1.wallpainting Machine

JIMMA UNIVERSITYJIMMA INISTITUTE OF TECHNOLOGY 6/5/2017
DECLARATION
We hereby declare that the thesis paper titled design of wall painting machine is submitted by
us is based on actual and original work carried out by us. Any reference to work done by any
other person or institute or any material obtained from other sources have been duly cited and
referenced. We further certify that the research paper has not been published or submitted for
publication anywhere else nor it will be send for publication in the future.
DESIGN OF WALL PAINTING MACHINE I

ABSTRACT
Painting started long years before, around 300 B.C [9]. Painting the wall is normally done
manually, which is very difficult and troublesome for humans to work in an upright position and
also not good for eyes, skin and on respiratory system on the painters. Due to fatigue and
surrounding environment, painting might not even all over the wall. To overcome these
difficulties, the wall painting machine has been designed.
The aim of the design of this machine is to minimize the risk of climbing, human fatigue, time and
cost of painting and to maximize the quality of painting. The thesis objective was conducted to
design the wall painting machine. In this objective, the existed machine where assessed and
analyzed, concepts where generated best concept was selected, functional design and strength
analysis of components where performed. Thus the developed machine has frame which supports
all parts of designed machine. Frame parameters are length of 3m, height of 2.8m, and width of
1m. Also some parts of our machine is motor, gear box, wire rope, crank shaft, cylinder, piston
pump, brush, brush holder and tanker. When motor is on the gear box starts to rotate then the
crank shaft also rotates, immediately the piston pump starts to suck the liquid/ink from tanker
through inlet valve and discharges to the brush in outlet valve through the pipe. The wire rope is
tighted to the brush holder and fixed tight to the sheave found on the main shaft. As the main
shaft starts to rotate the rope tighten on the sheave in one end and looses in other ends. This will
cause as the brush holder to move in the grooved way of frame and paints the wall vertically and
paints the roof horizontally. Thus the designed machine was manual control for perfectly
painting and hand switch control for direction of motor rotation.
DESIGN OF WALL PAINTING MACHINE II

ACKNOWLEDGMENTS
Firstly, we would like to thank our Almighty GOD, the most gracious, merciful for his great
merit in fulfill this work.
Secondly, we would like to thank our project advisor, Dr. Anil (PHD) and Mr. Getachew A.
(BSc). Who helped guide us throughout the entire project process and made this project possible.
Thirdly, we would like to thank our families, for encouraging us throughout our collage career
and having faith in us.
DESIGN OF WALL PAINTING MACHINE III

GROUP MEMBERS
No Name of Peer Group ID No Sign
1. Obsinan Girma 01519/05 --------------

2. Gemmechu Tesfaye 01890/04 --------------
3. Tekalign Yemane 01952/05 --------------
4. Jetama Abera 01345/05 -------------
5. Yonas Abdo 02167/05 -------------
6. Getahun Muluneh 01187/05 -------------
Advisor:
Name sign
1) Main advisor: Dr. Anil (PHD) ----------------

2) Coadvisor: Mr. Getachew Admasie (BSc) ----------------
DESIGN OF WALL PAINTING MACHINE IV

TABLE OF CONTENT
Table of Contents
DECLARATION ................................................................................................................................................ I
ABSTRACT...................................................................................................................................................... II
ACKNOWLEDGMENTS .................................................................................................................................. III
GROUP MEMBERS ........................................................................................................................................ IV
TABLE OF CONTENT ...................................................................................................................................... V
LIST OF FIGURE ........................................................................................................................................... VIII
LIST OF TABLES ............................................................................................................................................. IX
NOMENCLATURE AND ABBREVIATIONS ....................................................................................................... X
CHAPTER ONE ............................................................................................................................................... 1
INTRODUCTION ............................................................................................................................................. 1
1.1 BACKGROUND ..................................................................................................................................... 1
1.2 Statement of the problem .................................................................................................................. 2
1.3 Objectives of study.............................................................................................................................. 3
1.3.1 General objectives: ...................................................................................................................... 3
1.3.2 Specific objectives:-...................................................................................................................... 3
1.4 Methodology....................................................................................................................................... 3
1.5 Design and analysis ............................................................................................................................. 4
1.6 Organization of the thesis ................................................................................................................... 4
CHAPTER TWO .............................................................................................................................................. 6
LITERATURE REVIEW ..................................................................................................................................... 6
2.1 Introduction ........................................................................................................................................ 6
2.2 Historical perspective.......................................................................................................................... 6
2.2.1 An automated multicolor system for interior wall painting (2007): ............................................ 6
2.2.2 Conceptual Design of Fixture for Automate Exterior Wall Painting and Design and Analysis
Its Main Component (May 2013): ......................................................................................................... 7
2.3 DESIGN AND FABRICATION OF WALL PAINTING ROBOT USING LEAD SCREW (March 2015): ........... 8
DESIGN OF WALL PAINTING MACHINE V

2.4 The conclusion from literature review................................................................................................ 9

CHAPTER THREE .......................................................................................................................................... 10
RESEARCH METHODOLOGY ........................................................................................................................ 10
3.1 Introduction ...................................................................................................................................... 10
3.2 Function structural of wall painting .................................................................................................. 11
3.2.1 Overall Function ......................................................................................................................... 11
3.2.2 Breaking a Function Down into Sub functions ........................................................................... 12
3.3 Developing Working Structure.......................................................................................................... 12
3.3.1 The component of developing Working Structures ................................................................... 12
3.3.2 The general working principle of wall painting machine ........................................................... 13
CHAPTER FOUR ........................................................................................................................................... 15
4.1 Design and analysis of wall painting machine .................................................................................. 15
4.2 Design of wire rope ........................................................................................................................... 17
4.3 Design of gear box; ........................................................................................................................... 20
4.3.1 Design of Pinion ......................................................................................................................... 20
4.3.2 Design of gear ............................................................................................................................ 23
4.4 Gear bending and wear..................................................................................................................... 25
Result and discussion of the pinion .................................................................................................... 28
4.3.3) design of shaft pinion ............................................................................................................... 29
Result and discussion of the pinion shaft ........................................................................................... 34
4.3.4 Design of main shaft .................................................................................................................. 36
4.3.5 Design of gear box housing ........................................................................................................ 42
4.3.6 Design of key .............................................................................................................................. 44
4.4 Design of piston pump ...................................................................................................................... 46
4.5 Selection of flexible pipe (hose) ........................................................................................................ 51
4.6 Design of crank shaft......................................................................................................................... 52
4.7 Design of coupling ............................................................................................................................. 59
4.8 Bearing selection ............................................................................................................................... 63
4.9 Frame design and analysis ................................................................................................................ 65
CHAPTER FIVE ............................................................................................................................................. 67
5.1 Manufacturing procedure ................................................................................................................. 67
DESIGN OF WALL PAINTING MACHINE VI

