Design, Modeling, Analysis of Self Cleaning Step

DESIGN, MODELING AND ANALYSIS OF SELF-CLEANING STEP MECHANISM
1. INTRODUCTION
In our day to day life we see different type of staircase, having different dimensions and design, stair
case is simply a number of steps. A set of steps formed to make it possible to pass to another level on
foot by putting one foot after the other on alternate steps to climb up or down the stair. Stairs can be
made of concrete, stone, wood, steel or combination of any of these.
The shoe cleaner is designed to take its place in the modern type of living of today and the future and
for use in both public and private life. It is constructed in a manner whereby its initial cost of
manufacture and maintenance cost will be maintained at a minimum and its installation in at least
public places will result in savings in cleaning maintenance that will more than offset the cost of the
shoe cleaner. It will hereinafter be readily apparent that the shoe cleaner can be made in any size to
suit the present demand and that the portions of the shoe cleaner which are visible may readily be
designed to provide a pleasing appearance.
In a city, road is mostly covered with asphalt or cement. Therefore, when a people are living in a city,
shoes are not generally soiled. Even if the shoes are soiled, as long as the shoes are taken off in a
house, the cleaning of the shoes is not so important, but at some sensitive areas provision of cleaning
is important factor.
However, shoes with dust or mud on the sole are often used on a natural field or ground. Since the
dust, dirt stick to the shoes, the shoes with dirt are generally carried to a specific place, the shoes are
taken off. Therefore, it is preferable to clean the shoes without taken it off.
Especially, golf shoes are used in a natural field, and soil is likely to attach to the golf shoes. Also, in
a golf course, in order to maintain lawn or grasses on a field and green, a large amount of chemical is
put on the field and green. Therefore, it is preferable to clean the golf shoes after use.
In many sensitive areas like defence, blood bank, hospitals, research laboratory also in educational
institute, outdoors game eg. Golf, cricket cleanliness is important parameter. Steps are the basic
element which is responsible for climbing from one place to another so it is important to introduce
such a mechanism over a stair case which directly cleans the sole of the shoe to maintain the
cleanliness in such areas .Self-Cleaning Steps is a mechanical steps design for cleaning sole of shoe
by its self-energy.
The present Project relates to footwear cleaning apparatus, a unit of the Project may be located on the
outside of an entry into a building or it may be placed inside a hallway or foyer of the building or at
any other location where hygiene is at top priority. There are numerous other locations which would
S.S.V.P.S.B.S.D.C.O.E.,DHULE Page 1
be desirable for the apparatus of the Project such as, for example, golf courses, residential homes, or
other places that could benefit from such an apparatus.
Self-cleaning step includes combination of sector gear, pinions and idler gears driven by sector gear,
which is driven by human weight, whenever human puts his foot over oscillating top of the step. Idler
gears are mounted in between pinions. There are three shafts mounted on the pinions which carry
bristles on its periphery to clean footwear. Whole assembly is enclosed in a steel frame mounted at
require location. Torsion spring is provided in order to reposition the step. Dust or any particulate
matter attached to footwear is collected in removable tray provided at the bottom, which can be
reinserted after cleaning.
When human puts his foot over the top of upper frame it gets moved down because of potential
energy, causes the gears and pinion to rotate and hence the shafts, pinion having contact with fix
sector gear. Bristles mounted on shaft makes contact with footwear, cleans it. Lower frame consists of
dirt collecting tray which is removable so at every morning sweeper can take out this tray to clean and
reinsert it. Both upper and lower frame are connected together using steel hinges. The complete
assembly can be placed at entrance of required location.
Figure 1.1 Self-Cleaning Step Mechanism
The sole objective of Present study is to design the self- cleaning step by considering various
parameters such as static load, material selection, frame dimensions, frameselection to model and
analysed various possibilities using CAD software‟s like AUTOCAD, CATIA V5, ANSYS-14, to
provide cost effective, non-attentive, user and environmental friendly, without use of external source
of energy, self-cleaning step which is used for footwear cleaning. This Project uses user‟s energy by
simple mechanism for its operation, to maintain cleanliness wherever necessary.
2. LITERATURE SURVEY
The present study relates to an apparatus for removing debris or cleats from spikes and/or mounted on
shoes, boots and other footwear and, in general, is employed while standing over the device and
placing one foot wear across the top of the device to have the debris removed, and then bringing the
other footwear to be cleaned likewise. Examples of footwear having spikes and/or cleats include golf
shoes, baseball shoes, and so on.
Soung Kiy Min [1] worked on the Shoe cleaning device. A shoe cleaning device is formed of a
housing having an opening to put a shoe to be cleaned, and a low pressure chamber communicating
with the opening; an air sucking and compressing device disposed in the housing and communicating
with the low pressure chamber for sucking air; a heating chamber disposed in the housing and
communicating with an outlet of the air sucking and compressing device; and a nozzle portion
disposed outside the housing and having a flow path communicating with the heating chamber to eject
compressed air passing through the air sucking and compression device. A liquid valve is attached to
the flow path to provide moisture to air passing through the flow path, and a controller connected to
the air sucking and compressing device, the heater and the liquid valve for controlling the same.
Materials attached to the shoe can be blown out by compressed air ejected from the nozzle and
collected through the opening. The shoe can be cleaned by the moisture ejected together with the
compressed air and dried by the heater, as well.
Figure 2.1 Pneumatically operated Shoe cleaning Device
In order to remove soil from the golf shoe, conventionally, there is a device to eject high pressure air
from a nozzle. In this device, soil is blown away by high pressure air ejected from a nozzle handled by
a user, but the removed soil scatters all around the area. In this respect, though the subject to be used
is different. This device discloses a nozzle to eject pressurized air to remove an attachment. In these
mechanisms, soil attached to the shoes can be removed, but chemicals attached to the shoes are not
removed.
William Hollander [2] worked on footwear cleaning apparatus, which includes a well receptacle.
Integrally connected to the bottom of the receptacle, two motor-controlled, telescoping stems
supporting a circular, rotating brush, which features heavy-duty yet gentle bristles for cleaning the
sole of footwear without damage. Brushes may be of nylon construction, for example, and it is
preferable that the bristles for the brushes be of such a character that they do not hold contamination
or spread any particles that are of contagious nature.
Figure 2.2 Motor operated Bristles Shoe cleaning Device
A unit of the invention may be located on the outside of an entry into a building or it may be placed
inside a hallway or foyer of the building or at any other location where needed. There are numerous
other locations which would be desirable for the apparatus of the invention such as, for example, golf
courses, residential homes, or other places that could benefit from such an apparatus.
The user activates the inventive device for use by use of a switch that may be activated by, for
example, retracting a cover for the device. Once the cover is retracted, the device is activated, causing
the telescoping stems to rise and the brush to spin. The sole of the footwear would be placed against
the rotating brush, and the user would maneuver the footwear to make sure the brush reaches between
each spike. After each footwear has been cleaned, pressure would be applied on the brush with the
user's foot to deactivate the device. Once the user has left the device, the cover slides back.
In a preferred Project, the well receptacle is adapted for containing a liquid cleaning solution and the
brush is immersed in the liquid cleaning solution prior to use of the inventive device by the user.
When the cover is retracted and the device is activated, the telescoping stems rise from the cleaning
solution and raise the brush to such a level that the top of the brush is accessible to the user's sole for
cleaning and the bottom of the brush is at least partially in contact with the cleaning solution. As a
result, the spinning action of the brush allows the bristles having cleaning solutions thereon to come
into contact with the user's sole after a partial revolution and the bristles having removed soils from
the user's sole to come into contact with the cleaning solution after the a partial revolution. The
inclusion of a cleaning liquid serves to improve the cleaning efficacy.
Shousong Bai [3] worked on Shoe cleaning device which uses rotating cleaning rollers with cleaning
fabric carrying cleaning liquid to clean shoe soles. The cleaning fabric, after wiping the shoe soles, is
squeezed by a scraper so the used cleaning liquid is separated from the cleaning fabric to be filtered
before reusing. The cleaning fabric can be made of different materials to fit the various types of
building entrances. After the shoe soles are cleaned by the wet rollers, they may be dried by the
drying rollers next to the cleaning rollers.
Figure 2.3 Motor Operated Roller shoe cleaning Device
In this invention, multiple rollers, rotating in opposite directions and carrying cleaning liquid, clean
the shoe soles. The purpose for rollers rotating in opposite directions is to enhance the efficiency of
the device. The cleaning fabric, after rubbing the shoe soles, is squeezed by a scraper on its way
down. The scraper assembly directs the separated dirty cleaning liquid to the dirty liquid chamber.
The dirty cleaning liquid returns to the clean liquid chamber by passing through a filter. The
partitioning wall between the dirty liquid chamber and the clean liquid chamber is of such height that
when the filter is clogged, the dirty cleaning liquid would overflow from the dirty liquid chamber into
the clean liquid chamber to keep the unit running. The cleaning liquid level is shown on the side of
the unit. Next to the cleaning rollers, a set of drying rollers are installed so the user may dry the shoe
soles. By assuring that the roller fabric is soaked in fresh cleaning liquid, and by rubbing the shoe
soles with rollers rotating in opposite directions, is more efficient than the prior arts.
User can tap the switch to turn on the unit, put the shoes against the cleaning rollers The fabric on the
cleaning rollers can be made of different materials to fit the various types of building entrances. After
the shoe soles are cleaned by the cleaning rollers , the shoe soles can be placed on the drying
rollers to be dried. Then, the user can tap the switch again to turn off the unit. If the user does not
switch off the unit, the unit can be switched off by a timer. A liquid level indicator on the side of the
unit shows the level of the cleaning liquid.
Figure 2.4 Motor Operated Roller shoe cleaning Device Gear Arrangement
Two rollers driven by two mating gears wipe the shoe soles. The rollers rotate up from the point that
two rollers meet and down on the other side where a scraper squeezes the roller and directs the dirty
cleaning liquid to flow to the dirty liquid chamber over the top of the scraper assembly. The pressure
of the scraper on the roller can be adjusted by the scraper adjustment screw. The partitioning wall that
connects the dirty liquid chamber and the clean liquid chamber comprises a filter so that impurities
from the shoe soles would not enter the clean liquid chamber.
Paul Counts [4] worked on Shoe cleaning device comprising a mounting plate, said plate having an
opening formed therein, a grillwork, means mounting said grillwork in said opening, a roller brush
assembly including at least one roller journaled for rotation about a longitudinal axis and having
bristles, thereon, means mounting said roller brush assembly beneath said grillwork with the ends of
the bristles on the upper surface of said roller projecting through open areas of said grillwork, and
motor means drivingly connected to said roller, receptacle means including a lower end, means
supporting said receptacle means beneath said roller brush assembly for catching foreign material
removed from footwear by the bristles on said brushes, said receptacle means including an opening
formed in its lower end, a receptacle, means about said opening for removably supporting said
receptacle therein, said receptacle means including a plurality of upstanding side walls, an opening
formed in one of said side walls, an elongated handle secured to said receptacle and extending
upwardly through said side wall opening and to a point spaced slightly below said mounting plate, an
access opening having a removable closure therefor formed in said mounting plate closely adjacent
the upper end of said handle whereby said receptacle may be removed from said cleaner through said
wall and access openings for emptying.
Figure 2.5 Bristles Mounted Roller shoe cleaning Device
The electric motor is also provided with a junction box from which a conductor extends and is
connected to a third junction box. A plurality of electrical heating assemblies and are provided with
conductors and respectively and are secured to selected walls of the housing. The conductors and are
each connected to the conductor within the junction box and a suitable toggle switch is disposed in the
electrical conduit whereby the toggle switch may be utilized to render the vacuum means.
The electrical heating elements and inoperative. It is of course to be understood that the heating
elements and could alone be operatively connected to the toggle switch whereby the toggle switch
would then be operatively connected to the electric motor for driving the rollers brushes of the shoe
cleaner and the vacuum of the shoe cleaner. In this manner, the electrical heating elements could be
disconnected during the warmer months.
3. DESIGN OF ELEMENTS
3.1. Design of Frame
Frame for self-cleaning step should be designed on the basis of various factors. The most important
factor for designing this step is material to be selected which withstands the static load without
deformation. So step can be operated satisfactory without any trouble at given conditions.
3.1.1. Material for Frame
Sheet metal with suitable yield strength should be used for step fabrication. Following are the list and
properties of materials which can be used for fabrication of self-cleaning step. [5]
i. Stainless steel [6]
 Grade 304 is the most common of the three grades. It offers good corrosion resistance while
maintaining formability and weldability.
 Grade 316 possesses more corrosion resistance and strength at elevated temperatures than
304. It is commonly used for pumps, valves, chemical equipment, and marine applications.
 Grade 410 is a heat treatable stainless steel, but it has a lower corrosion resistance than the
other grades. It is commonly used in cutlery.
ii. Structural steel [18]

