DEFENCE FORCES TECHNICAL COLLEGE

ARTISAN IN AERONAUTICAL ENGINEERING

(AIRFRAMES AND ENGINES OPTION)

PROJECT TITLE:DESIGN AND FABRICATION OF WHEELED SWEEPER
PROJECT NUMBER:

PRESENTED BY: DONATO KAPSOWE KIPLAGAT.

COLLEGE NO: 408101

SERVICE NO:

PRESENTED TO: THE KENYA NATIONAL EXAMINATION COUNCIL FOR

PARTIAL FULFILMENT OF AWARD IN DIPLOMA IN

AERONAUTICAL ENGINEERING

[AIRFRAMES AND ENGINES OPTION]

SUPERVISOR: Mr. NJERU

SERIES: JUNE /JULY 2022

i
DECLARATION

I declare that this project report is my original research work and to the best of my knowledge. It

has not been submitted anywhere for the award of diploma in equivalent course.

Signature…………………………………………………………..

Date …………………………………………………………………..

This project has been submitted to KENYA NATIONAL EXAMINATION COUNCIL with my

approval as the project supervisor.

Signature ………………………………………………………..

Date ………………………………………………………………………

ii
DEDICATION

This project is dedicated to Almighty God for his protection, kindness, strength over my life

throughout the period and to my friends for their support and moral care towards me. Also to my

mentor Mr.Njeru for her academic advice, she often gives to me. May Almighty God shield them

from the peril of this world and bless their entire endeavor Amen.

iii
ACKNOWLEDGEMENT

I express my deep sense of gratitude and indebtedness to my thesis supervisor Mr. Njeru, Trainer of

Mechanical Engineering for providing precious guidance, inspiring discussions and constant

supervision throughout the course of this work. His timely help, constructive criticism, and

conscientious efforts made it possible to present the work contained in this thesis.

I express my sincere thanks to Mr. John student for their support during the project work. I am also

thankful to all the staff members of the department of AIRFRAMES AND ENGINES OPTION and

to all my well-wishers for their inspiration and help. I am also thankful to my classmates for their

help during my project work.

I feel pleased and privileged to fulfil my parent’s ambition and I am greatly indebted to them for

bearing the inconvenience during my course .

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Table of Contents
DECLARATION.......................................................................................................................................ii
DEDICATION..........................................................................................................................................iii
ACKNOWLEDGEMENT........................................................................................................................iv
Abstract...................................................................................................................................................viii
CHAPTER ONE........................................................................................................................................1
1.0 INTRODUCTION...............................................................................................................................1
1.1 BACKGROUND INFORMATION................................................................................................1
1.2 Objectives.........................................................................................................................................2
1.3 Project hypothesis............................................................................................................................3
1.4 Problem statement...........................................................................................................................3
1.5 Future Scope....................................................................................................................................4
an energy generative vehicle....................................................................................................................4
1.6 Methods of data collection..............................................................................................................4
1.6.1 Questionnaires..........................................................................................................................4
1.6.2 Secondary sources.....................................................................................................................4
1.6.3 Measurement.............................................................................................................................4
1.7 Significance of the study..............................................................................................................4
BILL OF MATERIALS............................................................................................................................5
Block diagram............................................................................................................................................6

v
.................................................................................................................................................................... 6
CHAPTER TWO.......................................................................................................................................8
2.0 LITERATURE REVIEW...................................................................................................................8
For the ease of human beings different designs of brushes are evolved. Again during the age of monarchs
carpets of different designs are utilized to cover the floor to keep it clean. As the time passed new
scientific era begins a lot of new methods are used to clean the floor. The first among those was the
reciprocating action of brush actuated by muscular force. The brush design is changed time to time
depending upon the floor structure and ease of washing personnel. As the electricity came into role
vacuum cleaner are invented to clean a dry surface. Moving forward different floor cleaning machines are
being invented to clean the floor with less application of muscular power. Then came the concept of
mobile robot..Mobile robots have the capability to move around in their environment and are not fixed to
one physical location. By contrast, industrial robots are usually more-or-less stationary, consisting of a
jointed arm (multi-linked manipulator) and gripper assembly (or end effector), attached to a fixed surface.
.................................................................................................................................................................... 8
2.1 BACKGROUND................................................................................................................................10
2.2 EXISTING METHODS....................................................................................................................11

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2.2.1 Pneumatic press machine...............................................................................................................11
2.2.5 Manually operated hydraulic press...............................................................................................11
2.3 Operating principles of the wheeled sweeper machine...................................................................11
CHAPTER THREE.................................................................................................................................17
3.0 METHODOLOGY........................................................................................................................17
3.1 Introduction...............................................................................................................................17
3.1.1 What Is a Hydraulic Press.....................................................................................................17
3.1.2 How Do Presses Work?..........................................................................................................18
3.1.3 What Types of Presses Are There?........................................................................................19
i. H-Frame........................................................................................................................................19
ii. Roll Frame...................................................................................................................................19
iii. Bench Frame........................................................................................................................19
iv. Arbor Press/C-Frame..........................................................................................................20
3.2 Material Selection......................................................................................................................20
3.3 Interpretation of Block diagram...............................................................................................21
3.3.2 Safety Door:.............................................................................................................................22
3.3.3 Limit switch:...........................................................................................................................22
3.3.4 Manual control Valve:............................................................................................................22
3.3.5 Relief valve:.............................................................................................................................22
3.3.6 Pressure gauge:.......................................................................................................................23
3.3.7 Hydraulic cylinder:.................................................................................................................23
3.3.8 Oil tank:...................................................................................................................................23
3.3.9 Pressing Plate:.........................................................................................................................23
3.3.10 Bailing Compartment:..........................................................................................................23
3.3.4 Calculation of force.................................................................................................................23
3.4.1 Design analysis of some machine components:.....................................................................24
3.4.2 Machine frame........................................................................................................................24
3.4.3 Determination of volume of hydraulic tank..........................................................................24
3.4.4 Design of Bolts.........................................................................................................................24
3.4.5 Determination of weight of the piston of the Hydraulic press.............................................26
3.4.6 Determination of the weight of the press cylinder................................................................26
3.4.7 Determination of oil flow rate................................................................................................27
3.5.0 Machine fabrication process..................................................................................................27
3.6.0 Design parameters..................................................................................................................30