5.2 Cost Estimation ................................................................................................................................. 69

5.2.1 Cost of materials .............................................................................................................. 69
5.2.2 Manufacturing cost (CM) Estimation ................................................................................... 73
Conclusion ................................................................................................................................................... 74
Recommendation........................................................................................................................................ 75
REFERENCE .................................................................................................................................................. 76
Appendix ..................................................................................................................................................... 77
Appendix A -1 List of Tables Required .................................................................................................... 77
Appendix A – 2) The Graph We Used...................................................................................................... 87
Appindex B: Detail of part drawing. ........................................................................................................ 89
Appindex C: Assemble of wall painting machine (3D) .......................................................................... 100
DESIGN OF WALL PAINTING MACHINE VII

LIST OF FIGURE
Figure 4. 1 wall painting machine............................................................................................................... 15
Figure 4. 2 wire rope ................................................................................................................................... 17
Figure 4. 3 pinion gear ................................................................................................................................ 20
Figure 4. 4 gear ........................................................................................................................................... 23
Figure 4. 5 The diagram of deformation and maximum shear stress for pinion ......................................... 29
Figure 4. 6 The deformation and shear stress analysis diagram for gear .................................................... 29
Figure 4. 7 pinion shaft ............................................................................................................................... 29
Figure 4. 8 Diagram of bending moment for vertical load ......................................................................... 31
Figure 4. 9 Diagram of bending moment for horizontal load ..................................................................... 33
Figure 4. 10 Diagram of resultant bending moment for pinion shaft ......................................................... 33
Figure 4. 11 The diagram of ideal diameter of pinion shaft........................................................................ 34
Figure 4. 12 Diagram of the maximum and minimum deformation and shear stress ................................. 35
Figure 4. 13 main shaft ............................................................................................................................... 36
Figure 4. 14 Diagram of the bending moment for vertical load.................................................................. 38
Figure 4. 15 Diagram of bending moment for horizontal load .................................................................. 39
Figure 4. 16 Diagram of resultant bending moment for load ...................................................................... 40
Figure 4. 17 Diagram of ideal gear shaft .................................................................................................... 41
Figure 4. 18 Diagram of the maximum and minimum deformation and shear stress ................................. 42
Figure 4. 19 3D gear box and housing half view ........................................................................................ 42
Figure 4. 20 The key for pinion shaft.......................................................................................................... 44
Figure 4. 21 The key for main shaft for gear and sheave ............................................................................ 45
Figure 4. 22 the piston rod .......................................................................................................................... 46
Figure 4. 23 crank shaft .............................................................................................................................. 52
Figure 4. 24 coupling .................................................................................................................................. 60
Figure 4. 25 Bearing ................................................................................................................................. 63
Figure 4. 26 Wall painting machine frame. .............................................................................................. 65
Figure 4. 27 legs of frame ........................................................................................................................... 66
VII
LIST OF TABLES
Table 1 the application wire rope ................................................................................................................ 77
Table 2 the safety factor of our rope ........................................................................................................... 77
Table 3 the property of wire rope, nominal diameter and weight of rope................................................... 78
Table 4 the diameter of wire and area of wire ............................................................................................ 78
Table 5 the sheave diameter of wire rope ................................................................................................... 79
Table 6 the table of allowable static stress .................................................................................................. 79
Table 7 the table of elastic coefficient of gear ............................................................................................ 80
Table 8 the table of deep groove and angular contact ball bearing ............................................................. 80
Table 9 The table of flexible coupling ....................................................................................................... 81
Table 10 the table of hose (pipe) ................................................................................................................. 82
Table 11 Material property of the given for structure (frame). ................................................................... 82
Table 12 the formula for beam and column. ............................................................................................... 83
Table 13 specified motor selection. ............................................................................................................ 84
Table 14 the application of motor ............................................................................................................... 84
Table 15 table of the constant value............................................................................................................ 85
Table 16 selection of pinion gear teeth ....................................................................................................... 85
Table 17 uniform load factor ...................................................................................................................... 86
Table 18 reliability factor............................................................................................................................ 86
Table 19 Physico-chemical properties of produced paints ......................................................................... 86
DESIGN OF WALL PAINTING MACHINE IX

NOMENCLATURE AND ABBREVIATIONS
Design load for wire rope
Power
Area of wire rope
Torque
Diameter of wire rope
Angular speed
Weight of rope
Number of tooth on pinion
Diameter of sheave
A fraction by which standard addendum of the wheel should be multiplied
Bending stress
Gear ratio or velocity ratio
Equivalent bending load
Pressure angle or angle of obliquity
Angular speed on shaft
Pitch line velocity
Angular speed on sheave
Module
Speed of wire rope
DESIGN OF WALL PAINTING MACHINE X

Tangential tooth load
Additional load due to acceleration
Velocity factor for cut tooth
Impact load during starting
Tooth form factor for pinion
Effective load during normal working on the wire rope
Tooth form factor for gear
Actual safety factor during normal working
Diametral pitch
Effective load on rope during starting
Pitch diameter
Actual safety factor during starting
Circular pitch
Outer diameter
Reliability factor
Addendum
Backup ratio
Dedendum
Bending factor of safety
Tooth thickness
Allowable bending stress
DESIGN OF WALL PAINTING MACHINE XI