Table 3.1 variation of minimum yield strength (N/mm2) with thickness
Steel Nominal thickness (mm)

grade ≤ > > > > 80 >
16 16 40 63 ≤ 100
≤ ≤ ≤ 100 ≤
40 63 80 150
S275 275 265 255 245 235 225
S355 355 345 335 325 315 295
S420 420 400 390 370 360 340
S460 460 440 430 410 400 380
 S275 steel is used on railway bridges, where stiffness rather than strength governs the design,
or where fatigue is the critical design case.
 S355 steel is predominantly used in highway bridge applications, as it is readily available, and
generally gives the optimum balance between stiffness and strength.
 S420 & S460 steels can offer advantages where self-weight is critical or the designer needs to
minimise plate thicknesses. However, the use of such steels confers no benefits in
applications where fatigue, stiffness or the instability of very slender members is the
overriding design consideration.
iii. Aluminium [5]
Aluminium is also a popular metal used in sheet metal due to its flexibility, wide range of options,
cost effectiveness, and other properties. The four most common aluminium grades available as sheet
metal are 1100-H14, 3003-H14, 5052-H32, and 6061-T6.
 Grade 1100-H14 is commercially pure aluminium, highly chemical and weather resistant. It
is ductile enough for deep drawing and weldable, but has low strength. It is commonly used in
chemical processing equipment, light reflectors, and jewellery.[22]
 Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost.
It is corrosion resistant and weldable. It is often used in stampings, spun and drawn parts, mail
boxes, cabinets, tanks, and fan blades.
 Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It
maintains high corrosion resistance and weldability. Common applications include electronic
chassis, tanks, and pressure vessels.
 Grade 6061-T6 is a common heat-treated structural aluminium alloy. It is weldable,

corrosion resistant, and stronger than 5052, but not as formable. It loses some of its strength
when welded. It is used in modern aircraft structures.
Conclusion- Material selection for self-cleaning step fabrication is depends upon its tensile and
compressive strength when 60 to 120 kg load of persons acting on It., which can be analysed by
ANSYS 14 for different materials. but as per physical and chemical properties, structural steel S355
with yield strength 355MPa, ultimate tensile strength 470 MPa, young‟s modulus 210 MPa and gauge
4 (5.59mm) is best material for frame fabrication because of following characteristics.
-it gives the optimum balance between stiffness and strength.
-it can withstand impact energy of 27J
-it gives maximum yield strength with minimum thickness
-Up to 100mm thickness it gives 630 MPa tensile strength. So it has better tensile properties.
3.1.2. Frame Dimensions
There are various types of Stairs can be made of concrete, stone, wood, steel or combination of any of
these. Staircase can be made of different dimensions and design.
 Stair [7] a set of steps formed to make it possible to pass to another level on foot by putting
one foot after the other on alternate steps to climb up or down the stair. To design frame
dimension basic parameters like trade width, rise need to specify
Figure 3.1 Stair case Geometry-A
 Tread – horizontal surface of a step

 Riser – vertical surface or near vertical of a step
For human comfort tread width should be 220to 260mm max, rise should be 220mm max and length
should be 600 to 800 mm [8]
3.1.3. Design For Static Load
According to “National institute of nutrition” the average weight of Indian people is 60kg [9], so self-
cleaning step should be design to withstand such a static load without deformation.
Figure 3.2 Stair case Geometry-B
3.1.4. Design of Angle (Ɵ)
Calculation of Angle (Ɵ) for various rise and tread width:
Figure 3.3 Schematic for calculation of angle of rise
a) For 1 inch rise(h)=25.4mm
i. Tread width=250mm
tan Ɵ=25.4/250
Ɵ =5.80
ii. Tread width=260mm
tan Ɵ=25.4/260
Ɵ =5.58
iii. Tread width=270mm
tan Ɵ=25.4/270
Ɵ =5.37
iv. Tread width=280mm
tan Ɵ=25.4/280
Ɵ =5.18
b) For 2inch rise(h)=50.8mm.
i. Tread width=250mm
tan Ɵ=50.8/250
Ɵ=11.50
ii. Tread width=260mm
tan Ɵ=50.8/260
Ɵ=11.05
iii. Tread width=270mm
tan Ɵ=50.8/270
Ɵ=10.66
iv. Tread width=280mm
tan Ɵ=50.8/280
Ɵ=10.280
c) For 2.5inch rise(h)=63.3mm
i. Tread width=250
tan Ɵ=63.3/250
Ɵ=14.35
ii. Tread width=260
tan Ɵ=63.3/260
Ɵ=13.68
iii. Tread width=270
tan Ɵ=63.3270
Ɵ=13.20
iv. Tread width=280
tan Ɵ=63.3/280
Ɵ=12.7
Conclusion-Hence basic dimension for frame fabricated as a step we select are [7]
i. Trade width: 260mm

