𝑃𝑎
𝑠𝑠𝑦 337.54
 𝜏= = = 168.77 𝑀𝑃𝑎
𝐹𝑆 2
𝜋
Then , 𝑇𝑒 = ∗ 𝜏 ∗ 𝑑𝑝3 where dP= Diameter of the pinion shaft, and
16

τ= Shear stress for the material of the pinion shaft.

3 (16𝑇𝑒 ) 3
𝑑𝑝 = √ = √16 ∗ 196/(𝜋 ∗ 168770) = 10.058 𝑐𝑚
𝜋𝜏

2.6. Design of shaft

 Material selection
 Steel AISI 1045
 Yield strength – 505 MPa
 Ultimate stress – 585 MPa
 E=210 GPa

σssy =0.577σy =291.385 MPa

F=34 KN*5
r= 1.2 m
require the ds
 𝑇 = 𝐹 ∗ 𝑟 = 34𝐾𝑁 ∗ 1.2𝑚
𝑇 = 40.8 𝐾𝑁𝑚 ∗ 5
𝜋
𝑇= ∗ 𝜏 ∗ 𝑑𝑠3
16
16𝑇 16 ∗ 40.8 𝐾𝑁𝑚 ∗ 5
𝑑𝑠3 = =
𝜋∗𝜏 𝜋 ∗ 291.385 𝑀𝑃𝑎
𝑑𝑠 = 15.277 𝑐𝑚
 Let us take the diameter of the shaft to be 170 mm

2.7. Design of key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft.

 Lets select the sunk key are provided in the key way of the shaft and half in the key way
of the chain
 Material selection
 Steel AISI 1045
 Yield strength – 505 MPa
 Ultimate stress – 585 MPa
 E = 210 GPa
 Given that ds= 170 mm
  Analysis
W=t=d/4=170/4=42.5 mm
In order to find the length of the key
 Failure due to shearing
𝑑
𝑇 =𝐿∗𝑤∗𝜏∗
2
𝜋
And for the shaft 𝑇 = ∗ 𝜏1 ∗ 𝑑 3
16
𝜋 𝑑
Since the torque is the same ∗ 𝜏1 ∗ 𝑑 3 = 𝐿 ∗ 𝑤 ∗ 𝜏 ∗
16 2

𝜋 ∗ 𝑑 2 𝜋 ∗ 1702
𝐿= =
8∗𝑤 8 ∗ 42.5
𝐿 = 267 𝑚𝑚

4𝑇 𝜋
The failure of key due to crushing 𝜎𝑐 = ,𝑇= ∗ 𝜏 ∗ 𝑑 3 Lets take FS= 2
𝐿∗𝑡∗𝑑 16
𝜎𝑦𝑡
𝜎𝑐𝑘 = = 505𝑀𝑃𝑎
𝐹. 𝑆
𝜋 ∗ 𝑑2 𝜏 𝜋 ∗ 1702 ∗ 291.385
𝐿= =
4 ∗ 𝜎𝑐 ∗ 𝑡 4 ∗ 505 ∗ 42.5
𝐿 = 308.15 𝑚𝑚
Take the maximum L= 308.15mm
Checking the shear strength of the key against the normal strength of the shaft.
Strength of the shaft with key way
𝜋 𝜋
Normal stress= ∗ 𝜏 ∗ 𝑑3 ∗ 𝑒 = ∗ 1702 ∗ 291.385 ∗ 𝑒
16 16

0.2𝑤 1.1𝑡
𝑒 =1− −
𝑑 2𝑑
𝑒 = 1 − 0.2 ∗ 0.25 − 1.1 ∗ 0.25 = 0.675
𝜋
∴ ∗ 1702 ∗ 291.385 ∗ 0.675
16
F(normal strength )=1116.088
𝐿𝑤𝜏𝑑
Shear strength of the key =
2
 291.385
= 308.15 ∗ 42.5 ∗ = 1908.043 𝑁
2
𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑘𝑒𝑦 1908.043
Then F.S = =
𝑛𝑜𝑟𝑚𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑘𝑒𝑦 1116.088

 𝐹. 𝑆 = 1.70958 the key is quite safe

2.8. Design of shaft coupling

A flange coupling usually applies to a coupling having two separate cast iron flanges. Each
flange is mounted on the shaft end and keyed to it. The faces are turned up at right angle to the
axis of the shaft.