Working depth
Fillet radius at root
Clearance
Whole depth
Normal force
Radial force
Pitch line velocity
Root diameter
Face width
Number of revolution in rpm
Center distance
Dynamic factor
Size factor
Face load distribution factor
Rim thickness factor
Bending strength geometry factor
Hardness ratio factor
Stress cycle factor
Crushing tensile strength
Shear stress
Viscosity
DESIGN OF WALL PAINTING MACHINE XII

Density
Flow rate
t Thickness of the paint
Diameter of the pipe
Pressure in the pipe
Motion of piston in the cylinder or length of stroke
Thickness of cylinder head
Force acting on studs
Number of stud
Resistance force offered by stud
Force extracted
Mass of connecting rod
Maximum bending moment
Direct stress
Diameter of crank pin
Twisting moment on the crankshaft
Equivalent twisting moment
Diameter of the shaft at the juncture of the right hand crank arm
Bending moment at the juncture of the right hand crank arm
Diameter of hub
XII
Pitch circle diameter of bolts on flange
Diameter of bolts
Outer diameter of flange
Thickness of ranger protective
Length of bush in the flange
Number of bolts
Diameter of bush
Expected life of bearing
Equivalent load
Dynamic load rating
Cost of material
Manufacturing cost
Direct labor cost
Manufacturing overhead cost
Total cost
XI
DESIGN OF WALL PAINTING MACHINE V
CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND
The paint is one of the improvements through in long period of time [5]. The oldest evidence of
painting was left by primitive peoples. During the period 3000–600 BC. Many paint-making
advances were made by the Egyptians. They not only developed pigments with a wider range of
colors but are also credited with producing the first synthetic pigment (Egyptian Blue) and
developing the first lake pigments. Preservative paints and varnishes were also used during this
time. Drying oils as part of varnishes were used during the period 600 BC – 400 AD by the
Greeks and Romans. In the tenth century AD, Theophilus describes a varnish made by heating
amber resin with linseed oil. Varnish was used to protect painting on wood during the middle
Ages. Pigments were suspended in a varnish like the one described by Theophilus in order to
make a more durable paint [6].
For hundreds of years, paint formulations were handed down from one generation to the next and
were often carefully guarded. Paints were produced in small batches, with the procedure being a
relatively expensive one and the product not affordable to many. However, the demand for paint
became great enough that by the late eighteenth and early nineteenth century it became profitable
to make paint for wider consumption. The first paint and varnish factories were established
during the nineteenth century [6].
The industrial revolution and the mass production of the automobile strongly influenced the
growth of the paint industry. The need for anti-corrosive coatings as well as other special-
purpose coatings helped to accelerate the rate of scientific discovery. Titanium dioxide, the white
pigment that would replace white lead, was introduced in 1918. After the middle of the twentieth
century, the natural oils that had been used in paint formulations were replaced by synthetic
DESIGN OF WALL PAINTING MACHINE 1

resins. Today’s painting manufacturers offer a wide variety of products for beautifulness of
house and make more comfortableness.
In the later part of the twentieth century, society’s growing environmental awareness has
presented a new challenge to the paint and coatings industry to produce coating products that
meet the demands of manufacturers and consumers and at the same time comply with the
government environmental constraints. Certain chemicals have been shown to be toxic and
hazardous to humans and/or the environment.
Generally, most of material around us painted, that described how various applicable. From those
application we selected for the construction, which the wall and roof can be paint, in order to
reduce labor force, reduce cost, increase time consume, and high quality of the paint. For this
reason we need to design the machine to paint the wall and roof
1.2 Statement of the problem
We have seen many problems from previously designed and developed wall painting machine.
The painting chemicals can cause hazards to the human painters such as eye and respiratory
system problems. Also the nature of painting procedure that requires repeated work and hand
rising makes it boring, time and effort consuming. For beautiful, coating and reduce the crack of
the wall painting is needed. In our country there is no enough technology to wall panting and
available in the world are not easly obtained because of their cost and damage the respiratory
system with the spray wall painting and other its own effect. The other problem in our country is
lack of technology which producing the product used for the wall painting. So, in this paper
design the method for wall painting to reduce the above defects of machine.

1.3 Objectives of study

1.3.1 General objectives:
 Design the wall painting machine used for painting the wall and roof properly.
1.3.2 Specific objectives:-
 Undertake simulation of sample using Autodesk Inventor.

 Conduct part analysis of the mechanism by using simulation and analysis by ANYSIS
software
 Design and specification of main part.
 Prepare general working document as guideline for demonstration of a wall painting
device.
1.4 Methodology
By assessing existing wall painting system designs, through collecting relevant data’s,
making a trough strength analysis of all load carrying elements of the wall painting, by
selecting suitable materials considering all the economic, ergonomic and safety
characteristics, we design the wall painting machine. This includes design of rope, design
of gear box, design of shaft, design of key, design of piston pump, design of crank shaft ,
selection of flexible pipe, etc. and design part and assemble by INVENTOR and analysis
using ANYSIS and finally by making a reasonable cost analysis we design the wall
painting machine.
Literature collection input data

 Identification of the type painting device mostly used by users which used to study their
property.
 Study the physical property like strength, length,content weight , their cost etc.
 Discribe the effect of those physical property on the full process.