ii. Rise: 120.65+60.35 (2.5”)=190mmLength: 609mm
iii. thickness:5.59 mm
iv. Angle: 13.68
3.2. Design for Torsion Spring[14]
Torsion spring whose ends are generally rotated in angular deflection, offer resistance to externally
applied torque. The wire itself generally subjected to bending stresses rather than torsional stresses.
Torsion springs are generally close wound, reduce in coil diameter and increase in body length as they
are deflected.
3.2.1. Stiffness calculation [10]
To find out stiffness of spring we have to find stress (σ) &Angular deflection (dψ) of spring. [10]
Now calculate stiffness,
Where, k-Stiffness (N/Rad)
f-force applied(N)
r-spring length(mm)
dψ-angular deflection(Rad)
D-mean coil diameter-10mm
d-wire diameter-2.5mm
n-number of active coil
p-pitch-4mm
E-modulus of elasticity- for steel
Figure 3.4 Schematic for calculation of spring stiffness
3.3. Design for Gears
In practical conditions gear design is based on central distance between shafts, number of teeth of
gears and revolution of shaft.
In our project central distance between two shafts is 80 mm; hence we have to design the gears for 80
mm central distance.
Pair of gear designed should be such that, it will give maximum rotation of shaft.
3.3.1. Calculation of Diametral pitch and Diameter for different number of teeth
For self-cleaning step mechanism sector gear and pinions are selected on the basis of central distance between
two shafts and standard module available.
Following table shows standard module for reference.
Table 3.2 Standard Module series
Table 3.3 Spur Gear Catalogue for Standard Module
Following are the points to be considered before design of pinions.
 As in self-cleaning mechanism pinions are mounted on upper frame hence dimension of pinions are
within frame dimensions.
 Vertical height of upper frame is 50 mm; therefor diameter of gear should not be more than 50 mm.
 Central distance between shaft is 80 mm there for central distance between pinions is also 80mm
 Diameter of shaft use for self-cleaning mechanism is 10mm
 Diameter of pinion increases shaft revolution decreases[23]
From table 3.3 for 18 teeth pinion maximum bore is 11mm; therefore calculation is started from 18 teeth.
For 18 teeth pinion we select standard module of 1 mm from table 3.2
Let number of teeth=18
C= centre distance between shaft= 80 mm
 Therefore module is given by
DP=25.4
 Outside diameter of pinion„d‟ is find by,
d=20 mm-----------------(Table 3.3)
 Now find out teeth of sector gear
( )
( )
N2=142
 Outside diameter of Sector gear „D‟ is find by,
D=144 mm
 From the above calculations it is clear that if 18 teeth are chosen for pinion when Ɵ is ,
circular pitch is 3.14mm and module is 1
 working depth=2.15 (working depth =2.157x module)
 If we select pinion with 18 teeth and sector gear with 144 teeth , then for one rotation of
sector gear pinion will rotate
Where, R1-rotation of sector gear

R2-rotation of pinion
R1=8 Revolution
 In our project sector gear is fixed and 1/4th portion of gear is kept in contact with pinions.
 Therefore numbers of teeth‟s on sector gear which are kept in contact with pinions are 36
teeth. Hence rotation of pinions is 2 revolutions.
3.4. Design of shaft

Shaft is a common important machine element. It is a rotating member, in general, has a circular
cross-section is used to transmit power [19]. The shaft may be hollow or solid. The shaft is supported
on bearings it rotates a set of gears or pulleys for the purpose of power transmission. The shaft is
generally acted upon by bending moment, torsion axial force. Design of shaft primarily involves in
determining stresses at critical point in the shaft that is arising due to loading, deflection at various
points.
3.4.1. Material for shaft
Most shafts are made from steel, either low- or medium-carbon. However, high quality alloy steel,
usually heat treated, may be chosen for critical applications. Other metals, e.g. brass, stainless steel or
aluminium, may be used where corrosion is a problem or lightness is required. Small, light-duty
shafts, e.g. in household appliances, may be injection- moulded in a plastic material such as nylon or
delrin[18]
3.4.2. Analytical calculation
Firstly we have to find failure stress for maximum loading to design the shaft for given set of
condition.
I. Design for 60kg direct load acting upon the shaft.
Table 3.4 Design Parameters for Direct 60 Kg load

Parameters of the Symbol value Unit
shaft
Diameter D 5 mm
Length of shaft L 609.6 mm
Point load P 588.6 N
Figure3.5 Simply Supported Shaft
Conditions -Shaft is supported by bearing
-Point load „P‟ act on centre of shaft
-Material is stainless steel
-Modulus of elasticity E-193X MPA
i) Shear force calculation
Step 1: Replace supports by their respective reactions consider overall equilibrium of the beam.
RA-588.6+RB=0
RA=588.6-RB
RAx0+588.6x304.8-RBx609.6=0
=179.40x =609.6RB
RB=294.29 N
RA=588.6-294.29
RA=294.29 N
Step 2: shear force calculations (considering forces acting on left side of the section)
S.F. at A=0
S.F. just to right of A=294.29N
S.F. just to left of P=294.29N
S.F. just to right of P=294.29-588.6
= -294.29N
S.F. just to left of B=294.29-588.6
=-294.29N
S.F. at B=0
ii) Bending Moment Calculations
Step 3: Since there is no moment acting on the beam, there shall not be sudden variation in BM.
B.M. at A=0
B.M. at P=294.29x304.8=86.69x Nmm
B.M.at B =0
Figure.3.6 Force Bending Moment Diagram
iii) Deformation Calculations
Step 4: Moment of inertia of the circular shaft about neutral axis= I
I=
I=
I=30.67
Using conjugate beam method,
δ=
δ = -469.64 mm
iv)Equivalent twisting moment calculation
Figure.3.7 twisting couple diagram
Step 5: Twisting moment can be found by,

𝑇 Ʈ 𝐺𝜃
𝐽 𝑅 𝐿
 Polar moment of inertia

J=
=61.35mm4
 shear stress
Ʈ=
=29.97MPa
 Angle of twist is find by the equitation
Ɵ= 0.037 Rad
 There for twisting moment is given by,
T=718.43Nmm
Now find factor of safety for above conditions (588.6 n force) using, maximum shear stress theory
Step 1: calculation of maximum shear stress
Ʈmax= √( ) Ʈ
There for, Ʈmax=33.54 MPa
Ʈ< Ʈmax hence our design is safe for 588.6N
Where, = 30 N/mm2
Step 2: calculation of factor of safety (FOS)
Ʈmax=
Where, Syt= 207 MPa for stainless steel.
There for, FOS=3.0 for 588.6 N
II. Design for 60 kg load
Table 3.5 Design Parameters for 60 Kg load
Parameters of the shaft Symbol value Unit
Diameter D 5 mm
Point load P 588.6 (60kg) N
Moment of inertia I 30.67
Coefficient of friction μ 0.1 -
Modulus of elasticity E 193X MPa
For designing of self-cleaning step we use polypropylene bristles. Hence coefficient of friction
offered when there is leather to metal & metal to plastic contact is in the range of 0.1 to 0.3. Which is
depending on contact pressure and surface roughness.[16]
We take coefficient of friction (μ) as 0.1[16]
μ=
0.1=
N=58.86 N
Therefor Normal force acting on shaft is 58.86
(i) Deflection of shaft (δ) at normal force (N)
δ=
δ=
δ=-46.97 mm
(ii) Bending moment of shaft at normal force:
RAx0+58.6x304.8-RBx609.6=0
RB=29.4 N
RA=29.4 N
-B.M. at A=0
B.M. at P=29.4x304.8=8.96x N.MM
B.M.at B=0
III. Design for 120 kg load
Table 3.6 Parameters for 120 Kg load.