1. Design for hub

- it is designed by considering is as a hollow shaft, transmitting the same torque as the
shaft.
 Material selection
 Cast iron
 Τ= 291.385 (𝑠ℎ𝑎𝑓𝑡, 𝑘𝑒𝑦, 𝑏𝑜𝑙𝑡)
 σc=252.5 MPa (bolt and key)
 shear stress for cast iron = 8 MPa
 Assumption
 Outer diameter of the hub is taken as 2D
 Length of the hub is taken as 1.5d
- Given p=20 Kw
D=170 mm
  Analysis
60 20∗60∗103
The torque transmitted by the shaft is 𝑇 = 𝑃 ∗ =
2𝜋𝑁 2∗𝜋∗0.796

𝑇 = 240 𝐾𝑁𝑚
The service factor =1.1 ∗ 240 𝐾𝑁𝑚 = 264 𝐾𝑁𝑚
The diameter of the shaft is calculated from the gear design, to check the torque in the shaft
𝜋 𝜋
𝑇= ∗ 𝜏 ∗ 𝑑3 = ∗ 291.385 ∗ 0.173 ∗ 106
16 16
𝑇 = 281 𝐾𝑁𝑚
The shaft is quite safe
D outer=2*d=340
Length of the hub L=1.5*d=255
By considering the cast iron hub material
𝜋 𝐷4 − 𝑑4
𝑇𝑚𝑎𝑥 = ∗𝜏∗
16 𝐷4
𝜏 = (𝑇𝑚𝑎𝑥 ∗ 160 ∗ 𝐷)/(𝜋 ∗ (𝐷4 − 𝑑 4 ))
264∗16∗340
𝜏= = 0.50042 𝑀𝑃𝑎 which is less than 8MPa ,So it is safe
𝜋(3404 −2554 )

2.8.1. Design of the key

 From table 13.6 gupta book for 170 mm diameter w=45 mm and t=25 mm
The length of the key is taken equal to the length of hub L= 255 mm
𝑑
Checking the induced stress for the key 𝑇𝑚𝑎𝑥 = 𝐿 ∗ 𝑊 ∗ 𝜏 ∗
2

2 ∗ 264 ∗ 1000
𝜏= = 0.46 𝑀𝑃𝑎
255 ∗ 45 ∗ 10−6
Since it is less from the permissible stress 291.385
𝑡 𝑑
Considering the key in crushing 𝑇𝑚𝑎𝑥 = 𝐿 ∗ ∗ 𝜎𝑐𝑘 ∗
2 2

2𝑇𝑚𝑎𝑥 2 ∗ 264 ∗ 1000

𝜎𝑐𝑘 = =
𝐿∗𝑡 255 ∗ 25 ∗ 106
𝜎𝑐𝑘 = 82.823 𝑀𝑃𝑎
The key is safe for both crushing and shearing
 2.8.2. Design of flange
The thickness of the flange is taken as 0.5d
𝑡𝑖 = 0.5𝑑 = 0.5 ∗ 170 = 85 𝑚𝑚
𝜋𝐷2
Shearing stress in the flange 𝑇𝑚𝑎𝑥 = ∗ 𝜏𝑐 ∗ 𝑡𝑖
2

𝜏𝑐 = (246 ∗ 2)/(𝜋 ∗ 85 ∗ 1702 )

𝜏𝑐 = 0.6841 𝑀𝑃𝑎
Which is less than the permissible shear stress of the cast iron material 8MPa
Design for bolt
Let d1 = nominal diameter of bolt
ds =170 mm which is between 150 to 230 mm
h=8
Picth circle of the diameter of bolt
D1 =3d=3*170=510mm
𝜋 2
𝑇𝑚𝑎𝑥 = 𝑑 ∗ 𝜏 ∗ 𝑛 ∗ 𝐷1 /2
4 1 𝑏
𝑑1 = 6 𝑚𝑚
From standard size M8
Other proportion of the flange are taken as
D2 =outer diameter of flange
D2 = 4d=4*170=680 mm
Thickness of the protective circumferential flange
tp = 0.25d=0.25*170=42.5 mm
 2.9. Design of support
Frame and support is the structural body which holds the total rotary system. Every component
like the assembly of pallet, motor drive chain, sprocket, is installed over it.