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 3.6.1 Design of hydraulic jack.........................................................................................................30
3.6.2 Design calculation...................................................................................................................30
3.6.3 Motor specification.........................................................................................................................31
3.6.4 spring specification.................................................................................................................32
3.6.5 Motor specification.................................................................................................................33
CHAPTER FOUR...........................................................................................................................35
4.1 Data analysis..............................................................................................................................35
4.1.2 The hydraulic press machine.................................................................................................35
4.2.0 Related Reports. 4.2.1 Hydraulic Cylinder Market.............................................................35
4.3 Project findings..........................................................................................................................36
4.3.1. 3D surface plot.......................................................................................................................38
4.4 Recommendations......................................................................................................................40
4.5 Conclusion..................................................................................................................................40
4.6 Bills of Quantity.................................................................................................................................41
Reference..................................................................................................................................................42

viii
 Abstract

Automatic floor cleaner is a system that enables cleaning of the floor by the help of highly stabilized

and rapidly functionalized electronic and mechanical control system. Current project work targets to

use automatic floor cleaner for large floor in household purposes and office floors. The cleaning

purpose is specifically carried out by continuous relative motion between a scrubber and the floor

surface. During the cleaning and moving operation of vehicle propulsion mechanism such as driven

wheels and guide wheels for the dry tracking on the floor surface to be cleaned, suction of water is

carried out by vacuum pump; the scrubber directing water towards rear end does scrubbing action.

Preferably, a sweeper mechanism is mounted on the body forwarded by propulsion mechanism and

operated with such control system for advance sweeping of a debris-laden floor surface. A PID

controller is used to govern the motion of system, which takes the input from sensor circuit and feeds

it back to microcontroller, which gives rise to the simulation of wheel in a synchronized manner. The

new automatic floor cleaner will save huge cost of labor in future. The basic advantage of this

product is that it will be cost effective and no human control is needed. Once put in on mode it will

clean the whole room without any omission of surface.

ix
 CHAPTER ONE

1.0 INTRODUCTION

Sweepers are most everywhere forms of cleaners in the world Prefer to use trains or buses for

commuting and hence these places are littered with biscuits covers, cold drink bottles etc. Hence,

it is necessary to clean the bus stands, street, road and railways stations at regular interval. Our

sweeper is suitable for all locations, occasions, effective cleaning depends upon the type of

cleaning device, technique, and the equipment should be user friendly. Cleaning work can be

physically demanding and a need has been identified to developed methods for Systematic

efficiency evaluation of new products. Hence, the present work is aimed to design, development

and evaluation of a pedal operated sweeping machine and this should reduce labour and time. An

effort has been made to develop a mechanically operated sweeping machine so that it can be an

alternative for small space cleaning. On other hand in rural area the road cleaning is done by an

manual operated which renders fatigue hazards like asthma, bronchitis etc. to the worker. [1]. In

this work, achieve the aim of road, cleaning and cleaning below the vehicles that are parked

roadside such as cars and trucks. We are doing some modifications in the present sweeping

machine.

1.1 BACKGROUND INFORMATION

Present work is aimed at working of an automated motion controlled machine that could clean

the floor of normal Indian house-hold. Once the machine is put in ON mode it will move all over

the surface without omitting any bit of floor space. Again the machine should avoid the obstacles

on its path. Proper cleaning is achieved by motion of the scrubber which is relatively rotational

in manner. The cleaning process is carried out by making the floor wet and scrubbing it and

1
again making the floor dry. The floor should be dry after the process is complete because wet

floor leads to different sort of problems as discussed above. For this purpose vacuum pumps are

to be used. The cleaning also meet challenges like which type of debris it will meet. So dry

cleaning arrangements are installed. This leads to proper cleaning when heavier particles are

there as debris particle. Thus leading to proper cleaning of the surface. There may be oily

surfaces in some cases. To counter act this situation necessary disinfectants are to be used. 4

wheel drive mechanism should be used for proper control of the machine. To control all the

motors and vacuum pumps basically micro controller of Aurdino type is used. For completing

the motion all over the surface spiral mechanism and particle swarm optimization method is

being utilized. Image sensing technique for avoiding obstacles are to be used. Optimization

methods are used for increasing efficiency of movement algorithm. It ensures no repeatability of

the motion over a certain space. Basically we are to design a portable machine that could move

automatically all over the floor surface avoiding obstacles and cleaning the floor.

1.2 Objectives

 To design and develop road cleaning machine capable of cleaning road as well as

 around space.

 To make machine operate manually so that it does not require any power supply.

 To make the machine economical.

 To design, fabricate and test wheeled sweeper motor as the mechanism.

 To reduce the cost of purchasing wheeled sweeper machine in that the materials are

locally available and are relatively cheap.

 To increase the speed of the work in the workshop or street done by the sweeper machine

and also reduce the human effort that would have otherwise been used when doing

manually.

2
1.3 Project hypothesis

1.4 Problem statement

The present work is aimed at designing a compact floor cleaner that can be useful for house-hold

purpose. The complete process of the machine starts from the front vacuum pump. It is used to

suck dry debris from the floor. This is very much useful for the purpose of pre-cleaning the

surfaces having heavier dirt particles. The debris thus sucked has to be stored so that it could be

removed later. This is achieved by using a 12v vacuum pump with a debris chamber attached to

it. The next aim is to make the surface wet which is carried out by sprinkling water on the floor.

The aim is achieved by using a motor and a sprinkler system. This system has a shower like

outlet and a chamber whose outlet is controlled by a dc motor pump. To clean the surface

scrubber has to move or scrub over the floor. The dirt should be completely removed and the

debris laden water will flow towards the rear of the bot. the scrubber is fixed to the chassis using

clamps. The construction of the scrubber includes fixing one side to the motor and the other to

the ball bearing. The bearing is clamped to the chassis. At the rear of the system a vacuum

mechanism is used to suck the debris laden dirty water. This is also the same type of pump and

the chamber. Hence the total system can be sub-divided into different parts, such as:

1. Chassis
2. Vacuum pumps
3. Sprinkler system
4. Scrubber
5. Motor driver
6. Wheels
7. Control system

3
1.5 Future Scope

In future dust particle are clean. In future speed for cleaning can be increase. Common

person can buy this product for earning their lively hood. This of machine will be used in

railways and bus stand. Common person can buy this easily. Cleaning will be lot easier. Used

an energy generative vehicle.