Parameters of the Symbol value Unit
shaft
Diameter D 5 mm
(i) Normal force (N)
μ=
0.1=
N=117.72 N
(ii) Deflection of shaft (δ) at normal force (N)
δ=
δ=
δ=-93.95 mm
(iii) Bending moment of shaft at normal force:
RAx0+117.72x304.8-RBx609.6=0
RB=58.86 N
RA=58.86 N
B.M. at A=0
B.M. at P=58.8x304.8=17.92x Nmm
B.M.at B=0
IV. Design for 60 kg load and shaft diameter 10 mm
Table 3.7 Parameters for 60 Kg load

Diameter D 10 mm


(i) Normal force (N)
μ=
0.1=
N=58.86 N
δ=
δ=
δ=-2.93 mm
(iii) Bending moment of shaft at normal force
RAx0+58.6x304.8-RBx609.6=0
RB=29.4 N
RA=29.4 N
B.M. at A=0
B.M. at P=29.4x304.8=8.96x N.MM
B.M.at B=0
V. Design for 120 kg load and shaft diameter 10mm
Table 3.8 Parameters for 120 Kg load

Diameter D 10 mm
Coefficient of friction Μ 0.1 -
(i) Calculation of Normal force (N) μ=
0.1=
N=117.72 N
Using conjugate beam method, δ=
δ=
δ=-5.87 mm
(iii) Bending moment of shaft at normal force
RAx0+117.72x304.8-RBx609.6=0
RB=58.86 N
RA=58.86 N
B.M. at A=0
B.M. at P=58.8x304.8=17.92x N.MM
B.M.at B=0
3.5. Design for Bearing:
Bearing s should be selected on the basis of static load ratings C0 instead of bearing life when one of
the following conditions exists:
 Static loads are not only those that are applied with the bearing at rest or at very low
rotational speeds (n < 10 r/min) but should include checking the static safety of heavy shock
loads (very short duration loads).
 The bearing is stationary and is subjected to continuous or intermittent (shock) loads.
 The bearing makes slow oscillating or alignment movements under load.
 The bearing rotates under load at very slow speed (n < 10 r/min).
 The bearing rotates and, in addition to the normal operating loads, has to sustain heavy shock
loads.
In all these cases, the permissible load for the bearing is the maximum load the bearing can
accommodate without permanent deformation to the rolling elements or raceways. Permanent
deformation is typically caused by:
i. Heavy loads acting on the bearing while it is stationary or oscillating slowly
ii. Heavy shock loads acting on the bearing while it is rotating
For self-cleaning step mechanism following are the important factor to be considered.
 Load acting –maximum 1177.2 N radial load is acting on bearing

 Speed- speed of shaft is in the range of 7.5-10 rpm.
 Space required - top frame of step is 260 mm in trade width and there are three shafts and
three pins are used. Hence number of bearing required at one end is 9 nos.
 Shaft diameter-for optimum performance 10 mm diameter shaft is used.
Table 3.9 Bearing requirements
Self-cleaning step Bearing type Bearing applications Remark

requirement (Can used in self-
cleaning step?)
1) Use for radial and
thrust load Yes
1)Radial load Deep groove
2)Use for medium and
2) low speed ball bearing No
high speed
3) limited Space
3)less space required Yes
1) Use for radial load Yes
Cylindrical 2)Use for low speed Yes
bearing 3)More space as required No
 For cylindrical roller bearing available minimum bore diameter is 20 mm so it is inapplicable

in self-cleaning step [14]
 Therefor for above requirements deep groove ball bearing 6300zz is suitable having following
specifications
Table 3.10 catalogue for 6300 Deep Groove Ball bearing
3.5.1 calculation for static safety factor at maximum load 1177.2N
Now find out Static safety factor for selected bearing-
Where,
S0- Static safety factor
C0-Basic load ratings or static load carrying capacity [14]
P0- Static bearing load
3.6. Design for bristles
Fig shows top frame of self-cleaning step mechanism in which height of top frame is 50 mm, bearings
are mounted at centre vertically. Hence vertical position of shaft is 25 mm. there for height of bristles
Figure 3.8 Schematic for Bristles

not so high that is will interrupt gear rotation and not less that it will not touch the sole of shoe. In
other words bristles should be such that it will effectively clean shoe surface without obstruction.
3.6.1. Material for bristles
Polypropylene: A versatile low cost filament used for a wide variety of applications. [24] It has
excellent wet stiffness, abrasive tip cleaning action, non-brittle, and is inert to most solvents, oil,
acids, and chemicals, can be used wet or dry, durable and provide good abrasion resistance and
shear/break strength, resulting in longer product life.. It is, in fact, one of the most chemically resistant
synthetic filament materials. They are best for medium to heavy floor sweeping, including on
carpeting and entry mats. Polypropylene bristles are more flexible than corn bristles. Polypropylene
bristles can be easily washed and dry quickly to reduce mold and fungal growth and extend product
life.[24]
Figure 3.9 Polypropylene Bristles
Polyester: A polymer that replaces horsehair. Its features of toughness and high temperature
resistance resemble those of Nylon, but Polyester is noted for its ability to recover without whip or
slapping. Polyester has excellent resistance to all acids, alkalis, alcohols, gasoline, benzene and most
cleaning solvents. It is a medium-priced filament that resists mildew, bacteria and fungus growth. [24]
Tampico: Has a soft to medium texture and is off white in colour. It is often dyed and blended to
give the desired effects to a bristle brush. It is heat, alkali, and acid resistant. The porous fibres absorb
water and work wet or dry. More aggressive than nylon or horsehair. Used for removing surface
particles and tool marks, dusting, wet scrubbing, cleaning, and spreading liquids. Excellent for
removing light feather burrs and for light edge blending when used with a compound. [24]
Figure 3.10 Tampico Bristles
Carbon Steel: Available both tempered and untendered, in a variety of sizes, straight or crimped.
This is a widely used metal fill material. It has excellent cutting ability and fatigue resistance for long
brush life at a low cost. It is used for general-purpose cleaning, rust removal, debarring, edge
blending, and roughing for adhesion. [24]
Figure 3.11 Tampico Bristles
Therefor bristles used in self-cleaning step have following specifications.
 Length along shaft: 569.6mm

 Bristles height: 30 mm
 Fibre diameter: 0.4mm
 Material: Polypropylene.
3.7.Design for frame hinges
Frame hinges are used for clamping top and bottom frame each other. Required hinges should be able
to hold top frame when frame incline at .
Length of self-cleaning step is 609.8mm [7] therefor length of hinges should be 50-100mm. door
hinges are located 127mm from one end. Number of hinges for frame length up to 1524mm is 2nos.
[13]
There for standard frame hinges used for self-cleaning step is 64x35x1.4mm.
Figure 3.12 Frame hinges
4. SOLID MODELING
Solid modeling (or modelling) is a consistent set of principles for mathematical and computer
modeling of three-dimensional solids. Solid modeling is distinguished from related areas of geometric
modeling and computer graphics by its emphasis on physical fidelity Together, the principles of
geometric and solid modeling form the foundation of computer-aided design and in general support
the creation, exchange, visualization, animation, interrogation, and annotation of digital models of
physical objects[20]
A solid part model is created by using computer aided software like CATIA generally consists of a
group of features, added one at a time, until the model is complete. Engineering solid models are built
mostly with sketcher-based features; 2-D sketches that are swept along a path to become 3-D.
4.1. Methodology-Part Generation

4.1.1. CATIA tree structure
In CATIA the part objects, which are used for developing part model i.e. three dimensional objects
are structured under a tree as shown in the following Figure.
Figure 4.1 CATIA tree structure
4.1.2. Lower frame

For modeling of lower frame following operation should be performed.
Sketcher: drafting of lower frame with designed dimensions.
Figure 4.2 Lower frame 2-D Sketch
Pad: extrude 2-D geometry into required axis to form 3-D part model of lower Frame.
Figure 4.3 Lower frame Pad defination
Pocket: apply pocket definition to remove unwanted surface from lower frame for making dirt
removing tray space.
Figure 4.4 Lower frame pocket definition
Apply material: apply material properties for frame.
Figure 4.5 Lower frame
4.1.3. Upper Frame

For modelling of upper frame same operation should be performed. I.e. drafting of 2-d frame in
sketched, extrusion of 2-d geometry in part design, then 60 mm x 569.6 mm length pocket for bristles
space and 10 mm pocket for shaft, applying material to the frame.
Figure 4.6 Upper frame 2-D Sketch
Figure 4.7 Upper frame

4.1.4. Dirt Collecting Tray
For modelling of dirt collecting tray following are the operations performed stepwise.
sketcher: Fig. shows 2-d drafted sketch having dimensions 220 x569.6 mm length
Figure 4.8 Dirt collecting tray 2-D Sketch
Pad: Fig. shows extrusion of drafted sketch having length 80 mm.
Figure 4.9 Dirt collecting tray 2-D Sketch
Pocket: Fig. shows pocket definition of solid model having depth 74.41mm.
Figure 4.9 Dirt collecting tray Pocket Definition
Rib: Fig. shows rib definition of model for making handle for holding the tray.
Figure 4.10 Dirt collecting tray Rib Definition
Apply material: apply material properties for tray.
Figure 4.11 Dirt collecting tray
4.1.5. Shaft And Bristles