 Assumption
 L=2m
 It is hollow support

 Material selection
 Steel AISI 316
 Yield strength =205 MPa
 Ultimate strength = 515 MPa
 E=200 GPa
  Analysis
- F.S=2
A=2*30*100+2*40*30
A=8400mm2 =b2-h2
𝐼𝑥𝑥 = 𝐼𝑥𝑦 = (𝑏 4 − ℎ4 )/12 = (1004 − 404 )/12

𝐼𝑥𝑥 = 𝐼𝑥𝑦 = 812 ∗ 104 𝑚𝑚4

 Since the structure is one end fixed and one end free its effective length is Le =2*2=4m
𝑃𝐶𝑟 = (𝜋 2 ∗ 𝐸 ∗ 𝐼)𝐿2𝑐 = (𝜋 2 ∗ 200 ∗ 109 ∗ 8.12 ∗ 10−6 )/42
𝑃𝐶𝑟 = 1001.76 𝐾𝑁
𝑃𝐶𝑟 1001.76
𝑃𝑎𝑙𝑙 = = = 500.88 𝐾𝑁
𝐹. 𝑆 2
𝜎 = 𝑃𝑎𝑙𝑙 500.88 ∗ 103
=
𝐴 8.4 ∗ 10−3
𝜎 = 59.6288 𝑀𝑃𝑎
𝜎𝑢𝑡 515
𝜎𝑎𝑙𝑙 = = = 257.5 𝑀𝑃𝑎
2 2
𝜎 < 𝜎𝑎𝑙𝑙 Then the support is safe.
FEA analysis of plate by ANSYS workbench:-
The three dimensional model of frame prepared in solid edge modeling software is imported in
ANSYS workbench and load is applied at the wheel resting portion and results are obtained.
 2.10. Design of connecting bar

The connecting bar is used to connect the body structure. And it is subjected to tensile load.

Assumption
- The length of connecting rod, L=5600mm

Material selection
Steel AISI 1040
Yield strength = 353.4MPa
Ultimate strength = 519.8MPa
E = 200GPa

Analysis
As we mentioned before the bar is subjected to tensile load. So we are going to calculate the
diameter of the bar.

Take factor of safety = 3

𝑃
σ= where, σ= σy/F.S=353.4/3=117.8N/mm2
𝐴
50∗100
117.8 =
𝑡2
2
t = 540.43
t = 23.25mm say
t = 50mm.

2.10.1.Design of weld
For the connecting bar
Given
P = 50KN
e = 2000mm
t= 50mm
F.s = 3
AnalysisThe throat area for a circular fillet weld,
A =t*πd = 0.707st
= 0.707*s*50
= 111.1s
Direct shear stress, τ
τ = p/A
= 50*1000/111.1s = 450.1/s
We know the bending moment, M
M = p*e
= 50*1000*2 = 100KNm
Section modulus, Z
𝑡(𝑏+𝑙)3 )
Z=( = 1388.2s
6

Bending stress, σb
σb = M/Z
= 100*1000/1388.2s
= 72036/s
We know the maximum shear stress, τmax
τmax = ½√(σb2 + 4τ2)
180 = ½√ (72036/s) 2 + (450.1/s) 2
s = 15.8mm, say 16mm
Similarly the throat thickness will be,
t = 0.707s
t = 11.3mm

2.11. Design of bearing

Selection of bearing for triangular plate

I select sliding contact bearing for the triangular plate. And the load is along the axis of the circular
bar from solid journal bearings I select the thrust bearing which is used to guide or support the
cage which is subjected to a load along the axis of the circular bar. It has also two types. Among
them I choose foot step or pivot bearing. In this case loaded shaft is in vertical and the end of the
shaft rests with in the bearing.
 Fig20. Bearing

2.12. Design of triangular plate

 It is mounted on the guide

 Used to hold the whole frame both side of the structure and move it while the system start
working.

 Assumption
 Width and thickness of the triangular plate have following formula b=3t
 The maximum length of the triangular L=550mm2

 Material selection
 We select which is higher strength, hardest and stronger steel
 Yield strength =1365 MPa
 Ultimate strength =1669 MPa
 Analysis
Take factor of safety =3.5
The force act on each triangular plate is 34 KN
Checking for buckling
𝑃𝑐𝑟 = 𝐹 ∗ 𝐹. 𝑠 = 34 ∗ 3.5 = 119 𝐾𝑁
𝜎𝑢𝑡 1669 𝑘𝑁
The compressive stress 𝜎𝑐 = = = 476.9 𝑀𝑃𝑎
𝐹𝑆 3.5