 Study the profitability by comparing the amount of wall painting can produce(m3/s) with
loss by time, energy and etc. Based on this profit we can decide the specification like input
energy (to know the amount of total power need),input material, speed and etc
1.5 Design and analysis
In this project we try to calculate the dimension of every parts, speed of movable parts
,maximum force applied on the parts, bending and shearing effects and their diagrams.
Some of works are:-
 Selection of material which can be obtained in our country.
 Evaluate the alternative mechanisms.
 Calculate the maximum force the material can stand without failure.
 Calcute the dimension of parts.
 Selection of standard material which we get from market like: bearing, sealing, etc.
 Identify the source of input power.
1.6 Organization of the thesis
The thesis is divided into five chapters, an introduction to the wall painting machine which
contains background, statement of problem, objective study and methodology is described in
Chapter One. Chapter Two explains the Literature review of wall painting systems. The next
Chapter deals with the idea generation of design of wall painting system. Design each part and
analyzing, and simulation of the existing and proposed methods is carried out in Chapter Four.
Results are interpreted in this chapter. In the chapter five there are manufacturing procedures and
cost analysis. Finally, the conclusions drawn from this thesis work and the recommendations for
the future work in this chapter.

Summarized organization of the thesis is as follows:
chapter three
chapter one chapter two
concept
introduction literatureview generation
chapter five
chapter four
manufacturing procedure, cost
design and
analysis, conclusion and
analysis
recommendation
Chart 1.1: The hierarchy of the organization of the thesis.

CHAPTER TWO
LITERATURE REVIEW
2.1 Introduction
There are many research have been done on wall painting systems but yet they are not safe and
time consuming design. But in our design we have done as it not consume time, safe (i.e. not
hazardous on human health/operators), reduce product cost, durability/life span.
2.2 Historical perspective
The following is a summary of the most important aspects of the explored literature and their
draw back at the end.
2.2.1 An automated multicolor system for interior wall painting (2007):
In this paper ,the designers Berardo Naticchia & et al. have first the issue of a new
miniature laboratory for developing light weight and well-coordinated robotized systems
is pursued, then a novel robot device for high quality multi-colour interior wall painting
carried by a robot arm is developed and successfully tested. Their new multicolour
spraying end-tool was developed and fixed on the robot arm, in order to be able to
reproduce coloured artworks.
Mechanisms
The mechanisms involved in the equipment are for the following functions:
Suction and pouring of colors
This mechanism is used to select the appropriate amount of color into the syringe and pouring it
into the mixing vessel. This uses a rack and pinion arrangement of gears attached to it at the end
of the syringe.
Lifting and dipping of colors

This is used to lift up or down the syringe in the appropriate colored container. This also uses a
rack and pinion arrangement. This does not depend upon the number of teeth present in the gear.
Mixing of colors
This is used to select the color and mixing tem by agitating. This uses a high torque motor for
fast agitation ant precise rotation. [5]
Figure 2. 1 The color compartments
The problems we have seen from this project:

 This design contains roboting systems (contain several joints) which have high cost.
 Complex structure and it require high torque.
 Since it related to computer program it difficult for every individual people to operate.
 It is also related with coloured line sensing device which makes the design complex.
 The painting method is in spraying form which will affect human health.
2.2.2 Conceptual Design of Fixture for Automate Exterior Wall Painting and Design and Analysis
Its Main Component (May 2013):
Jitendra N. Shelar & Prof. N. R. Gilke has developed this project with the objective to
designing of fixture for automated spray painting of building wall. Basically this fixture is design
to paint outside wall of a building. Fixture is placed on top of tare ace wall and fixture is used to
give vertical and horizontal motion to color pipe. It consists of two motors of which one is
attached to lead screw for horizontal forward and backward motion. Other motor is attached to
gear for vertical upward and downward motion of color pipe. Generally, it will reduce the cost
and time of painting considerably as compare to manual painting. Analysis shows that lead screw
is adequate to use in fixture. [6]

The problems we have interpretation from this project is:

 In this design it has many components which needs more cost.
 Since it required two Dc motor it need high cost and more safety.
 The painting method is in spraying form which will affect human health.
 Also contains fixture components.
2.3 DESIGN AND FABRICATION OF WALL PAINTING ROBOT USING

LEAD SCREW (March 2015):
In this paper the researchers Selvamarilakshmi D et al. have made a robot which comprises of a
set of heavy load capacity wheels moving along a railing and a pulley mechanism. Their design
involves using a spray gun painting mechanism that moves vertically with the help of a lead
screw from a platform mounted on a horizontal railing. Painting is achieved by the horizontal
movement of the platform coordinated with the vertical movement of the lead screw attached
with the spray gun, thus covering the plane of the wall in a zigzag manner. The robot also
employs IR sensing to differentiate between the surface of the wall and other furniture. [7]
Figure 2. 2Full Design of Painting Robot

The interpretation (problems) we have seen from this project:

 In this design the robot is comprises from heavy load which short life span.
 The method proposed here applies only for buildings with flat wall surfaces. If buildings
of complex shapes were to use this method, complicated railing shapes should be called
to play.
 The covering plane of the wall in a zigzag manner which causes no similar painting wall.
 In this design it has many components which needs more cost.
 The painting method is in spraying form which will affect human health.
2.4 The conclusion from literature review
Since the painting is vaster in the world it can be done in simple way in order to lead with
technology and fulfill the good and best quality of wall painting. But in our country, it’s a big
problem in the construction section because of lack of technology, high cost of related wall
painting and safety problems. Therefore, low quality of painting, high labor force, it consumes
time; climbing risks and etc. Depending on these problems, we generate idea in order to improve
these problems; we try to design the wall painting machine.

CHAPTER THREE
RESEARCH METHODOLOGY
3.1 Introduction
The main objective of this thesis is to design and manufacture the wall painting machine in order
to solve the community problem. There are some options to paint the wall and roof. Those are:-
By gun spray
By hand with brush (by human) and
By wall painting machine
A) By the gun spray:
It is possible to paint wall by using spray like paint the furniture and shaped metal. It used the
motor to pressurize the paint and it can be handling by painter in hand. During spray the paint to
wall there is the draw back with it:-
 It damages the respiratory system during the inhalation in breathing system.

 It also damages the skin and other body like eye, hand, etc.
 Lack of quality of the wall painting i.e. it is not uniform paint the wall
B) By hand with brush (by human):-
It is most commonly found in our country. It required more human power to paint the given wall.
But it has some limitation those are listed below;
 It required large number of labour.