1.6 Methods of data collection

1.6.1 Questionnaires

A good number of questionnaires were dispatched to workshops in the Kenya Navy

Dockyard and other workshops such as African Marine and General Engineering

Company limited (AMGECO) and Southern Engineering Company (SECO). For

determination of useful data on how the wheeled sweeper.

1.6.2 Secondary sources

A number of textbooks, manuals and the internet enabled the designer to obtain useful

information for the design of wheeled sweeper machine.

1.6.3 Measurement

The design was involved in a lot of measurement work during the designing of a wheeled

sweeper machine and specifying its components, also measured the distance of the ram

and the speed of the motor in which it will drive the driven wheel.

1.7 Significance of the study

 A street sweeper cleans the streets, usually in urban areas.

 Street sweepers have been employed in cities since sanitation and waste removal

become a priority.

 Used as an energy generative vehicle.

 Suitable for dust removal of large areas of dry grounds and wood floors.

4
BILL OF MATERIALS

Serial Item Description Quantity Unit price Amount

number

01 Vacuum Rotatory vane 1 15000 2500

pumps pump

02 Driver and Aluminum alloy or 1 1500 1500

driven gear carbon fiber

03 Belt Plain carbon or 1 1000 1000

alloy steel

04 Electric 0.5 Horse power 1 9000 2500

motor

05 Springs 1.7x0.25 2 500 1000

06 Flat bar 5Mx2inches thick 1 1000 1000

07 Pedal 9x20outside 1 2000 1500

crankshaft diameter 14.2mm

inside diameter

13mm

08 Bolts 8.8 gauge 10 20 200

3x1

09 Nuts 3\8 10 10 100

10 Wheels 200mmx50mmx3m 5 1000 3500

5
 11 Sprinkler Impact sprinkler 1 1000 1000

system heavy duty

12 Chassis Tubular chassis 1 3000 3000

13 Scrubber Steel scrubber 1 400 400

TOTAL Ksh

14,800/=

Block diagram.

6
7
 CHAPTER TWO

2.0 LITERATURE REVIEW

Traditionally floor is cleaned by hand using different handmade instruments. Initially it was

being washed by different reed brushes. According to Egyptian houses were built of sun-dried

mud bricks at times white-washed and the floors were stamped earth. The floor of the outdoor

kitchen too was simply the ground baked stone hard by the sun. Unless it was raining, which

happened only rarely, these floors were easy to keep clean by sweeping. Like most ancient

Egyptian tools, these brushes did not have long handles which would have rendered their use less

irksome, and required bending low when employing them.

For the ease of human beings different designs of brushes are evolved. Again during the age of

monarchs carpets of different designs are utilized to cover the floor to keep it clean. As the time

passed new scientific era begins a lot of new methods are used to clean the floor. The first among

those was the reciprocating action of brush actuated by muscular force. The brush design is

changed time to time depending upon the floor structure and ease of washing personnel. As the

electricity came into role vacuum cleaner are invented to clean a dry surface. Moving forward

different floor cleaning machines are being invented to clean the floor with less application of

muscular power. Then came the concept of mobile robot..Mobile robots have the capability to

move around in their environment and are not fixed to one physical location. By contrast,

industrial robots are usually more-or-less stationary, consisting of a jointed arm (multi-linked

manipulator) and gripper assembly (or end effector), attached to a fixed surface.

For the help of mankind the first floor cleaner was manufactured during 1980s. In those

equipment the aim was to wash the floor with less power utilization. There sweeping mechanism

of mop is actuated by a timing motor which was controlled by the dc circuit. Here water is

8
sprinkled on the mop and hence the wet mop is used to clean the debris from the floor. But the

problem here was it can’t use any chemical solvent or disinfectant. Again for soaking purpose

only hot air is used. Again for moving the machine a worker has to be engaged. To overcome

these conflicts current study was done to enable the cleaner move automatically throughout any

kind of room. The moping mechanism is also modified to lessen the cost. In current study the

mop is continuously revolving about a axis perpendicular to the motion of the cleaner which also

helps in directing water on the floor backward. Instead of using a wet mop a sprinkle mechanism

is used to make the floor wet which is scrubbed by the mop. A vacuum cleaner was used to soak

dirty water from the floor surface and side by side cleaning the surface. For automatic motion of

the cleaner mobile robotics is used.

Mobile robots are a major focus of current research and almost every major university has one or

more labs that focus on mobile robot research. Mobile robots are also found in industrial,

military and security settings. Domestic robots are consumer products, including entertainment

robots and those that perform certain household tasks such as vacuuming or gardening. From

then on more sophisticated robot is designed for household equipment for automating the tasks

including washing machine, micro woven. After that only the revolution of mobile robotics came

to household usages.

The problem with current automatic floor cleaning machines are they are only used in

households for only dry and wet cleaning but not as infection remover. So it is only used in

households and not in hospitals or small areas in public. The automatic floor mops like hydrobot

are bulky and they also require large power and are used for commercial purpose. But we think

this (Our cleaner) will solve all in one go… We will basically focus on a smart and smaller and

good designed robot which can be used in many sectors like healthcare and educational areas

(which are of course small areas) and also for household use. So it will be both for terminal

9
cleaning like medicals and indoor floor cleaning.in future we will focus on indoor air cleaning

service as an additional feature to this machine.

2.1 BACKGROUND

A Hydraulic machine is a machine that uses hydraulic fluid to generate a compressive force. The

top and bottom segment has to resist the force generated while pressing operation and it is

significant to calculate the mechanical properties like total deformation and stress developed on

the machine. The machine is designed and fabricated for this special purpose of loading only the

load capacity of 10tonnes. In this 10Ton motorized hydraulic press machine the observation was

that the deformation is high and the optimization of cylinder and tie rod are analyzed by using

analysis system (ANSYS).