Using Rankovess’s formula we are going to calculate the thickness triangular plate
𝜎𝑐 ∗ 𝐴
𝑃𝑐𝑟 = 2
𝐿
1+𝜏∗( )
0.068𝑡
550 2
2
119000 = (476.8 𝑀𝑃𝑎 ∗ 3𝑡 )/(1 + 7500 ( )
0.068𝑡
𝑡 = 31.44 𝑚𝑚 to be more safe we can take t=40 mm
∴ 𝑏 = 3𝑡 = 3 ∗ 40 = 120𝑚𝑚
𝑃 34000
Average stress  𝜎𝑎𝑣𝑔 = = = 7.08 𝑀𝑃𝑎
𝑏𝑡 40∗120

To calculate the bearing stress on the triangular plate

𝐴 = 𝜋𝑡𝑑 = 𝜋 ∗ 40 ∗ 50 = 𝜋2000𝑚𝑚2
34000
𝜎𝑏 = = 5.4 𝑀𝑃𝑎
𝜋 ∗ 2000
Checking for bending
𝑙
𝑀 𝑊(2+5𝑚𝑚)
We know that bending stress𝜎 = =( 𝜋 )
𝑍 ∗𝑑 3
32 1

𝑑 = 98.68 𝑚𝑚
Checking for crushing

F= Area resisting crushing × Crushing stress =𝐴 ∗ 𝜎𝑐

𝐹 34
𝐴= = = 0.48 ∗ 10−3
𝜎𝑐 70000
𝐴 = 0.48 = 𝜋𝑑𝑡
𝑡 = 106.2 𝑚𝑚
FEA analysis of plate by ANSYS workbench:-
The three dimensional model of triangular plate prepared in solid edge modeling software is
imported in ANSYS workbench and load is applied at the wheel resting portion and results are
obtained.
No table of figures entries found.

2.13. Design of the roller

Assumption
Diameter of the roller, = 80mm

Material selection
- Alloy of cast iron
- Yield strength, = 60MPa
- Factor of safety, =3

Analysis
The stress on the roller can be calculate by the following formula
F = σt*A where A=πdrt
= σt *(πdrt)
𝐹
t= σt= σy/F.S
𝜋𝑑𝑟𝑡
170000
= =60/3= 20N/mm2
𝜋∗20∗80
=29.8 say
t= 60 mm
 2.14. Design of bolt
 Used to connect the small plate and the triangular plate with the roller.
 Material selection
 Steel property class 8.8 medium carbon Q & T
 Sp =600 MPa – proof strength
 σt =830 MPa –tensile strength
 σy =660 MPa –yield strength

As = 368 mm2
 Analysis
 M30*5 bolts
 Length of the threaded part Lt =2d +6
The bolt is subjected to shear force so we are going to calculate shear stress for the bolt
𝐹 119 ∗ 103
𝜏= = = 308.29 𝑃𝑎
𝐴𝑠 386
2.15. Design of small plate
 Used to guide the load on the guide by using the roller
 Assumption
 Length, L=475
 Thickness, t=12
 Material selection
 Cast iron
 Yield strength =170 MPa
 Ultimate strength =100 MPa
 E=120 GPa
 Analysis
 The stress on the small plate
𝑃 119 ∗ 103
𝜎= =
𝐴 2𝐴
119 ∗ 103 119 ∗ 103
𝜎= =
2∗𝑡∗𝑤 2 ∗ 120 ∗ 475
 𝜎 = 1.0438 𝑀𝑃𝑎
 Calculate the bearing stress
𝐴𝑏 = 𝑡 ∗ 𝜋 ∗ 𝑑 = 12 ∗ 30 ∗ 𝜋
𝐴𝑏 = 1130.973 𝑚2
119
∗ 103
𝜎𝑏 = 2
1130.973
𝜎𝑏 = 52.609 𝑀𝑃𝑎
CHAPTER THREE
3. Drawing part
3.1. Part drawing
3.1.1. Pallet

3.1.2. Pallet hanger

3.1.3. Rectangular bar

3.1.4. Circular bar

3.1.5. Triangular plate

3.1.6. Roller

3.1.7. Roller connector plate

3.1.8. Roller connector

3.1.9. Frame (upper support)

3.1.10. Frame (lower support)

3.1.11. Chain house

3.1.12. Shaft

3.1.13. Sprocket Gear

3.1.14. Key
3.2. Assembly drawing
CHAPTER FOUR
4. DESIGN AND DEVELOPMENT
4.1. OBJECTIVES OF THE PRODUCT
 Change the traditional way of parking mechanism