 It require more time.
 The quality of paint not uniform paint because using by hand.
 It also effect the body as spray gun wall painting and etc.
C) By wall painting machine
This is also another option we decided for painting the wall. It required the motor that, is used to
pressurize paint and the motion of rope. It also has some draw back like more cost than the above

two. But has no (small) damage to the human (painter) because, it is not near to the paint in order
to paint it.
From those the above options we select the wall painting machine because of:
 It required low labor force i.e one or two enough

 It not damages the painter body.
 It also it runs with technology with in globalization.
 The painting quality is best because the paint flow rate is constant.
3.2 Function structural of wall painting

3.2.1 Overall Function
A function specifies the relationship between inputs and outputs. Express relationships between
inputs and outputs independently of the solution. Facilitate the subsequent search for solutions.
The overall problem has been formulated, it is possible to indicate an overall function that, based
on the flow of power, material and paint, with the use of a block diagram, express the solution-
neutral relationship between inputs and outputs.
The block diagram has the following input and output elements:
Conversion of material: Varying material dimensions (e.g. pinion and main shaft)
Motion of material: displacing the materials (e.g. brush movement)
Unpainted wall: painted wall
Therefore the block diagram of overall function is simple described the input and output
relationship below:-
Mixed paint
Input power Overall function
Unpainted wall Paint wall/roof
Chart 3.1 over all function.

3.2.2 Breaking a Function Down into Sub functions
Depending on the complexity of the problem, the resulting overall function will in turn be more
or less complex. By complexity we mean that the transparency of the relationships between
inputs and outputs is relatively poor, that the required physical processes are relatively intricate,
and that the number of assemblies and components involved is relatively large. The technical
system can be divided into subsystems and elements, so a complex or overall function can be
broken down into sub functions of lower complexity. The combination of individual sub
functions results in a function structure representing the overall function. [8]
The starting point of the formulation for the overall function given below in to sub functions
Power paint wall
Gear Main shaft Rope Brush

box holder
Crank Piston pipe Brush and

shaft pump paint
Chart 3. 2 development of function structure of wall painting
3.3 Developing Working Structure

3.3.1 The component of developing Working Structures
To fulfill the overall function, it is then necessary to generate overall solutions by combining the
working principles into a working structure, that is, system synthesis. The basis of such a
combination is the established function structure, which reflects logically and physically possible
or useful associations of the sub functions.

Generally, the component of each for wall painting machine structure.
wall paint
machine
power
tire force frame
transimtion
main shaft crank shaft pull/push
rope piston pump
base plate brush pipe
brush
paint wall
Chart 3.3 The component of developing Working Structures
3.3.2 The general working principle of wall painting machine
The working principle of wall painting machine can be, when the power source is on/opened
motor is start to rotate then the shaft on the pinion is rotate with pinion gear after that the gear
rotate due to mesh with pinion. And also rotate the main shaft which holds the sheave with rope
tighten on the sheave or loose from the sheave. Since the one end of rope is attached to the base
plate of brush holder, then it can be move in grooved frame upward and down ward in order to
wall painting and move forward and backward in order to paint the roof. And also, since the
crank shaft is coupled to the pinion shaft due to rotation of the pinion shaft, the crank shaft also
rotate, which hold the piston pump to create pressure and suction from the reservoir and
discharge of paint to the brush through pipe and due to rotation of the brush with wall produce
paint the wall and roof. The direction of motor is controlled by hand switch and the movement of
the frame from one place to another is by manual.
As summarized the working principles of wall painting are the following.
Dc motor
rotate
Switch ON/OFF dc motor
Pinion rotate Crank shaft rotate
Couple to pinion
Gear rotate
Up and down piston

movement
Shaft rotate
Reverse direction of Dc motor
Forward direction of motor Loose rope Pressure paint through pipe

Tight rope
Brush down ward/forward Brush

Brush upward/toward
Paint wall/roof Paint wall/roof Paint wall/roof
Chart 3.4 The hierarchy of working principle of wall painting machine.

CHAPTER FOUR
4.1 Design and analysis of wall painting machine
Figure 4. 1wall painting machine
Assumption:-
Design B is the general purpose design used for industrial motors. This design has low starting
current and normal torques and slip (approximately 3%) which can be used for many types of
industrial loads. From B we selected the smallest number of revolution and low torque because,

when the power is low the cost of the motor is also low so we select 286T type of motor [from
Appendix A-1 table 13 and table 14]. Type motor selection we have
The specification of our parts
Motor:
Torque = 120 Nm
Speed = 900 RPM
In design, we need to follow by detail construction where the final details are added to the
product before any manufactured. Therefore in this chapter part design, structural design,
material selection, the stress of each part, part design can be assembly and animation by inventor,
simulation of fluid flow is done by ANSYS. The part of the project going to present the parts that
we are going to be design.
We will design the following parts:
 Design of rope
 Design of gear box
 Design of shaft
 Design of key
 Design of piston pump
 Design of crank shaft
 Selection of flexible pipe
 Selection of tire

4.2 Design of wire rope
Figure 4. 2wire rope

The ropes drives use the following two types of ropes (Fiber ropes, and Wire ropes). From this
rope we selected the wire rope because,
 they are lighter in weight

 silent operation
 more reliable and durable
 low cost
 efficiency is high
 do not fail suddenly
Assumption
Let our rope carry the mass of , which the mass of our table it is the all mass of table
which contains brush, brush arm, brush arm holder, table, etc.
1) weight of load
Where, = mass rope can carry and
= acceleration due to gravity

2) From the Standard designation of ropes and their applications depending on the purpose
(It is a standard hoisting rope used for the purposes of elevators), therefore, we select
the wire rope is [from appendix A-1 table 1],
3) The application of our wire is sling and have factors of and the coefficient of safety
factory is range between – we take safety, [from appendix A-1 table 2]
4) Therefore, design load for the wire rope is
5) We have tensile strength is between – is [From appendix A-1

table 3],
From this, (from standard table)
6) We have the area wire and diameter wire rope [From appendix A-1 table 4],