The objective of this project is to reduce the weight and cost of the pressing machine in the

quality of output in the component of the machine. The size and shape of the machine is such

that it not only provides safe operation but also the working stress and deformation do not exceed

specific limit. It depends upon Pascal’s principle that is; the pressure throughout an enclosed

system is constant.

There exists several types of hydraulic press machines which are used in the workshops. Some of

the existing press machines are expensive or ineffective.

10
2.2 EXISTING METHODS

2.2.1 Pneumatic press machine.

2.2.5 Manually operated hydraulic press.

A manual hydraulic press comprise of a frame, cylinder and piston, two threaded studs,

hydraulic pump and hose, workpiece support. A manual hydraulic press contains two

cylinders which are connected to one another. Each cylinder contains hydraulic fluid and

one is larger than the other. The larger cylinder is known as the ram and the small one is

known as the plunger. The pressure between the plunger and the ram then works to crush

the item placed between them.

2.3 Operating principles of the wheeled sweeper machine.

The purpose of this machine is to be used in cutting, shaping, blending and pressing any metal

sheet into required shape. This is a multipurpose machine used to shape the metal sheet to be

used for getting the desired shape of the parts to be used in mechanical, electric and electronic

appliances and also in automobile industry.

Earlier, the task of giving shape to the metal sheet was done manually with great effort and force.

The motorized hydraulic has revolutionized this process by adding force and accuracy in the

operation of pressing.

The motorized press machine works on the principle of reforming the metal sheet by applying

required force. The major parts are;

11
 Hydraulic Jack

 Motor

 Connecting bar

 Cam

 Ram

 Return springs

 Release valve

 Column

 Bed

 Gears (driver and driven)

1. Hydraulic jack

Hydraulic jack is a device that is used to press and is controlled with hydraulic control.

Hydraulic jack working is based on Pascal’s principle. That is, the pressure applied to a

fluid stored in a container will be distributed equally in all directions.

www.google.com

2. ELECTRIC MOTOR

12
 The electric motor will aid in the jacking process in that the pumping piston will be

connected to the motor and as it rotates, the rotation will be converted to reciprocating

motion by the cam in the driven gear.

www.google.com

3. BELT

The belt connects the driver wheel and the driven gear to help in transmission of motion

from the motor.

www.google.com

13
4. CAM

The cam is connected to the driven gear where it aid in converting rotary motion to

reciprocating motion that drives the piston whereby after jacking causes the motion of the

ram that in turn causes the pressing.

14
5. RETURN SPRINGS

The return spring helps to return the ram in position after the pressing activity. The

springs are connected to the column and is used to restrain the ram back into position.

15
 www.google.com

6. BED

The bed is used to hold the workpiece. It is made of steel because it is incredibly sturdy

and can handle high compression loads.

www.google.com

7. Connecting bar

The connecting bar links the pumping piston to the driven wheel through the cam.it also

transmit the reciprocating motion of the driven wheel to the pumping piston that results to

the motion of the ram from the jack.

16
 CHAPTER THREE

3.0 METHODOLOGY

3.1 Introduction

Across a wide range of industries, hydraulic presses play a key role in fabrication, assembly and

maintenance, helping operators fit, bend and assemble sheet metal, parts, bearings and

equipment.

3.1.1 What Is a Hydraulic Press

A hydraulic press is a device used to press out materials, aiding facilities in fabrication, assembly

and maintenance. It employs pressure generated by a pump to push a steel cylinder into a

material at a set force.

The main parts of a press include:

 A frame that holds the press together and gives it strength, with different frame shapes

used for various pressing applications

 A table or bolster, which supports the material as it is pressed and can often be

repositioned to properly line up materials with the press

 A hydraulic steel cylinder or ram, which is extended to apply force to compress parts or

separate them.

 A pump that uses hydraulic fluid to create pressure that drives the cylinder to create a

specific force output.

Presses are used in a variety of facilities and applications where materials need to be pressed

together or separated. Presses are typically used to press two things together or press two things

17
apart, such as bearings, other shaft fitted metal parts or to bend or straighten materials. Certain

smaller presses, such as C-frame presses, can also be used to hold materials together during

assembly or to disassemble parts for maintenance.

3.1.2 How Do Presses Work?

While there are many different types of presses, each hydraulic press works in essentially the

same way. Presses are powered by a hydraulic pump, which can be manual, pneumatic or electric

depending on the application and press size. Pumps create a fixed pressure that determines the

force of the press, rated in tons. Once engaged, the pressure created by the pump forces the

pressing cylinder to extend. This cylinder makes contact with the material, pressing against it

with a set force controlled by the pump.

Once pressure is removed, the cylinder retracts to its housing. The process is repeated with each

press operation. In larger scale pressing operations, or when a press is frequently used, pumps

may be electric- or air-operated to reduce the need for a press operator to control the pressure by

hand. Operators may also set the press and the bolster one time and complete repetitive tasks

without the need to constantly realign or adjust the press.

Varying the pump type that you choose to create more or less power allows press force to be

controlled. The most basic pump is a hand-operated model, used for low-volume, low-force tasks

such as folding metal or placing bearings. Hand pumps allow the press to move as quickly as you

pump, while electric and air pumps can provide more consistent, even force. Operators set up a

press before each application, so that the right force, alignment and spacing are achieved. Presses

need to be adjusted when materials or parts are changed.

18
3.1.3 What Types of Presses Are There?

i. H-Frame

H-frame presses are large floor units that combine a steel frame, a press cylinder, a pump and a

movable bolster—forming an "H" shape. These presses can be used for a variety of applications,

including in repair and maintenance facilities and on production lines for assembly. H-frame

presses are typically paired with hand pumps for low-volume applications, with air pumps in

facilities where pressurized air is available or with electric pumps for consistent operation.