For modelling of dirt collecting tray following are the operations performed stepwise.
Sketcher: Fig. shows 2-d drafted sketch having diameter 10mm.
Figure 4.12 Shaft 2-D Sketch
Pad: Fig. shows extrusion of drafted sketch having length 609.6 mm.
Figure 4.13 Shaft Pad Definition
Circular pattern: Fig shows circular pattern of bristles fibre having 20 instances at angle
Figure 4.14 Shaft Circular Pattern
Translate: Fig shows translation of circular pattern about z axis at 10 mm distance along the
shaft.
Figure 4.15 Shaft Translate Definition
Apply material: apply material properties for bristles.
Figure 4.16 Shaft Bristles
4.1.6. Sector Gear And Pinion

I. Sector Gear:
Fig. shows modelling of sector gear. As per calculation done in design section, only 1/4th part of gear
is kept in contact with pinions. i.e. for one rotation of sector gear pinion will rotate 1 revolutions when
sector gear has 36 teeth.
Following are the operations performed to model sector gear
 Drafting and extrusion of 2-D sketch using Pad definition.
 Create plane offset to xy plane at a distance mm.
 Draw tooth profile on yz plane having dimensions working depth 2.157 mm and Pitch
3.14mm
Figure 4.17 Extrusion of 2-D sketch
Circular pattern of tooth profile having 36 teeth.
Figure 4.18 Circular Pattern of sector gear
Spilt pinion in xy and zx plane respectively
Figure 4.19 Split Definition of Sector Gear
Apply material: apply material properties for sector gear.
Figure 4.20 Sector Gear
II. Pinion: Similar operation is performed to model pinion and idle gear.
Circular pattern: 18 teeth Pinion modelled with Circular pattern of tooth profile with dimensions
2.157 mm working Depth as shown in Fig.
Figure 4.21 Circular Pattern of Pinion
Pocket definition: 10 bore x 20mm deep pocket is made on pinion
Figure 4.22 Pocket Definition of Pinion
Apply material: apply material properties for pinion.
Figure 4.24 Pinion
Torsion Spring: For modelling of torsion springs following operations are performed.
Helix: As per torsion spring designed 2-d sketch of helix is drawn with helix curve definition as
shown below.
Figure 4.25 Helix curve Definition for spring
Rib: Fig shows rib definition of torsion spring having pitch 4mm and wire diameter 2.5mm
Figure 4.26 Rib Definition for spring
Apply material: apply material for torsion spring
Figure 4.27 Torsion Spring
4.1.7. Deep Groove Ball Bearing 6300:
For modelling of ball bearing 6300 following operations are performed.
Sketcher: 2-D sketch of ball bearing with outer diameter 35mm, inner diameter 10mm and thickness
0.6mm is drafted as shown in Fig.
Figure 4.28 2-D sketch of ball bearing
Pad: 2-D Sketch is extruded with length11 mm as per bearing specification.
Figure 4.29 Pad Definition sketch of ball bearing
Shaft: balls are drawn using shaft command. in this ball profile is drafted by creating new plane as
shown in Fig. 2-D drafted sketch is then then revolved about x axis
Figure 4.30 Shaft Definition of ball bearing
Circular pattern: using this command 10 nos. balls are rotated at about bearing axis as shown
in Fig.
Figure 4.31 Circular Pattern of ball bearing
Apply material: apply material for bearing.
Figure 4.32 Deep Groove Ball Bearing
4.1.8. Frame Hinge:
For modelling of ball door hinge following operations are performed.
Sketcher:As per specifications 2-D Sketch of door hinge is drafted having following dimensions as
shown in Fig.
Figure 4.33 2-D Sketch of Frame Hinge
Pad: extrusion of 2-D hinge with thickness 1 mm.
Figure 4.34 Pad Definition of Frame Hinge
Apply material: apply material for door hinges
Figure 4.35 Frame Hinge
4.2. ASSEMBLING OF PARTS:

Fig shows cut section of assembled frame using CATIA v5, in which all the modelled parts are
assembled in assembly section, where lower frame is fixed , upper frame is kept incline to lower
frame and hinged together using door hinges. In order to make upper frame incline two torsion
springs are used at both ends and in between top and bottom frame. Inside of top frame at both ends
there were ball bearings are mounted for frictionless rotation of shaft. Dirt collection tray is inserted in
lower frame which is removable.
Figure 4.36 Assembled cut Section of Self-Cleaning Step

Mechanism
At one end of whole assembly one sector gear is fixed to lower frame and pairs of pinions are kept in
contact with sector gear. These pinions are mounted on shaft at upper frame. Bristles are mounted
along length of shaft.
Figure 4.37 Self-Cleaning Step Mechanism
5. FINITE ELEMENT ANALYSIS

FEM enables to find critical locations and quantitative analysis of the stress distribution and deformed
shapes under loads. However detailed modeling and specialized knowledge of FEM theory are
indispensable to perform these analyses with high accuracy. They also require complicated meshing
strategies. Simulations of actual boundary conditions to equivalent FE. Boundary conditions have to
be done carefully because a wrongly modeled boundary condition leads to erroneous result[19]
In self-cleaning step, top frame, bottom frame and shafts are critical members subjected to normal
force, bending and twisting moment. Therefor careful analysis of these members is crucial for design
purpose. Using finite element software like ANSYS 14.0 modeled parts are analysed by importing
them into workbench and applying constrains to it.
5.1. Analysis of shaft
With finite element modelling a three-dimensional (3D) finite element model is developed to simulate the
behaviour of shaft. Analysis is done using finite element software package ANSYS 14.
Simulation using Ansys 14.0 consist of following
i. preparatory work prior to analysis:

ii. pre-processor modelling through the pre-processor
iii. Solution
iv. Result review
Figure.5.1 Material properties in Ansys 14.0
Fig. shows properties of stainless steel material used for shaft.
Modelling- create model from work page or directly export using external software.
Meshing: meshing of model includes selection of element size, type, number of elements use. shaft is
meshed by hexahedron element which has 8 vertices, 12 edges, bounded by 6 quadrilateral faces. It is
also called a hex or a brick. For the same cell amount, the accuracy of solutions in hexahedral meshes
is the highest
 Relevance centre-coarse
 Element type- hexahedron
 Nodes-45
 Number of element-22
Figure. 5.2 Meshing of solid shaft
Applying boundary conditions: Fig. shows boundary conditions of shaft.
 at A- Remote displacement
 at B- Displacement
 at C- Force 588.6 N
 at D-Remote displacement 2
Figure. 5.3 Boundary conditions for shaft
A. Analysis for 588.6 N (60kg) force
Table 5.1 Parameter for 588.6 N force

Diameter D 5 mm
Normal force N 588.6 N

i) Bending moment at point ‘p’
Fig. shows bending moment having following results
Figure. 5.4 Bending moment
ii) Deformation at point ‘P’
Fig. shows the Directional Deformation analysis having following results.
Figure 5.5 Maximum deformations for 60 kg load
iii) Twisting moment ‘T’
Fig. shows the twisting moment analysis having following results
Figure 5.6 Twisting moment
B. Analysis for 58.86 N normal force

Diameter D 5 mm

i) Directional deformation
Figure. 5.7 Deformation for 58.86 normal force
ii) Total bending moment
Fig. shows the bending moment analysis having following results.
Figure 5.8 Bending moment for 58.86 normal force
C. Analysis for 117.7 N normal force

Diameter D 5 mm
Figure 5.9 Deformation for 117.7 normal force
Figure 5.10 Total bending moment for 117.7 normal force
D. Analysis for shaft diameter 10 mm and 58.8 N normal force

Diameter D 10 mm

Fig. shows the Directional Deformation analysis.
Figure. 5.11 Deformation for 10 mm diameter
Figure. 5.12 Bending moment for 10 mm diameter
E. Analysis for shaft diameter 10 mm and 117.7 N normal force
Parameters of shaft Symbol value Unit

Diameter D 10 mm
Length of shaft L 609.6 Mm
Fig. shows the Directional Deformation analysis
Figure. 5.13 Deformation for normal force 117.2 & diameter 10 mm
Figure 5.14 Total Bending moment for normal force 117.2 & diameter 10 mm
5.2. Analysis of upper frame
Upper or top frame of self-cleaning step is analysed for deflection when 60 kg and 120 kg load of
persons acted on it.
Meshing:
 Element type- hexahedron and unstructured grids
 Nodes521
Figure 5.15 Meshing of upper frame
A. Analysis for 60kg load and Structural steel S355
Table 5.6 Parameter for 588.6 N force & structural steel
Parameters of frame Symbol value Unit

Length L 609.6 mm
Width B 260 mm
Height H 50 mm
Thickness T 5.69 mm
Force N 588.6 N
Material S355 - -
Modulus of elasticity E 210x MPa
Yield tensile strength Syt 355 MPa
Ultimate tensile strength Sut 470 MPa
i) Deflection of frame
Fig. shows deflection of frame when 60 kg of load acts on it. maximum deflection of frame is 2.241
which is shown by red colour.
Figure 5.16 Deflection of upper frame for 60 kg weight and structural steel
B. Analysis for 120kg load and Structural steel S355