 Create safe environment in more traffic areas

 Introduce new technology to the people

4.2. PRODUCT PLANNING PROCESS

4.2.1. Identify opportunities
 Increment of automobile

 Scarcity of parking place

 In case of natural disaster

 In case of security

 Safety

 Quick installation process

4.2.2. evaluate and prioritize projects

Competitive strategy
 Customer focus

The team follows customer focus strategy and work closely with new and
existing customer to assess their changing needs preferences.
Market segmentation
The market for the development automated rotary car parking system which is
subjected to work groups. Therefore, the systems of market division for this
system product are
 Commercial buildings

 Hotels

 Garages

 Automobile industries

 Government organization
  Individual organization

4.2.3. Allocate resource and plan timing

 Resource allocation

 The product will be done by team of four engineering students.

 Money/capital

The budgets allocated for this product design is one hundred thousand of
Ethiopian birr (100,000.00 birr)
 Project timing

 6 month including design and manufacturing

4.3. MISSION STATEMENT

In order to provide clear guidance for the product development organization, generally the team
formulates a more detailed definition of the target market and of the assumptions under which the
development team operate. These decisions are captured in a mission statement, a summary of
which is illustrated below
o Description of the product

This product is used to park car by stacking them in a vertical manner at some height.
From these project the customer benefits in a way that they me able to save their property
from theft as well as from naturally caused accident that may be caused by man like car
accident.
o Key business goal

 Capture 50% of product sales in primary market.

 Based on time

The product as seen on the basis of time could be said its time efficient. Because, first
of all it takes time to build the structure and during work in between the entrance and
exit at simultaneous cars, the time interval is fair.
 Based on cost

It’s less costly in building the structure but its costy to manufacture the product and
also needs little space to plant the structure. And also the price paid for parking by
individual is small.
 Based on quality

o Target market for the product

  primary market

 Commercial buildings

 Hotels

 Garages

 Secondary market

 automotive industries

 government organization

 private organization

o Assumptions

 All parts of the product will be manufactured using the available machines in
our country.

 Standard parts are from the market.

 Compatible with all buildings which can provide small area.

o Stake holders

 Users

 Manufacturing operation

 Service operation

 Marketing groups

4.4. IDENTIFYING CUSTOMER NEEDS

The product of identifying customer needs is an integral part of product development process
and is related to concept generation, concept selection, bench marking and establishing target
specifications. The customer need were identified based on the following steps
I. Gather raw data from customers(VOC)

II. Interpret raw data in terms of customer needs

III. Organize needs into hierarchy

IV. Establishing relative importance of needs

V. Reflect on the results and the process

 4.5. PRODUCT SPECIFICATION
General
For producing sustainable products, effective communication between all parties is necessary
and human needs have to be taken into consideration. A structured process is required to match
human needs with the product specifications. One of the key objectives is to ensure that the needs
of the customer are incorporated into the design.
4.5.1. Establish Relative Importance of Needs
Relative importance is a value that is subjectively allocated to customer needs from scale 1-5
points. It is selected a range from 1-5 to rank the customer needs where 5 indicating the most
important need and 1 indicating the least importance need. The relative importance of needs shown
in table
No. Product design Need Imp.
1 Automated rotary car parking system Easy to operate 4
2 Automated rotary car parking system Least trouble 4
3 Automated rotary car parking system Least noise and vibration 3
4 Automated rotary car parking system Cheap running cost 2
5 Automated rotary car parking system Space preservation 4
6 Automated rotary car parking system Environment friendly 3
7 Automated rotary car parking system Security 5
8 Automated rotary car parking system Safety 5
9 Automated rotary car parking system Quick installation process 2
10 Automated rotary car parking system Works for a long period of time 5
11 Automated rotary car parking system Comfortable for cars 4
12 Automated rotary car parking system Portable 5
13 Automated rotary car parking system Suitable for drivers 4
14 Automated rotary car parking system Helps to save time 5
15 Automated rotary car parking system Easily maintained 3
16 Automated rotary car parking system Easily assembled 2
Table 1: relative importance of needs

4.5.2. ESTABLISHING TARGET SPECIFICATIONS

The team members were considered the following steps/process to establish the target specifications.
1. Prepared the lists of metrics

2. Collect competitive benchmarking information

3. Set ideal and marginally acceptable target values

4. Reflect on the results and the process

5. Preparing list of metrics

A list of metrics for each of the customer needs to establish the relationship between the requirements of
the design and the production characteristic. These metrics are generally referred to the preliminary
specifications which are established after identifying customer needs and before concept generation.