7) We find the weight of rope [From appendix A-1 table 3],
Average weight of rope
We take the largest length of tope (the height of our frame is , width and
which the tight rope on sheave due to forward and reverse direction)
8) Diameter of sheave for preferred sheave diameter is [from appendix C-1

table 5]
(Is diameter of sheave)
9) For determine the bending stress (
10) Equivalent bending load ,
11) We know that acceleration for rope and load; to calculate the speed of rope first we have
to take speed of shaft (since the angular speed on one shaft can be the same). The power
of shaft can be,

–
a) The angular speed on one shaft
But,
From this
b) We know that, the speed of wire rope
c) We know that acceleration of the rope and load assume we take for
d) Additional load due to acceleration
12) Impact load during starting (when there is no slackness in the rope),
13) The effective load during normal working on the rope
 Actual factor of safety during normal working
14) Effective load on rope during starting
 Actual factor of safety during starting
NOTE: - since, the working factor of safety is less than recommended factor of safety.
Therefore, we have to change our rope number to carry load/to safe the rope.

4.3 Design of gear box;
From this parameter the motor can be generated
Where, = is power (in
= is torque (in
= is angular speed (in
But, we know that,
4.3.1 Design of Pinion
Figure 4. 3 pinion gear
Let pressure angle of full depth involute is we select this angle because it is stronger in
tooth and for design gear first, we have to gate gear ration, since we know that the number of

teeth on the pinion in order to avoid interference may be obtained from the following
relation:

[√ ]
Where Fraction by which the standard addendum for the wheel should be multiplied,
= Gear ratio or velocity ratio ,
= Pressure angle or angle of obliquity.
But, the teeth of pinion
From this equation can get,

[√ ]
NOTE: Our shaft speed from motor somewhat high, to reduce this speed we use single spur gear
reduction because gear ratio become from the calculation below (i.e we know that when
gear ratio is we use single stage gear reduction, when we use the double
stage reduction and we use the third stage of reduction).
 To find the module we have the following formula

1. We know that pitch line velocity, where
2. Tangential tooth load and insert equation into

Where, –
– (Used for gear box)
3. Velocity factory for cut tooth
4. We know that tooth form factor for the pinion and for gear

And (take for pinion
cast iron ordinary ) from this
And (take for gear
cast iron medium from this,
Therefore the value of pinion is less than gear, so pinion is weaker than gear.
5. Now using the Lewis equation to the pinion, we have
but, assume
(from standard value)
NOTE: - The recommended series of modules in Indian standard are 1, 1.25, 1.5, 2, 2.5, 3, 4, 5,
6, 8, 10, 12, 16, 20, 25, 32, 40, and 50.
Spur gear formulas:-
1. Diametral pitch
2. Pitch diameter
[From Appendix A-1 table 14] the minimum number of teeth at full depth involute,
therefore teeth of pinion OR from the formula, above we can used.
3. Circular pitch
4. Outer diameter
5. Addendum
6. Dedendum
7. Tooth thickness
8. Working depth
9. Fillet radius at root
10. Clearance
11. Whole depth
12. Torque on pinion

From solve (i.e. is tangential force)
13. Normal force

14. Radial force
15. Pitch line velocity
16. Root diameter
17. Face width the optimum range face width is and we take
4.3.2 Design of gear
Figure 4. 4 gear

Gear ratio related with pinion and gear
Where, → is speed of pinion and gear respectively in
→ is angular velocity in
→ is torque on pinion and gear respectively in
→ is teeth of pinion and gear respectively.
From the above relation we can solve the gear parameters:-
 The speed of gear
 The angular velocity of gear
 The torque of gear

 The teeth of gear
Since, tangential force on mesh gear is the same we can drive the pitch diameter gear
from the formula we have,
 To solve pitch diameter gear
 To solve the outside diameter of gear
 To get the Center Distance

4.4 Gear bending and wear
We know that,
From this where velocity of pitch circle
Where
Assume the load is uniform,
Quantity is most common to (we select the average ) and to evaluate .
√
But, where, is
dynamic factor
√ √
For pinion
Where, size factor
√ √
For gear
Load distribution factor )
Where, = Face load distribution factor
For crowned
– –
For straddle-mounted pinion with

From table below substitute each value
For gearing adjusted at assembly
Therefore,
Rim thickness factor since the ratio of rim thickness below the tooth and the
tooth height is greater than
Bending-Strength Geometry Factor from the graph (appendix C graph 1)
Hardness-Ratio Factor
but since
Stress Cycle Factors and
Assume a pinion life of cycles and a reliability of ,
From the graph (appendix C graphs 2), we have the:
Reliability Factor
From the table below, since we take the reliability is
Temperature Factor KT
From Appendix A-1 table 18, KR = 0.85 since we take the reliability is 0.90

Temperature Factor KT
Assume the machine is work at (120°C), for oil or gear-blank temperatures up to 250°F (120°C),
use
Rim-Thickness Factor
Backup ratio therefore,
 Bending stress
 For pinion
 For gear
 Bending factor of safety
 For pinion,
Where, allowable bending stress (for pinion we select medium cast iron)
 For gear,
Where, allowable bending stress (for gear we select high cast iron)
 Wear (contact) stress
√
 For pinion,

We have [from Appendix A-1 table 7] coefficient,

because not determine by AGMA but greater than
 For gear, √ √
 Safety factor of wear

 For pinion,
 For gear,
Since the of bending is greater than of wear stress. The gear and pinion is from wear.
Result and discussion of the pinion
The gear is subjected to the tangential load, as we can see from the image below the minimum
displacement is and maximum displacement is . Therefore, this is
insignificant (very small), so the material size and factor of safety is satisfactory for our design.
And the minimum shear stress and maximum shear stress .In
generally, our shaft design is safe.