Length L 609.6 mm
Width B 260 mm
Height H 50 mm
Thickness T 5.69 mm
Force N 1777.2 N
Material S355 - -
Figure 5.17 Deflection of upper frame for 120 kg weight and structural steel
ii) Factor of safety
Here we are find out safety factor for 120 kg load and safety margin as well so that our frame is safe
even if 120 kg of person will pass over the.
Factor of safety for 120kg load is 2.46 as shown in below Figure.
Figure 5.18 Factor of safety for 120 kg weight and structural steel
iii) Safety margin
Fig. shows safety margin for 120kg load which is 1.46
Figure 5.19 Safety Margin for 120 kg weight and structural steel
C. Analysis for 60kg load and Aluminium 1100
Table 5.8 Parameter for 588.6 N force & Aluminium-1100

Length L 609.6 mm
Width B 260 mm
Thickness T 5.69 mm
Height H 50 mm
Force N 588.6 N
Material Aluminium 1100 - -
Figure 5.20 Deflection of upper frame for 60 kg weight and aluminium-1100
D. Analysis for 120kg load and Aluminium 1100

Length L 609.6 mm
Width B 260 mm
Thickness T 5.69 mm
Height H 50 mm
Force N 1777.2 N
Fig. shows deflection of frame when 120 kg of load acts on it. maximum deflection of frame is 13.64 mm which
is shown by red colour.
Figure 5.21 Deflection of upper frame for 120 kg weight and aluminium-1100
Factor of safety for 120kg load is 0.52 as shown in below Figure.
Figure 5.22 Factor of Safety for upper frame for 120 kg weight and aluminium-1100
iii)Safety margin
Fig. shows safety margin for 120kg load which is -0.47
Figure 5.23 Safety Margin for upper frame for 120 kg weight and aluminium-1100
5.3. Analysis of lower frame
Lower or bottom frame of self-cleaning step is analysed for deflection when 60 kg and 120 kg load of
persons acted on it.
Meshing:
 Element type- tetrahedron
 Nodes-4018
Figure 5.24 Meshing of lower Frame
A. Analysis for 60kg load and Structural steel S355
Table 5.10 Parameter 588.6 N force & structural steel

Length L 609.6 mm
Width B 260 mm
Thickness T 5.69 mm
Height H 100 mm
Force N 588.6 N
Material Structural steel S355 - -
Figure 5.25 Deflection of lower Frame for 60 kg weight and structural steel
B. Analysis for 120kg load and Structural steel S355

Length L 609.6 mm
Width B 260 mm
Thickness T 5.69 mm
Height H 100 mm
Force N 1777.2 N
Material Structural steel S355 - -
mm which is shown by red colour.
Figure 5.26 Deflection of lower Frame for 120 kg weight and structural steel
Factor of safety for 120kg load is as shown in below Figure.
Figure 5.27 Factor of Safety for lower Frame for 120 kg weight and structural steel
iii) Safety margin
Fig. shows safety margin for 120kg load which is 1.29
Figure 5.28 Safety Margin for lower Frame for 120 kg weight and structural steel
C. Analysis for 60kg load and Aluminium 1100

Length L 609.6 mm
Width B 260 mm
Thickness T 5.69 mm
Height H 100 mm
Force N 1777.2 N
Ultimate tensile Sut 110 MPa
strength
Fig. shows deflection of frame when 60 kg of load acts on it. maximum deflection of frame is 1.07 mm which is
shown by red colour.
Figure 5.29 Deflection of lower Frame for 60 kg weight and Aluminium-1100
D. Analysis for 120kg load and Aluminium 1100

Length L 609.6 mm
Width B 260 mm
Thickness T 5.69 mm
Height H 100 mm
Force N 1777.2 N
Ultimate tensile Sut 110 MPa
strength
Fig. shows deflection of frame when 120 kg of load acts on it. maximum deflection of frame is 3.23 mm which
is shown by red colour.
Figure 5.30 Deflection of lower Frame for 120 kg weight and Aluminium-1100
Factor of safety for 120kg load is as shown in below Figure.
Figure 5.31 Factor of Safety for Lower frame for 120 kg weight and Aluminium-1100
iii) Safety margin
Fig. shows safety margin for 120kg load which is -0.3111 mm
Figure 5.32 Safety margin for Lower frame for 120 kg weight and Aluminium-1100
6. VALIDATION
Validation is comparison of analytical results with CAD results. Analytical results obtained above
are compared with Ansys results.
6.1. Validation of Results for Shaft
Table 6.1 Analytical calculations and Ansys solution of shaft deflection for various diameters
Diameter of Deflection in mm at Deflection at

shaft in mm force force
-58.8 N (60 Kg weight) -117.2 N (120 Kg weight)
Analytical ANSYS Analytical ANSYS
5 -46.92 -46.95 -93.53 -93.54

5.5 -32.04 -32.08 -63.87 -63.88
6 -22.62 -22.65 -45.09 -45.08
6.5 -16.42 -16.42 -32.74 -32.76
7 -12.21 -12.22 -24.34 -24.35
7.5 -9.26 -9.28 -18.47 -18.45
8 -7.15 -7.16 -14.26 -14.27
8.5 -5.61 -5.62 -11.19 -11.20
9 -4.46 -4.42 -8.90 -8.92
9.5 -3.59 -3.60 -7.11 -7.18
10 -2.93 -2.94 -5.95 -5.97
10.5 -2.41 -2.42 -4.80 -4.81
11 -2 -2.01 -3.99 -4
11.5 -1.67 -1.68 -3.34 -3.36
12 -1.41 -1.40 -2.81 -3.80
12.5 -1.2 -1.21 -2.39 -2.41
13 -1.026 -1.03 -2.04 -2.05
13.5 -0.882 -0.85 -1.75 -1.77
14 -0.763 -0.77 -1.52 -1.52
14.5 -0.663 -0.67 -1.32 -1.33
15 -0.579 -0.58 -1.15 -1.16
Graph 6.1 Deflection verses diameter of shaft for 60 kg
ANALYTICAL & ANSYS RESULTS
-50
-45
-40
-35
DEFLECTION (mm)
-30
analytical ansys
-25
-20
-15
-10
-5
0
10.5
11.5
12.5
13.5
14.5
5
9
7.5
11
5.5
6.5
8.5
9.5
10
12
13
14
15
DIAMETER (mm)
Graph 6.2 Deflection verses diameter of shaft for 120 kg

-100
-90
-80
-70
DEFLECTION (mm)
-60
analytical ansys
-50
-40
-30
-20
-10
0
10.5
11.5
12.5
13.5
14.5
5
9
5.5
6.5
7.5
8.5
9.5
10
11
12
13
14
15
DIAMETER (mm)
Table 6.2 Validation of Analytical and Ansys Results of shaft deflection for various diameters and length l/2
Diameter of Deflection in mm at force Deflection in mm at

shaft in mm -58.8 N & Length 309.4 mm force -117.2 N & Length 309.4mm
Analytical ANSYS Analytical ANSYS
5 -5.87 -5.88 -11.69 -11.70

5.5 -4.01 -4.011 -7.98 -7.99
6 -2.83 -2.84 -5.63 -5.64
6.5 -2.05 -1.53 -4.092 -3.05
7 -1.52 -1.53 -3.04 -2.31
7.5 -1.16 -1.17 -2.30 -2.30
8 -0.89 -0.90 -1.78 -1.79
8.5 -0.70 -0.71 -1.39 -1.35
9 -0.559 -0.56 -1.11 -1.14
9.5 -0.450 -0.46 -0.896 -0.895
10 -0.36 -0.37 -0.73 -0.74
10.5 -0.302 -0.303 -0.60 -0.61
11 -0.25 -0.26 -0.495 -0.491
11.5 -0.20 -0.21 -0.413 -0.415
12 -0.177 -0.178 -0.355 -0.354
12.5 -0.150 -0.151 -0.259 -0.260
13 -0.128 -0.129 -0.258 -0.256
13.5 -0.110 -0.111 -0.214 -0.216
14 -0.095 -0.094 -0.190 -0.191
14.5 -0.083 -0.084 -0.168 -0.169
15 -0.0275 -0.0276 -0.143 -0.142
Graph 6.3 Deflection Verses Diameter of Shaft for 60 Kg load for centrally supported shaft

-6
-5
DEFLECTION (mm)
-4
-3
analytical ansys
-2
-1
10.5
11.5
12.5
13.5
14.5
5
9
5.5
6.5
7.5
8.5
9.5
10
11
12
13
14
15
DIAMETER (mm)
Graph 6.4 Deflection Verses Diameter of Shaft for 120 Kg for Centrally Supported Shaft