Cylinder size can also vary depending on the force needed and the application.

ii. Roll Frame

While similar to H-frame presses, roll frame presses feature a table that can be several feet long

to accommodate large materials, at the bottom of the press frame. Depending on the model,

either the table or the press frame can move, allowing operators to make more calculated presses

when working with large or complex materials. Roll frame press operators will often use a

forklift or an overhead lifting system to move materials onto the press, and slide either the frame

or the table (depending on model) to align the press and materials appropriately, explains Kurt

Huber, Senior Global Products Manager for Tools at Enerpac, a global manufacturing company

that produces hydraulic presses. Roll frame presses allow operators to bring materials down

safely and slide them into the press, rather than risk an accident with a large workpiece.

iii. Bench Frame

Like H-frame presses, bench frame presses combine a press cylinder with a steel frame. Bench

frame presses are smaller than H-frame presses, can mount to tabletops or workstations and often

feature hand pumps and removable cylinders. Facilities with higher-volume applications,

19
explains Huber, will often use bench frames to rapidly assemble bearings or other parts, saving

space when compared to larger H-frame models. They can also be used for lower-volume or

smaller fabrication tasks such as bending metal parts.

iv. Arbor Press/C-Frame

Arbor presses and C-frame presses both take on a smaller, more mobile design than larger H-

frame models. These presses combine a solid steel frame with a removable cylinder. The major

difference between arbor and C-frame presses is that arbor frame models are designed to be

mounted onto a surface and feature mounting holes. Arbor frame presses can also handle higher

tonnages for more intense pressing applications. C-frame presses are designed to be more

portable and can be used to hold parts in place for assembly, or can be used to remove

components or mount to a bench for repetitive tasks such as bearing installation.

While hydraulic presses all work the same way, they come in a range of types and sizes based on

your specific needs. Now that you know the types of hydraulic presses and how they work, you

can choose the right one for your application.

3.2 Material Selection

In this design, the main components of the machine are made of mild steel. This is

because of its cost, availability and the ability to lend itself to the manufacturing process

employed.

Also, certain mechanical properties of metals have greatly influenced my decisions.

These properties include:

20
  Strength: it is the ability of a material to resist the externally applied force

without breakdown or yielding the internal resistance offered without breakdown

or yielding the internally applied force is called stress.

 Stiffness: It is the ability of a material to resist deformation under stress

 Hardness: it embraces difference properties such as resistance to water,

scratching, deformation and machinability

 Elasticity: it is the property of a material to regain original shape after

deformation when the external forces are removed.

 Toughness: It the ability to absorb energy without fracturing or rupturing.

3.3 Interpretation of Block diagram.

21
3.3.1 Diagram of motorized hydraulic press machine

 Safety Door

 Limit switch

 Manual control valve

 Electrical control box

 Relief valve

 Pressure gauge

 Hydraulic cylinder

 Motor

 Oil tank

 Pressing Plate

 Bailing Compartment

3.3.2 Safety Door:

Safety door is just like the correction gate when any accessories get damage than from this door

we can fix this.

3.3.3 Limit switch:

It is a switch that prevents the travel of an object in a mechanism past some predetermined point,

mechanically operated by the motion of the object itself.

3.3.4 Manual control Valve:

The operation is controlled manually with the help of the valve.

22
3.3.5 Relief valve:

When pressure is high exceeds the limit this valve is used to release or control the pressure

3.3.6 Pressure gauge:

It is fixed thereto measure the pressure.

3.3.7 Hydraulic cylinder:

This is a mechanical actuator which is used to give a unidirectional force through a

unidirectional stroke

3.3.8 Oil tank:

Here hydraulic oil is stored and supply.

3.3.9 Pressing Plate:

The main works of pressing plates are to provide pressure to the object and this plate having high

strength.

3.3.10 Bailing Compartment:

Here the work piece and placed and press according to the required shape and size.

3.3.4 Calculation of force

In achieving the aim of this work, component parts of the machine were designed using various

design equations. The design results were used to select materials for various components. The

detailed drawing of the developed hydraulic press machine was done using Pro E software. In

23
fabricating the machine, mild steel was used as the locally sourced material. The use of mild

steel is due to the fact that its strength, rigidity and machinability falls within the design

specifications. It is also available and cost effective.

3.4.1 Design analysis of some machine components:

Some components parts of the machine developed include; the frame (stand, base support,

column, top plate), cylinder mounting table, press pin, working table/bed, cylinder/ram

assembly, hydraulic tank, hand lever, pressure hose, pressure indicator and hydraulic pump.

3.4.2 Machine frame

A frame is a structure on which main units of a machine tool are assembled. For this work, the

frame was designed to accommodate ram assembly, hydraulic pump, oil thank, and working

table (bed). The design consideration is that of direct tension imposed on the pillars. Other frame

members are subjected to simple bending stresses.

3.4.3 Determination of volume of hydraulic tank

The volume of hydraulic tank was calculated from the Equation (1);

V=LWH

(1)

where L is the length of the tank in metres, W is the Width of the tank in metres, H is the height

of the tank in metres.

24
3.4.4 Design of Bolts

The diameter of bolt was determined from Equation (2) according to Khurmi and Gupta, 2005:

P=π4(dc)2σtn

(2)

where: P is the external load acting on the cover plate, dc is the core diameter of the bolt thread,

σt is the allowable tensile stress for bolt material, n is the number of bolt

but P=π4(D)2p

(3)

where: p is the maximum pressure, D is the inside diameter of cylinder.

Determination of Tensile Stress Due to Stretching of Bolt

Initial tension in a bolt based on experiments may be found by the relationship in Equation (4) as

given by Sumaila and Ibhadode, 2011.

Pi=2840d(N)

(4)

where Pi is the initial tension in a bolt (N), d is the nominal bolt diameter

Determination of Stress Area on the Bolt

Stress area on the bolt was found using the relation in Equation (5) as given by Khurmi and

Gupta, 2005:

25
 StressArea=π4(dp+dc2)2

(5)

where dp is the pitch diameter, dc is the core or minor diameter.