Figure 4. 5 The deformation and shear stress analysis diagram for gear mesh
4.3.3) design of shaft pinion
Figure 4. 6pinion shaft

For design our shaft we select the material first, so we select the mild steel for it most common
for shaft design.

The applied load on the pinion shaft
Assumption, length of the shaft is
And there is bearing at point and motor itself used as supporting at point .
I. Considering vertical force only
Let and be the reaction at bearing at and motor itself at respectively due to
vertically load only.
(Free body diagram) are:
To calculate reaction force for vertical load only
To calculate the reaction force
To calculate from bending momentum

From equation we can get
To calculate bending moment for vertical load only
Bending moment at and is equal to , because reaction force on it.

Bending moment at
The diagram of the vertical load can be shown below
Figure 4. 7 Diagram of bending moment for vertical load
II. Considering horizontal force only
Let and be the reaction at bearing at and motor itself at respectively due to
horizontal load only.

The (free body diagram) for horizontal load:
To calculate reaction force for horizontal load only
To calculate the reaction force
– –
To calculate from bending momentum
To calculate bending moment for horizontal load only
Bending moment at and is equal to , because reaction force on it.

Bending moment at
The diagram of this bending moment is shown below

Figure 4. 8 Diagram of bending moment for horizontal load
To calculate bending moment resultant
We know that, the resultant bending moment at
The diagram of the resultant bending moment is shown below
Bending Moment
Figure 4. 9 Diagram of resultant bending moment for pinion shaft
We know that the equivalent twisting moment
√
We know that the equivalent twisting moment
Where, (we selected mild steel which used commonly)
Diameter pinion shaft
From this
Therefore, the nearest standard value, (is the diameter of shaft pinion)
Ideal Diameter
Figure 4. 10 The diagram of ideal diameter of pinion shaft
Result and discussion of the pinion shaft
The pinion shaft is subjected to the tangential load, as we can see from the image the minimum
displacement is and maximum displacement is . Therefore, this is
insignificant, so the material size and factor of safety is satisfactory for our design. And the
minimum shear stress is and maximum shear stress since steel for
shaft the maximum allowable shear stress is In generally, our shaft design is safe.

Figure 4. 11 Diagram of the maximum and minimum deformation and shear stress

4.3.4 Design of main shaft
Figure 4. 12 main shaft

To design the main shaft, first we know that the load on the shaft. We have overhang gear on the
main shaft which means, the bearing between the sheave.
I. Considering vertical load during wall painting
There are two sheaves on this shaft on which the rope is twisted over it. There is extra rope
twisted on the sheave during starting.
Assumption:-
 neglect the weight of sheave

 neglect the extra rope weight which twisted on the sheave
 the length of main shaft is
 the material we selected is mild steel (i.e most common for shaft)

Let and be the reaction at bearing at and respectively and also and is
the sheave in order to design wall painting.
We know that, effective load is and force on the gear
FB = 1337.65N FC = 1957.6N FD =1337.65N
A B C D E
0.1m 0.4m 0.4m 0.1m
FAV FEV
We know that,
Taking momentum about we get
– – –
From equation we solve,

We know that,
 Bending moment at and
 Bending moment at
Figure 4. 13 Diagram of the bending moment for vertical load
II. Considering horizontal load during wall painting

Let and be the reaction at bearing at and respectively in order to design wall
painting.
We know that,

Taking momentum about we get
From equation we solve,
We know that,
 Bending moment at and ,
Figure 4. 14 Diagram of bending moment for horizontal load
We know that, the resultant bending momentum at

Figure 4. 15 Diagram of resultant bending moment for load

NOTE: - Since, our design for the vertical is also used for horizontal their design is equal.
Therefore, the design of shaft for wall painting is also for the roof wall painting. So we neglect
the design for roof painting because of similarity.
Therefore, we know that the equivalent twisting moment
From the equation of twisting, we know that the equivalent twisting moment
Where, (we selected mild steel which used commonly)
Diameter main shaft
(From standard diameter of shaft

Ideal Diameter
Figure 4. 16 Diagram of ideal gear shaft
Result and discussion of the main shaft
The main shaft is subjected to the tangential load from gear and radial load from the rope. As we
can see from the image below, the minimum displacement is and maximum displacement
is therefore, this is insignificant, so the material size and factor of safety is
satisfactory for our design. And the minimum shear stress is and maximum shear
stress since the steel for shaft the maximum allowable shear stress is
In generally, our shaft design is safe.

Figure 4. 17 Diagram of the maximum and minimum deformation and shear stress
4.3.5 Design of gear box housing
Figure 4. 18 3D gear box and housing half view

Gear box casing is the most critical things in the design of gear box, since it is the cover of all
machine elements which are available in the gear box. It is may be made from many materials
based on the designed mechanical properties.

Most of gear box casing is made from cast irons because of it have the following mechanical
properties:
a) Structural rigidity b) High strength, especially in compression

c) Good strength to weight ratio d) High machinability
e) High corrosion resistance f) Inherently sound absorbing
g) Excellent cast ability h)The ability to absorb mechanical vibration
i) Relatively abundance raw material. j) Relatively cheep
Casing materials: cast iron, grade , which has the minimum tensile strength of
Gear box dimensions are fixed based on thumb rule, this given in the (Table13, Appendix A),
= Well thickness in mm of the gear box.
Where is the largest dimension of the housing in mm, therefore, for cast iron casting
case hardened gears from the above table:
Top cover thickness:
Flange cover bolt diameter , the nearest standard can be bolts
Bolt spacing:
Outside dimension of the bearing housing times of the outside diameter

of the bearing.
 Bearing (for pinion shaft),

 Bearing (for main shaft),
Take numbers of bolts for the bearing cover and the maximum total gear box size is

4.3.6 Design of key
Key is the device which is used for connecting two machine parts for preventing relative motion
or rotation with respect to other. After assembly, the key is partial in shaft and partial in hub. The
key are commonly made from cold rolled mild steel bars.
Assumption: - we select the parallel sunk key which is most commonly.
Design of key for pinion gear
Figure 4. 19 The key for pinion shaft