Metric Need Metric Imp. Units

No. Nos.
1 14 Configuration time 5 S
2 9,16 Assembly time 4 S
3 12 Light weight 2 KG
4 10 Life time 5 year
5 8,2 Safety 5 Subjective
6 1,6,3 Human interface 4 Subjective
7 15,16 Time to assemble/disassemble for 3 S
maintenance
8 4 Unit manufacturing cost 2 Eth. birr
9 13,5 Viability and suitability
Table 2: list of metric

Time to assemble and disassemble

Unit manufacturing cost

Viability and suitability

Metrics
Configuration time

for manufacturing
Human interface
Assembly time

Light weight

Life time

safety

Needs
1 Easy to operate *
2 Least trouble *
3 Least noise and vibration *
4 Cheap running cost *
5 Space preservation *
6 Environment friendly *
7 Security
8 Safety *
9 Quick installation process *
 10 Works for a long period of time * *
11 Comfortable for cars *
12 Portable *
13 Suitable for drivers *
14 Helps to save time *
15 Easily maintained *
16 Easily assembled * *

Table 3: the needs-metrics matrix

6. Collect competitive benchmarking information

The relationship of the new product to competitive products is to paramount in determining commercial
success. While the team will have entered the product development with some idea of how it wishes to
compete in the market place, the target specifications are the language the team uses discuss and agree on
the detailed positioning of its product relative to existing
Products, both its own and competitors’, Information on competing products must be gathered to support
these positioning decisions.
7. Set ideal and marginally acceptable target values

In this step, the team synthesizes the available information in order to actually set the target values for
the metrics. Two types of target value are useful: an ideal value and a marginally acceptable value. The
ideal value is the best result the team could hope for. The marginally acceptable value is the value of the
metric that would just barely make the product commercially viable. Both of these targets are useful in
guiding the subsequent stages of concept generation and concept selection, and for refining the
specifications after the product concept has been selected.

7.1. CONCEPT GENERATION

A product concept is a general description of the technology and form of the product.it is concise
description of how the product will satisfy the customer needs. A concept is usually expressed as a sketch
or as a rough three dimensional model and is often accompanied by a brief textual description. The concept
generation process begins with a set of customer needs and target specifications and results in a set of
product concepts from which the team will make a final selection. The structured approach to concept
generation consists of the following steps,

Step 1: Clarifying the problem

Clarifying the problem consists of developing a general understanding and then breaking the problem down
into subproblems if necessary. As a first step to concept generation for development of automated rotary
car parking system the first task was to clarify the problem by any suitable decomposition. The design of
a complex product like an automated rotary car parking system can be thought of as a collection of more
focused design problems.
Step 2: Search externally
Searching externally is aimed at finding existing solutions to both in overall problem and the sub
problems identified during the problem clarification step.

Figure
a& b:

externally search products

Step 3: search internally

The search is internal in that all of the ideas to emerge from this step are created from knowledge
already in the possession of the team. This activity may be the most open ended and creative of any in
new product development.
Figure 1: concept A

Figure 2: concept B

Figure 3: concept C

Figure 4: Concept
Four guidelines are useful for improving both individual and group internal search

1. Suspend judgment

2. Generate a lot of ideas

3. Welcome ideas that may seem infeasible

4. Use graphical and physical media

Step 4: Explore systematically

This system aims to integrate the results of the external and internal search activities that the team
collected many concept fragments-solutions to the sub problems. Systematic exploration is aimed to
navigating the space of possibilities by organizing and synthesizing these solution fragments. There are
specific tools for managing the complexity and organizing the thinking of the team but the team decides to
use only concept classification tree. The classification tree helps the team divide the possible solutions into
independent categories.

2.5.6 Concept Classification Tree

The concept classification tree is used to divide the entire space of possible solutions into several distinct
classes which will facilitate comparison and pruning. So the following classification shown us the refined
of the problem decomposition for a particular branch as follows.