3.4.5 Determination of weight of the piston of the Hydraulic press.

The weight of piston was determined from Equation (6)

Densityofmetal(ρ)=Massofmetal(m)Volumeofpiston(V)p

(6)

But density of metal ρm = 7850 kg/m3

Volume of piston (Vp)=πr2h

(7)

Mass of Piston, Mp=ρmVp

And WeightofPiston(Wp)=mpg

(8)

3.4.6 Determination of the weight of the press cylinder.

The weight of press cylinder was determined by applying Equation (9)

Weight of cylinder (Wc)=ρmVcg

(9)

26
where Vc is the volume of cylinder

Vc=π(r22−r12)h

(10)

h is the height of cylinder, r1 is the internal radius, r2 is the outer radius.

3.4.7 Determination of oil flow rate.

Oil flow rate of the pump was determined using Equation (11):

Q=AV

(11)

where Q is the flow rate in m3/s, V is the velocity of flow in m/s, A is the area of pipe in m2.

Equation (12) was used to determine the hydraulic power of the machine

Hydraulic Power Ph=Qρgh

(12)

where Q is the flow rate in m3/s, ρ is the density of oil in kg/m3, g is the acceleration due to

gravity in m/s2, h is the differential head in metres (m).

3.5.0 Machine fabrication process.

The various processes used in the fabrication of this hydraulic press machine include:

Measurement, Marking out, Cutting, Drilling, Welding, Fastening, Grinding and Painting.

27
Assembly and Welding of Machine Components

In welding various components of this machine together, electric arc welding technique was used

because of the ease of concentration of heat. Heat spread reduces buckling and warping. The heat

concentration also increases the depth of penetration and speeds up the welding operation. The

base which is made of U Channel mild steel was first set up. The base has a length of 840 mm,

breadth of 180 mm and thickness of 6 mm. The column which is made of four pieces of vertical

flat mild steel plate was welded to the base that has been set up. Each of the plate has length of

1650 mm (vertical height), breadth of 102 mm and thickness of 20 mm. They were all welded to

the base to form the column of the machine. Having done this, two pieces of flat mild steel plate

(length of 840 mm, breadth of 225 mm and thickness of 16 mm) were welded to the top part of

the frame. With all the major frame parts in firm position, the frame stand was welded to the base

of the frame to provide for stability of the machine during operations.

Three holes of 50 mm in diameter was made on each of the column. This is to give room for

adjustment of the bed (table). Also, a rectangular oil tank of (203.2 × 203.2 × 209.5) mm was

fabricated and welded to the centre part of the column

S/N Design Factor Design Values

1 Volume of Hydraulic tank 0.00867 m3

2 Core diameter, dc 7 mm

3 External load acting on bolt and nut 28.3 KN

4 Initial tension in a bolt, Pi 14.5 N

5 Stress area 7.28 × 10−6 m2

6 Weight of piston, Wp 42.4 N

7 Weight of Cylinder, Wc 150 N

28
 8 Velocity of flow of fluid, Vf 4.22 m/s

9 Oil flow rate, Q 0.00133 m3/s

10 Hydraulic Power, Ph 10.8 W

Table 1. Some designed values for the hydraulic press.

Figure 1. Shear force and bending moment diagrams for a simply supported beam with a point

load of 300 kN.

Figure 2. Isometric drawing of the machine and part list.

29
of the machine frame. This tank serves as oil reservoir needed to pump the hydraulic pump. A

hand operated lever, which is made of mild steel rod of 610 mm length, and 25 mm thickness

was connected to oil tank with the aid of a pivot. SAERI2 Pressure hose was fitted to the

hydraulic oil tank in order to convey hydraulic oil from the tank to a single acting hydraulic

pump which is mounted on the top part of the frame. The hydraulic pump has a load capacity of

30 tons. All the machine parts were firmly secured to ensure rigidity and support. The finishing

of the fabricated machine involves grinding the welded joints and painting with emulsion paint.

3.6.0 Design parameters.

3.6.1 Design of hydraulic jack

Inner diameter of cylinder = 45 mm

• Outer diameter of cylinder = 53 mm

• Thickness of the cylinder = 4 mm

• Pressure inside the cylinder = 9.43 N/mm²

• Maximum tensile strength = 210 N/mm²

•Factor of safety = 3

• Yield strength = 210/3

=70 N/mm²

3.6.2 Design calculation.

Assuming internal diameter = 45mm

Area = ∏r²

= ∏*(22.5)² = 1590.43 mm²

Pressure P = F/A

30
 Assuming pressure force (F) = 15000 N

P = 15000/1590.43 =9.43 N/mm²

Applying Lame’s theory Px = b/x² – a…………….Radial Pressure

σx = b/x² + a…………….Hoop stress

Where a and b are constant.

Px = b/x² – a

9.43 = b/(22.5)² – a………………(1)

σx = b/x² + a

70 = b/(22.5)² + a………………(2)

By solving this equation

b = 20105.72

a = 30.28

For external radius of cylinder Px = 0

Px = b/x² – a

0 = 20105.72/x² – 30.28

x² = 664

x = 25.77 mm

Therefore, thickness of cylinder = 25.77 – 22.5

= 3.27 mm

Therefore, we take the thickness of cylinder is 4 mm.

3.6.3 Motor specification

Motor is 12vDC

Motor power- 300w /= 0.4HP

Motor rpm = 3000rpm

31
 Motor toque =1N.M

3.6.4 spring specification.

All springs are constructed to have an initial tension, that force that keeps the coils together in a

set position. As a measurement, initial tension is the load or force necessary to overcome the

internal force to start coil separation. How to calculate spring tension, and its importance will

help to determine how effectively a spring will function in a particular application. Measuring

how much potential energy is stored in the spring and the force required to deform it must be

calculated.

Fs = kx

PEs = 1/2 k * x^2

Fs = spring force

k = spring constant (the spring constant (k) is defined as the ratio of the force affecting the spring

to the displacement caused by it).

32
x = change in spring length from starting position

PEs = Potential energy of the spring. (J)

3.6.5 Motor specification.

To calculate multiple pulley sets, where the first driven (large) pulley shaft drives the second

driver (small) pulley, and so on, enter first (small) driver pulley RPM and pulley set diameters

and centres separated by commas and - as shown below.

The RPM of the first driven (large) pulley is transferred to second set small (driver) pulley and

so on. The sets of pulleys will be drawn at the bottom of the page with each set RPM reductions

and total RPM reduction through all entered sets.