-14
-12
-10
DEFLECTION (mm)
-8
-6
analytical ansys
-4
-2
0
14.5
10.5
11.5
12.5
13.5
5
9
9.5
12
5.5
6.5
7.5
8.5
10
11
13
14
15
DIAMETER (mm)
Table 6.3 Results obtained for various loading conditions and dimensions in design and modelling section
Parameter Force Diameter Analytical results Ansys results

(N) (mm)
Bending
moment 588.6 5
(Nmm)
A
Twisting
moment 588.6 5 718.66 735
(Nmm)
Max
Deflection 588.6 5 -469.6 -470
(mm)
Max
B Deflection 58.8 5 -47 -46.97
(mm)
Bending
moment 58.8 5
(Nmm)
Max
Deflection 117.2 5 -93.62 -93.95
C (mm)
Bending
moment 117.2 5
(Nmm)
Max
Deflection 58.8 10 -2.93 -2.93
D (mm)
Bending
moment 58.8 10
(Nmm)
Max
Deflection 117.2 10 -5.58 -5.87
E (mm)
Bending
moment 117.2 10
(Nmm)
6.2. Validation of Results for Frame
Table 6.4 Result table for 60kg and 120 kg load and different material of shaft
Upper Frame Bottom Frame
Material Parameter
60kg 120kg 60kg 120kg
Structural Steel Deflection of 2.24 4.48 0.369 1.11

S355 Shaft (mm)
Factor of 4.93 2.46 6.93 2.29

Safety
Safety Margin 3.93 1.46 5.93 1.29
Aluminium Deflection of 6.82 13.62 1.07 3.23

1100 Shaft(mm)
Factor of 1.04 0.52 2.08 0.68

Safety
Safety Margin 0.04 -0.47 1.08 -0.31
Graph 6.5 Deflection, factor of safety and safety margin for structural steel at 60kg and 120kg load
UPPER FRAME
6
4
DEFLECTION
3
SAFETY FACTOR
2 SAFETY MARGIN
0
60 120
Graph 6.6 Deflection, factor of safety and safety margin for aluminium at 60kg and 120kg load
UPPER FRAME
15
10
DEFLECTION
5 SAFETY FACTOR
SAFETY MARGIN
0
60 120
-5
Graph 6.7 Deflection, factor of safety and safety margin for structural steel at 60kg and 120kg load
LOWER FRAME
8
7
6
5 DEFLECTION
4
SAFETY FACTOR
3
SAFETY MARGIN
2
1
0
60 120
Graph 6.8 Deflection, factor of safety and safety margin for aluminium at 60kg and 120kg load
LOWER FRAME
3.5
3
2.5
2 DEFLECTION
1.5 SAFETY FACTOR
1 SAFETY MARGIN
0.5
0
-0.5 60 120
7. CONCLUSION
i. From graph.6.1 and graph.6.2 it is conclude that when 60 and 120kg of load acts on shaft,
deflection is -46.97 and -93.95mm respectively when diameter of shaft is 5mm, Which is too much
from design view and not acceptable.
ii. From graph.6.1 and graph.6.2 it is conclude that, when diameter of shaft increases strength of shaft
also increases. i.e. when D=10 mm, deflection is -2.93 and -5.87 mm for 60 &120 kg load
respectively, Which is acceptable.
iii. From graph.6.3 and graph.6.4 it is conclude that, when shaft is supported centrally by bearing, load
on shaft is equalised. Hence deflection of shaft is minimum. Hence shaft can also be optimise by
selecting the diameter 6 mm with central bearing support, which gives deflections -2.84 and -5.63 mm
for 60kg & 120 kg respectively cut down excessive material cost with optimum performance.
iv. If 10 mm diameter shaft is used, then deflection is -2.93 & -5.87mm for 60kg and 120kg load,
hence clearance between sole of shoe and bristles is -2.93 or -5.87, which is acceptable. So we can
select bristles with medium stiffness (i.e. not so hard and not so soft) which effectively removes cleats
or dust particles from shoe.
v. For optimisation purpose i.e. minimizing excessive material, optimum performance and cost
cutting, shaft diameter should not be too larger or too small. Small diameter may cause more
deformation and larger diameter causes excessive material costing.
vi. From graph.6.5 it is conclude that, when 60kg and 120 kg load acting on upper frame, deflection of
frame is 2.24 and 4.82 mm, safety factor is 4.93 and 2.46, safety margin is 3.93 and 1.46 respectively
for structural steel S355. I.e.120kg and above load of person can passed over the step easily without
any trouble.
vii. From graph.6.6 it is conclude that, when 60kg and 120 kg load acting on upper frame, deflection
of frame is 6.82 and 13.64 mm, safety factor is 1.04 and 0.52, safety margin is 0.04 and -0.47
respectively for aluminium- 1100. In this case value of safety margin is negative i.e. we cannot
consider excessive load more than 120kg, and step will fail if load above 120kg act on it. So selection
of aluminium for fabrication of frame is not safe.
viii. From graph.6.7 it is conclude that, when 60kg and 120 kg load acting on lower frame, deflection
of frame is 0.369 and 1.11 mm, safety factor is 6.93 and 2.29, safety margin is 5.93 and 1.29
respectively for structural steel S355. I.e.120kg and above load of person can passed over the step
easily without any trouble.
ix. From graph.6.8 it is conclude that, when 60kg and 120 kg load acting on upper frame, deflection of
frame is 1.07 and 3.23 mm, safety factor is 2.08 and 0.68, safety margin is 1.08 and -0.31 respectively
for aluminium- 1100. In this case value of safety margin is negative i.e. we cannot consider excessive
load more than 120kg, and step will fail if load above 120kg act on it. So selection of aluminium for
fabrication of frame is not safe.
x. From point.3.2 it is conclude that, Stiffness of spring 4.73 N/rad can be selected to hold and retain
the upper frame at its original position (upper frame held incline at )
xi. From point.3.3 it is conclude that, more the diameter of pinion lesser the rotation of shaft. Also if
18 numbers of teeth on pinion are selected then it will rotate 8 revolutions for one complete revolution
of sector gear. For 18 teeth pinion diameter pinion is 20 mm having 2 complete revolution for 1/4th
portion of sector gear.
xii. From point.3.5 it is conclude that, deep groove ball 6300 is best suitable for shaft diameter 10 mm
having safety factor 2.93 for 120kg load, its compactness and performance characteristics are up to
the mark.
xiii. From Point.3.6 it is conclude that, Polypropylene bristles are wet or dry, durable and provide
good abrasion resistance and shear/break strength, resulting in longer product life. They are best for
medium to heavy floor sweeping, Polypropylene bristles are more flexible than corn bristles. Therefor
polypropylene bristles are suitable for self-cleaning step fabrication.
APPENDIX
Factor of Safety
is selected for describing the load carrying capacity of a system beyond the expected or actual loads
Safety Margin
Many government agencies and industries (such as aerospace) require the use of a margin of
safety (MoS or M.S.) to describe the ratio of the strength of the structure to the requirements. There
are two separate definitions for the margin of safety so care is needed to determine which is being
used for a given application. One usage of M.S. is as a measure of capacity like FoS. The other usage
of M.S. is as a measure of satisfying design requirements (requirement verification). Margin of safety
can be conceptualized (along with the reserve factor explained below) to represent how much of the
structure's total capacity is held "in reserve" during loading. [21]
This is a measure of excess capacity. If the margin is 0, the part will not take any additional load
before it fails, if it is negative the part will fail before reaching its design load in service. If the margin
is 1, it can withstand one additional load of equal force to the maximum load it was designed to
support (i.e. twice the design load). [21]
Gauge
Sheet metals thickness generally express in gauge.
Use of Gauge to designate sheet metal thickness is discouraged by numerous international standards
organizations. For Example, ASTM states in specification ASTM A480-10a "The use of gage number
is discouraged as being an archaic term of limited usefulness not having general agreement on
meaning." Manufacturers' Standard Gauge for Sheet Steel is based on an average weight of 41.82 lb
(18.96 kg) per square foot per inch thick. Gauge is defined differently for ferrous (iron-based) and
non-ferrous metals. [9]
Table- Gauge Catalogue for sheet metal
Tetrahedron
Tetrahedral elements are the default element type for most physics. Tetrahedral are also known as
a simplex, which simply means that any 3D volume, regardless of shape or topology, can be meshed
with tets. They are also the only kind of elements that can be used with adaptive mesh refinement.
For these reasons, tets can usually be your first choice. Tetrahedron (the vertices and edges) form
a graph, with 4 vertices, and 6 edges.[25]
Figure. Tetrahedron
Hexahedron
Triangles in two dimensions generalize to tetrahedral in three. The corresponding generalization of a