Vertical

Motion Rotary

Translational

Automatic Electrical
Operation Source

Pneumatic
Manual

Hydraulic
 7.2. CONCEPT SELECTION
Concept selection is the process of evaluating concepts with respect to customer needs and other
criteria, comparing the relative strengths and weaknesses of the concepts and selecting one or more
concepts for further investigation, testing, or development. Concept selection is the process of narrowing
the set of concept alternatives under consideration. Although, concept selection is a convergent process, it
is frequently iterative and may not produce a dominant concept immediately. There for we are going to
use the following techniques,
 Concept screening

 Concept scoring

The generic steps involved in both screening and concept scoring:-

 Prepare the selection matrix

 Rate the concepts

 Rank the concepts

 Combine and improve the concepts

 Select one or more concepts

 Reflect on the results and the process

2.7.1, CONCEPT SCREENING

Concept screening is based on a method developed by the late Stuart Pugh in the 1980s and is often called
Pugh concept selection. The purposes of this stage are to narrow the number of concepts quickly and to
improve the concepts.
The concept screening process matrix for the product design of projector mount the team rated the
concepts against the reference concept using a simple code (+ for” better than”,0 for “same as”,- for “worse
than”) in order to identify some concepts for further consideration.
Concept screening matrix
Concepts
A. Conveyor type

B. Wall mounted type

C. Scissor jack type

D. Rotary type (reference)

 Concepts
Selection criteria A B C D
Ease of manufacturing - - + 0
Low product cost - - + 0
Portability 0 - 0 0
Reliability + 0 0 0
Ease to use 0 0 + 0
Maintainability + - + 0
Space preservation - - 0 0
Security 0 + - 0
Environment friendly 0 0 0 0
Sum +’s 2 1 4 0
Sum 0’s 4 3 4 9
Sum –‘s 3 5 1 0
Net score -1 -4 3 0
Rank 3 4 1 2
Continue? No No Yes Yes
Table 4: concept screening matrix
As a result two concepts are passed out of four concepts for the next selection technique as showing in
concept scoring matrix below.
2.7.2 CONCEPT SCORING
Concept scoring is used when increased resolution will better differentiate among competing concepts. In
this stage, the team ways the relative importance of the selection criteria and focuses on more refined
comparisons with respect to each criterion. The concept scores are determined by the weighted some of
the ratings. In describing the concept scoring process, we focus on the differences relative to concept
screening.
After the concept screening next task was assigning weights to each selection criteria in the scoring
matrix. Several different schemes can be used to weight the criteria such as assigning the importance
value from 1 – 5 or allocating 100% point net. For the purpose of concept selection for car parking
system, the weights were determined subjectively by the team members. Rating of all the concepts for the
car parking system with respect to the selection criteria was done on a scale of 1 – 5 with the following
definitions for each scale.
2.7.3 Concept rating

Relative performance Rating

Much worse than reference 1

Table 5: concept
Worse than reference 2 rating
Among the internally
Same as reference 3 developed concepts:
the top two concepts
Better than reference 4
are selected to score
by the scoring matrix
Much better than reference 5
method

Concept
C D
Selection criteria Weight Rating Weighted Rating Weighted
score score
Ease of manufacturing 15% 3 0.45 2 0.3
Low product cost 10% 3 0.3 2 0.2
Portability 10% 2 0.2 4 0.4
Reliability 15% 2 0.3 5 0.75
Ease of use 10% 3 0.3 3 0.3
Maintainability 10% 3 0.3 3 0.3
Space preservation 15% 2 0.3 5 0.75
Security 10% 2 0.2 4 0.4
Environment friendly 5% 3 0.15 3 0.15
Total score 2.5 3.55
Rank 2 1
Continue? No Develop
Table 6: concept scoring

From the PDD we can design the concept D

CHAPTER FIVE
5. MANUFACTURING AND COST ANALSIS
a. Cost analysis
For painting
Anti-rust 2 kg * 50 birr =100 birr
Labor cost
2 skilled person * 3000 birr =6000birr
Machining 1500 birr
Drilling 500 birr
Bending machine 1000 birr
Power hacksaw 1000 birr
Grinder 600 birr
Welding machine 800 birr
Lath machine 900 birr

Material Cost (birr)