For a belt drive system, the motor torque required during constant velocity is simply the total

axial force (Fa) on the belt multiplied by the radius (r1) of the drive pulley.

Tc = torque required during constant velocity (Nm)

Fa = total axial force (N)

r1 = radius of drive pulley (mm)

η = efficiency of belt drive system

Notice that the efficiency (η) of the belt drive system is included in the torque equation. This

efficiency accounts for losses such as friction between the belt and pulleys. Also note that we’ve

assumed the drive and idler (driven) pulleys have the same radius, which is often the case for belt

driven linear motion systems.

33
Unlike screw drives, which often encounter axial forces due to external operations such as

pressing or drilling, belt drives aren’t designed to withstand external axial forces. So the total

axial force for a belt drive system consists only of the force required to move the load, which is

the weight (m*g) of the load (both the external load and the belt) multiplied by the coefficient of

friction (μ) of the guide supporting the load.

m = mass of moved load (external load plus belt) (kg)

g = gravity (m/s2)

μ = coefficient of friction of guide 

34
 CHAPTER FOUR

4.1 Data analysis.

The report on the motorized hydraulic press machine market provides a holistic update, market

size and forecast, trends, growth drivers, and challenges, as well as vendor analysis. This study

identifies the demand for fabricated metal in the automotive sector as one of the prime reasons

driving the hydraulic press machine market growth during the next few years. However,

advances in sheet hydroforming may hamper the market.

Technavio analyzes the market by End-user (Transportation, General Machinery, and Others)

and Geography (APAC, Europe, North America, MEA, and South America).

This report presents a detailed picture of the market of study, synthesis, and summation of data

from multiple sources by an analysis of key parameters.

4.1.2 The hydraulic press machine

 Hydraulic Press Machine Market Sizing

 Hydraulic Press Machine Market Forecast

 Hydraulic Press Machine Market Analysis

4.2.0 Related Reports.

4.2.1 Hydraulic Cylinder Market

The hydraulic cylinder market size is expected to grow by Ksh 2..54 billion and records a CAGR

of 4.96% during 2021-2025.

35
4.2.2 Hydraulic Equipment Market -The hydraulic equipment market size is expected to reach

a value of USD 15.50 billion, at a CAGR of 4.71%, during 2021-2025

4.3 Project findings.

The testing of engineering products to ascertain the level of performance is an expedient step that

needs to be considered during manufacturing processes (Sumaila and Ibhadode, 2011). The

design Expert software was used to set up experiment in order to ascertain the performance of

the machine as well as to determine the effect of press time, temperature and pressure on the

density of test samples. The machine was utilized for the production of ceiling board using

recycled low density polyethylene (rLDPE) and breadfruit seed coat. These materials were used

due to their good thermal and mechanical properties.

Table 2, shows the experimental factors and response that were considered in the test evaluation

of the machine. The factors considered are press time, temperature and pressure, while the

response is density.

Table 2. Experimental factors and Response.

S/N A:TIME (Mins) B:TEMPERATURE (oC) C:PRESSURE (Bar) DENSITY (Kg/cm3)

1 2 120 5 800

2 5 120 5 531

3 2 180 5 750

4 5 180 5 570

5 2 120 10 780

36
S/N A:TIME (Mins) B:TEMPERATURE (oC) C:PRESSURE (Bar) DENSITY (Kg/cm3)

6 5 120 10 612

7 2 180 10 700

8 5 180 10 510

9 1 150 7.5 750

10 6 150 7.5 622

11 3.5 100 7.5 700

12 3.5 200 7.5 370

13 3.5 150 3.3 760

14 3.5 150 11.7 730

15 3.5 150 7.5 600

16 3.5 150 7.5 630

17 3.5 150 7.5 650

18 3.5 150 7.5 630

19 3.5 150 7.5 700

20 3.5 150 7.5 630

4.3.1. 3D surface plot

The 3D surface plot gives the combined effect of factors on a particular response. It shows the

response surface estimation as a function of two factors with all other factors held constant. With

37
the 3D response surface plot, the effect of the interaction of two factors on a particular response

could be studied.

Figure 8, shows the 3D surface plot for press temperature against press pressure. It could be seen

from the figure that the increase in temperature and pressure reduces the density of the material.

This is justified with the fact that increase in temperature increases evaporation which in turn

reduces the moisture content of the material. The increase in pressure on the other hand also

reduces the moisture content of the material. This findings agree with that of Ezenwa et al.

(2019).

Figure 8. 3D surface plot for press temperature against press pressure.

Figure 9 shows the 3D surface plot of press time against press pressure. It shows that an increase

in press time and press pressure reduces the density of the material. This is true because if the

press time increases the effect of pressure on the material will cause an increase in the amount of

moisture content lost. This negative effect of press time and pressure was also reported by

Ezenwa et al. (2019) in their research.

38
Figure 9. 3D surface plot for press time against press pressure.

Figure 10, shows the 3D surface plot of press time against press temperature. The combined

effect of press time and temperature can be seen from the figure to also have a negative effect on

the density of the material, which is justified by the fact that both factors negatively affects the

moisture content of the material.

39
4.4 Recommendations.

3. Result and Discussion

The motor is rotating properly and it is efficiently able to rotate the sweeper machine. The tyres
are
able to rotate properly in the desired direction. The vacuum cleaner is able to clean things
properly
and also able to suck dusts and debris efficiently. The portable street cleaner is able to suck dust
particles of size less than 1 inch and approximate weight 25 grams or less efficiently. The bag is
able
to collect approximately 3-5 kg of debris and dusts in one time. The size of the debris collected
by the
street cleaner varied from some 10 millimetres to 4 centimetres. The debris collected also
depended
upon the weight of the debris collected. The PM10 certified cleaner are capable to collecting and
holding particle sized less than 10μm. However a modern air street sweeper creates very high
noise
level due to this fact it requires an extra engine. But this portable street cleaner is very effective
for
developing country likes India.