quadrilateral is a hexahedron, also known in the finite element literature as brick. A hexahedron is
topologically equivalent to a cube. It has 8 corners, 12 edges or sides, and 6 faces. Finite elements
with this geometry are extensively used in modeling three-dimensional solids. [26]
Figure. Hexahedron
Unstructured Grids
An unstructured (or irregular) grid is the tiling (arrangement) of part of two or bi-dimensional simple
shapes, such as triangles or tetrahedral, in an irregular pattern. Grids of this type may be used in finite
element analysis when the input to be analysed has an irregular shape.[27]
Figure. Unstructured Grids
FUTURE SCOPE
Current study is focus on design of self-cleaning step by mathematical formulation for basic
constrains and their analysis using CAD software‟s Techniques. Thus future study can be carried out
on practical model to analyse its performance at different locations.
References
1. Soung Kiy Min. (27. May 1999). Shoe cleaning device. US6105201 A
2. William Hollander (12 Feb 2009). Spike/shoe cleaner. US20090038096 A1
3. Shousong Bai. (22 Mar 2012). Shoe Cleaning Apparatus US 20120066847 A1
4. Paul Counts (3 Oct 1960). Shoe cleaner US 3048867 A
5. Lodhi, Veerendra Singh; Jain, Prof. A.K. (30 April 2014). "A Review of Experimental Study of Spring
Back Effect of Aluminum Sheet Metal". International Journal of Engineering Research and Science &
Technology (IJERST). College Jabalpur (M P), India: Academia.edu. 3 (4): 2. doi:10.7763/IJET.
ISSN 2277-9655. Retrieved 14 July 2015.
6. NA to BS EN 1993-1-10: 2005, UK National Annex to Eurocode 3: Design of steel structures.
Material toughness and through-thickness properties.
7. Frederick S. Merritt et. al, 2001. Building Design and Construction Handbook, 6th ed., McGraw Hill.
8. R.Barry,1992, The Construction of Building,Vol. 2, 5th ed, Blackwell Science Ltd.
9. NUTRIENT REQUIREMENTS AND RECOMMENDED DIETARY ALLOWANCES FOR INDIANS, A Report of
the Expert Group of the Indian Council of Medical Research 2009, NATIONAL INSTITUTE OF NUTRITION
,Indian Council of Medical Research Jamai-Osmania PO, Hyderabad – 500 604
10. Dr.ir. Anton van Beek, Design for lifetime performance and reliability (2010, October 29)
Retrieved from http://www.tribology-abc.com/calculators/t14_4.htm
11. Suriray, "Perfectionnements dans les vélocipèdes" (Improvements in bicycles), French patent
no. 86,680, issued: August 2, 1869 , Bulletin des lois de la République française (1873),
series 12, vol. 6, page 647.Louis Baudry de Saunier, Histoire générale de la
vélocipédie [General history of cycling] (Paris, France: Paul Ollendorff, 1891)
12. David M. Foy (2 February 2012). Great Discoveries and Inventions by African-Americans:
Fourth Edition. AuthorHouse. pp. 63–64. ISBN 978-1-4685-2435-2.
13. "Spring Hinges". Guden. Retrieved 15 December 2016.
14. Norton, R. L. “Machine design: an integrated Approach”, third edition, 2006 (Pearson Education,
Upper Saddle River, NJ)
15. Dr.ir. Anton van Beek, Design for lifetime performance and reliability (2010, October 29)
Retrieved from http://www.tribology-abc.com/calculators/t14_4.htm
16. Beer, Ferdinand P.; Johnston, E. Russel, Jr. (1996). Vector Mechanics for Engineers (Sixth
ed.). McGraw-Hill. p. 397. ISBN 0-07-297688-8.
17. Shapiro, Vadim (2001). Solid Modeling. Elsevier. Retrieved 20 April 2010.
18. Manual of Steel Construction, 8th Edition, 2nd revised printing, American Institute of Steel
Construction, 1987, ch 1 page 1-5
19. Sanjay B Chikalthankar, V M Nandedkar, Surender Kumar Kaundal, „„Stress Analysis and Design
Validation of Crankshafts under Dynamic Loading using CAE‟‟
20. Mavriplis, D.J. (1996), "Mesh Generation and adaptivity for complex geometries and
flows", Handbook of Computational Fluid Mechanics
21. Shigley, J and Mischke, C: Standard Handbook of Machine Design, page 2-15. McGraw-Hill,
1986.
22. SAE aluminium specifications list, accessed 8 October 2006. Also SAE Aerospace Council,
accessed 8 October 2006.
23. Uicker, J. J.; G. R. Pennock; J. E. Shigley (2003). Theory of Machines and Mechanisms. New
York: Oxford University Press.
24. The Grove Encyclopedia of Materials and Techniques in Art, Gerald W. R. Ward. Oxford
University Press, 2008.
25. Murakami, Jun; Yano, Masakazu (2005), "On the volume of a hyperbolic and spherical
tetrahedron", Communications in Analysis and Geometry, 13 (2): 379–400
26. Castillo, J.E. (1991), "Mathematical aspects of grid Generation", Society for Industrial and applied
Mathematics, Philadelphia
27. Robinson, Raphael M. (1971). "Undecidability and nonperiodicity for tilings of the plane.
LIST OF PUBLICATIONS
1. . Jayesh A.More, Dr.S.D.Suryawanshi, Indian Patent 172/MUM/201621000959 [SELF CLEANING

STEP], Filed on 30 Dec.2015.
2. Jayesh A.More1, Dr.S.D.Suryawanshi2, N.S.Deshmukh3 -Design and Analysis of Shaft Used in Self-
Driven Step Mechanism by Human Weight in Imperial Journal of Interdisciplinary Research (IJIR-
ISSN: 2454-1362), Published online on Vol-3, Issue-2, 2017

Design, Modeling, Analysis of Self Cleaning Step

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DESIGN, MODELING AND ANALYSIS OF SELF-CLEANING STEP MECHANISM

Figure 1.1 Self-Cleaning Step Mechanism

Figure 2.1 Pneumatically operated Shoe cleaning Device

Figure 2.2 Motor operated Bristles Shoe cleaning Device

Figure 2.3 Motor Operated Roller shoe cleaning Device

Figure 2.5 Bristles Mounted Roller shoe cleaning Device

3.1.1. Material for Frame

i. Stainless steel [6]

ii. Structural steel [18]

Steel Nominal thickness (mm)

iii. Aluminium [5]

 Grade 6061-T6 is a common heat-treated structural aluminium alloy. It is weldable,

-it gives the optimum balance between stiffness and strength.

-it can withstand impact energy of 27J

-it gives maximum yield strength with minimum thickness

3.1.2. Frame Dimensions

Figure 3.1 Stair case Geometry-A

 Tread – horizontal surface of a step

3.1.3. Design For Static Load

Figure 3.2 Stair case Geometry-B

3.1.4. Design of Angle (Ɵ)

Calculation of Angle (Ɵ) for various rise and tread width:

Figure 3.3 Schematic for calculation of angle of rise

a) For 1 inch rise(h)=25.4mm

b) For 2inch rise(h)=50.8mm.

c) For 2.5inch rise(h)=63.3mm

i. Trade width: 260mm

3.2. Design for Torsion Spring[14]

3.2.1. Stiffness calculation [10]

Now calculate stiffness,

Where, k-Stiffness (N/Rad)

D-mean coil diameter-10mm

n-number of active coil

E-modulus of elasticity- for steel

Figure 3.4 Schematic for calculation of spring stiffness

3.3. Design for Gears

Following table shows standard module for reference.

Table 3.2 Standard Module series

Table 3.3 Spur Gear Catalogue for Standard Module

Following are the points to be considered before design of pinions.

For 18 teeth pinion we select standard module of 1 mm from table 3.2

Let number of teeth=18

C= centre distance between shaft= 80 mm

 Therefore module is given by

 Outside diameter of pinion„d‟ is find by,

d=20 mm-----------------(Table 3.3)

 Now find out teeth of sector gear

 Outside diameter of Sector gear „D‟ is find by,

Where, R1-rotation of sector gear

3.4. Design of shaft

3.4.1. Material for shaft

3.4.2. Analytical calculation

I. Design for 60kg direct load acting upon the shaft.

Table 3.4 Design Parameters for Direct 60 Kg load

Figure3.5 Simply Supported Shaft

Conditions -Shaft is supported by bearing

-Point load „P‟ act on centre of shaft

-Material is stainless steel

-Modulus of elasticity E-193X MPA

i) Shear force calculation

S.F. just to right of A=294.29N

S.F. just to left of P=294.29N