Frame 5000
Motor 20000
Circular bar 3500
Gear box 80
Roller 1950
Pallet 1000
Connecting bars 3000
Bearing 520
Shaft 2000
Key 5000
 b. Manufacturing process
The following are the various manufacturing processes used in Mechanical Engineering.
1. Primary shaping processes. The processes used for the preliminary shaping of the machine
component are known as primary shaping processes. The common operations used for this
process are casting, forging, extruding, rolling, drawing, bending, shearing, spinning, powder
metal forming, squeezing, etc.
2. Machining processes. The processes used for giving final shape to the machine component,
according to planned dimensions are known as machining processes. The common operations
used for this process are turning, planning, shaping, drilling, boring, reaming, sawing, broaching,
milling, grinding, hobbling, etc.
3. Surface finishing processes. The processes used to provide a good surface finish for the
machine component are known as surface finishing processes. The common operations used for
this process are polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling,
electroplating, superfinishing, sherardizing, etc.
4. Joining processes. The processes used for joining machine components are known as joining
processes. The common operations used for this process are welding, riveting, soldering,
brazing, screw fastening, pressing, sintering, etc.
5. Processes effecting change in properties. These processes are used to impart certain specific
properties to the machine components so as to make them suitable for particular operations or
uses. Such processes are heat treatment, hot-working, cold-working and shot peening.
For our Design we used the following manufacturing processes.
Parts Required process
Pallet Hot rolling, sheet metal forming
Shaft by hot rolling and finished to size by cold drawing or turning
and grinding.
Key cutting and milling operations
-Bolts and nuts Turning, milling .thread cutting (lathe), or
Internal threads can be cut with dies.
Frames shearing or cutting to size, bending, welding
And grinding.
Gear casting and finishing process
Bearing S
Connecting bar welding
CHAPTER SIX
6. Assembly and disassembly of Automated rotary car parking system
Cage Assembly
1. Pallet is connected to four vertical pallet hangers
2. Pallet hanger is attached to two rectangular bar which are aligned horizontally.
3. The two rectangular bar is then attached to circular bar allowing free rotation at the end
with bearing. This bearing allows free rotation of the cage during cage rotation.
Frame and cage assembly
4. The upper and the lower support frame are attached in two positions at the corner of each
four legs
5. The chain house is welded to the frame.
6. Rollers are installed to the chain house
7. Rollers are connected to each other with connecting plate.
8. The triangular plate is attached to the chain using bolts.
9. Sprockets (the bigger gear which drives the chain) is meshed with chains in the chain
house.
10. The shaft from the motor which is connected by bevel gear is attached to the sprocket
using key.
11. Finally, the cage is connected to the triangular plate with bushing.
12. The reverse procedure will be the disassembly of the rotary car parking system
CONCLUSION
The major enablers or drivers for smart parking essentially are the problems of urban liability,
transportation mobility and environment sustainability. Some of the underlying benefits could
be lowering operating costs, while building value for customer to drive occupancy, revenues
and facility value. To solve this all issues we designed and analyzed Rotary Automated Car
Parking System. The Rotary Automated Car Parking System has been designed considering
the actual size, dimensions and weight of car up till sedan class. The scaled model has been
prepared and all the composite parts in it have been manufactured and assembled. Analysis
of important parts like pallet, joint, hanging rod and frame has been done at actual dimensions.
Finally, in the long run, the rotary automated car parking system can actually transform the
very makeup of our urban landscapes, making them more amenable to people rather than cars.
FUTURE SCOPE
This automated car parking system can be installed with safety installations such as,
whenever there is human movement in the system, the rotation of the platforms should be
immediately stopped and also the platforms can also be equipped with safety sensors guiding
the movement of vehicles in the platforms. It can be fully automated by integrating it with
a panel board, such that whenever a particular number is called on the panel board, the
respective platform should appear at the ground level. This calling can also be made more
secured by providing each platform a specific password, so that only whenever a particular
password is typed the platform is retrieved. A turntable can be incorporated with the system
in front of the ramp of platform so that cars can be easily turned and parked into the
platform. This is very useful in the areas where cars cannot turn easily to get into the platform.
REFERENCES
Text References
1) A Textbook of Machine Design by R.S. KHURMI AND J.K. GUPTA

2) Mechanical Engineering Design – Shigley

3) Mechanics of Materials Beer & Johnston

4) S S RATTAN, Theory of Machines, 4th Edition, McGraw Hill Education

5) R. K. Jain, Production Technology, 17th Edition, Khanna Publications Private Limited

6) V B Bhandari, Design of Machine Element, McGraw Hill Education

7) R. K. Rajput, Strength of Materials, S. Chand