4.5 Conclusion.

During the experiment we have faced many problems for fabricating portable street cleaner. The
problem with the rotation of the motor, which can be rectify by taking a more powerful motor.
The

40
dust and debris sucking are effectively depends on the power of the motor. No expertise is
required for operating street cleaner. The street vacuum cleaner is effectively clean the small dust
particle and
debris. The portable street cleaner is able to suck dust particles of size less than 1 inch

4.6 Bills of Quantity.

Serial Item Description Quantity Unit price Amount

number

01 Hydraulic 25tonnes (car jack) 1 15000 15000

Jack

02 Driver and Aluminum alloy or 1 1500 1500

driven gear carbon fiber

03 Belt Plain carbon or 1 1000 1000

alloy steel

04 Electric 0.5 Horse power 1 9000 9000

motor

05 Springs 1.7x0.25 2 500 1000

06 Flat bar 5Mx2inches thick 1 1000 1000

07 Pedal 9x20outside 1 2000 2000

crankshaft diameter 14.2mm

inside diameter

41
 13mm

08 Bolts 8.8 gauge 10 20 200

3x1

09 Nuts 3\8 10 10 100

10 C-channel 200mmx50mmx3m 5 1000 5000

columns

Reference.

[1]Scholl J E 2000 Development of a nonpoint source BMP control strategy for a watershed
TMDL
Watershed Management Conference 4 160-185.
[2] Allison S Mehta S 2001 Street sweepers stage a comeback, Los Angeles Times 9 120-125.
[3] Bannerman R 2002 Effectiveness of Enviro Whirl Technology, Schwarz Technologies 1 80-
85
[4] Crites, B 2004 Air quality issues in Coachella Valley, Prepared Witness Testimony before
House
of Representatives, Committee on Energy and Commerce, Subcommittee on Energy and Air
Quality
2 63-65.
[5] Selbig W R Bannerman R T 2005 Evaluation of street sweeping as a water-quality
management
tool in three residential basins in Madison, Wisconsin: U.S. Geological Survey Scientific
Investigations Report 103 2007–5156

Design and fabrication of analogue hydraulically operated palm oil press, Pac. J. Sci. Technol.,

14 (1) (2013), pp. 79-88P.E. Amiolemhen, A.N. Ogie

Design and manufacture of a 10-tonne hydraulic press, J. Prod. Eng., 22 (1) (2019), pp. 10-14

S.M. Bapat, Y.M. Desai

42
Design optimization of a 30-ton hydraulic press machine, Int. J. Res. Appl. Sci. Eng. Technol., 3

(2009), pp. 24-3 Okolie Paul Chukwulozie, Obika Echezona Nnaemeka, Azaka Onyemazuwa

Andrew, Sinebe Jude Ebieladoh

Steel work design and analysis of a mobile floor crane Br. J. Appl. Sci. Technol., 13 (3) (2016),

pp. 1-9 I. Dagwa, A. Ighadode

Design and manufacture of automobile disk brake pad Niger. J. Eng. Res. Develop., 4 (3) (2005),

pp. 15-2 O.N. Ezenwa, E.N. Obika, C. Umembamalu, F.C. Nwoye

Development of ceiling board using breadfruit seed coat and recycled low density polyethylene

Heliyon, Elsevier, 5 (2019) 1-10 Google Scholar Joshi, 2015 Ashwin Joshi

Institute/College Swami Vivekananda College of Engineering. City: Indore. March 9, 2015

(2015) Mohammed et al., 2020 Iqbal Khatib Mohammed, Zameer Ahmed Roshan, Saud Uddin

Md, Abdul Rahman Mohammad

Design and fabrication of 5 ton hydraulic press Machine,Article

Int. J. Sci. Res. Sci. Eng. Technol., 7 (2) (2020), pp. 22-30 View Record in ScopusGoogle

Scholar Kumar and Prashanth, 2017 S. Kumar, B. Prashanth

Design and fabrication of hydraulic press

Int. J. Sci. Develop. Res., 2 (7) (2017), pp. 227-230 View Record in ScopusGoogle Scholar

Kurmi and Gupta, 2005 R.S. Kurmi, J.K. Gupta

Machine Design (fourteenth ed.), Eurasia Publishing House (PVT) LTD (2005), pp. 1-1251

Google Scholar Lackner, 2004 L. Lackner The new generation of hydraulic presses

Art. Cer. Forum Int., 81 (11) (2004), pp. E12-E13 November 2004 View Record in

ScopusGoogle Scholar Muni and Amarnath, 2011 P. Muni, V. Amarnat

43
There are two process of street cleaning- (i) Manual process and (ii) Machinated process.
In first process, cleaning is done with the help of broom and shovel. In this process a person is
continuously swiping by a broom in the hand to clean the street by spreading the dust all over in
the
air. On the other hand second process is very costly. In this processes brooms and strong vacuum
head(s) for picking-up both large and small materials attached within typical pavement structure.
The
concept of design was taken such as that it can balance the vacuum cleaner and motors very
efficiently. Chassis was created and it was attached to the scooter. Motors were attached at the
front of
the tyres. Tyres were placed at one side and on another side the whole setup. The design was
created
with the help of solid works. All the necessary materials were attached with chassis. The design
on
solid works was created in such a way that it could be incorporate in real life.

The mop is attached with the hub. The mop will help in cleaning the road as it will rotate with
the help
of an A.C motor. The mop was placed on both sides of the scooter and it collects all the dusts in
the
middle of the scooter so that vacuum cleaner will suck up all the dusts and debris from the
middle of
the road by the vacuum cleaner.

This is the final picture of the street cleaner. It will be really helpful in picking up small debris
from
the streets and also dusts.
2.3 Fabrication Steps of Street Cleaner
First we purchase a scooter and vacuum cleaner from market. We first design the chassis by
joining
the two metals with the help of welding. The whole idea was to balance the scooter such a way
that it
doesn’t fall off. The sweeper was attached to the front of the wheel of the scooter one on both of
the
sides. The motor and the vacuum cleaner were operated by electricity 220 volt. The single phase
A.C
motor is attached to the sweeper. After assembling all the essential parts on scooter the rotation
of the
sweepers and the power of the vacuum cleaner were tested. Fig.1 shows the front view of the
street
cleaner in which two tyres are attached with the mop placed one on each side. The mop placed
on the
sides is free to move up and down according to the situation.
44
45