We know that,
1. Width where, diameter of pinion of shaft.
2. height
3. length
A. Check for shearing strength of this key
NOTE: Since, that design of key is less than allowable shear

strength hence dimension is safe.
B. Check for crushing tensile strength of the key

NOTE: Since, which the design of key is less than allowable

tensile strength hence dimension is safe.
Therefore, the design of key for pinion shaft is, and
Design of key for main gear and sheave
Figure 4. 20 The key for main shaft for gear and sheave
We know that,
a) where, = diameter of main shaft
b)
c)
1. Check for shearing strength of this key

NOTE: Since, that design of key is less than allowable shear strength
hence a dimension is safe.
2. Check for crushing tensile strength of the key
NOTE: Since, which the design of key is less than allowable tensile strength
hence dimension is safe
Therefore, the design of key for pinion shaft is, and

and it need three key on the main shaft which, of them connect with sheave and
the left key is for gear.
4.4 Design of piston pump
Figure 4. 21 the piston rod
The piston pump is used to pressure the paint in to the required brush for released to the area we
need to paint. When we design the piston pump we have to design the pipe through which the
paint flow.

Assumption:-
 From the physio-chemical properties of produced paint grade because it have low
viscosity [Appendix A-1 from table].
 The thickness of the paint is

 Our machine has finish the area with thickness
is
 Length of the pipe (flexible and position at center of frame) is .
The design can be listed below:-
1. To calculate the flow rate
Where, = area sample in
But, = thickness of the paint in
t = time required in
2. From flow rate, we can calculate diameter of pipe
Where, = area of pipe
= length of pipe in
= time in
(Standard diameter)
3. To calculate the pressure in the pipe (pr)
Where, height of brush from piston pump

4. To calculate the force in the pipe

.
5. The flow rate in the pipe is equal with flow rate in piston
But, velocity of piton rod is equal with the speed of shaft from the motor because it couple to
pinion shaft.
is piston diameter
Rewrite equation and into equation ( we can get
is the diameter of piston.
6. For determine the inside cylinder can get, from the allowance for reboring of
between is –
Where, inside diameter of cylinder
Is allowance
is the internal diameter of cylinder.

7. The power needed to drive the piston in the cylinder is calculated as follows
But,
Where, is the cylinder diameter.
.’. But,
This amount of power is needed to drive/moves the piston
pump.
From total amount of our initial input power the left power is needed for gear
shaft and the rope.
8. The motion of piston in the cylinder which is length of stroke
Averagely
9. To calculate outside diameter the cylinder can be solve (Do), the below formula
Where, outer diameter of the cylinder
= thickness of the cylinder
But, is thickness of cylinder
is outside diameter of cylinder.
10. The length of cylinder is greater than stroke
is the length of the cylinder

11. To find the thickness of the cylinder head
√ Where,
Constant value
We can
12. The force acting on the studs
13. The number of stud can be calculated from the formula we have,
Can
14. Resisting force offered by all studs can be get,
Where, core diameter of stud =
0.8d
Nominal diameter of stud
(Stud material nickel)
, substitute and we get,
(Nominal diameter of
stud)
15. For determine the arm, let us diameter of brush is

We know that,
But
The load on the arm can be calculated,
Let select the for the arm, arm length

Where, is arm length, is diameter of brush, and is arm diameter.
For aluminum alloy
From the above formula,
4.5 Selection of flexible pipe (hose)
Selecting the correct diameter hose for the required flow and length to properly suit the
application for transfer paint from tank to brush. Smooth bore Teflon hose offers laminar flow
and minimizes the potential for entrapment, but may not offer the flexibility or bend-ability of a
convoluted style Teflon assembly. Resist flex brand convoluted Teflon products are open
pitched and helical providing maximum flow, draining and flexing. Specification of the hoses:
 Inner core: “Seamless” convoluted Teflon PTFE

 Reinforcement: PVDF heavy double braid
 Temperature: -20 F-275F
Since the application that provides outstanding corrosion resistance and material
compatibility and resistant to most chemicals introduced to the external surface of the hose
through typical usage. For applications requiring an extremely flexible, lightweight Teflon
PTFE hose assembly conveying chemicals that permeate aggressively, or for harsh
atmospheric conditions that require extreme corrosion resistance on the exterior of the
assembly. From (Table 10, Appendix A-1)
 Internal diameter of the (pipe) hose, ID = 12.7mm

 Outer diameter of the (pipe) hose, OD = 24.9mm

4.6 Design of crank shaft
Figure 4. 22 crank shaft
Crank shaft is used to convert rotary motion to reciprocating motion in wall painting machine
design.

From the above force take the larger one and force of the piston becomes
In our design we use one/single cylinder with two suction and two discharge and one crank shaft
is enough for this design.
At point 1 and point 2 there is bearing used to support the load/shaft. We calculate load only
between point 1 and 2.
is the vertical/reaction force used to

support.
Bending moment at the center
………………… (1)
Allowable stress for steel is and to calculate diameter of crank pin
…………………………………………………. (2)
Equating the above equation (1) and (2) we gate the diameter of crank pin
Now, length of crank pin
The proportion of the crank shaft is as follows:-
1. Cylinder bore diameter

2. Cylinder center distance
3. Big end journal diameter
4. Main end journal diameter =
5. Big end journal width
6. Main end journal width
7. Fillet radius of journal and webs …………from (B. Dong
linger)
Stroke – and our stroke becomes
Concord ratio = crank radius/length of connecting rod
But – averagely
Crank radius
Length of connecting rod

Mass connecting rod
Total bending force due to the triangular distribution is
but
Max. bending moment occurs at √
LEFT HAND CRANK WEB
The thickness
……………….take the average
Width can be assumed as follows:-
take average
There are two stress on this crank web direct stress and bending stress
Direct stress
Bending stress
From the above bending moment
Total bending moment
Which is less than allowable stress of material so our design is safe.
RIGHT HAND CRANK WEB
Direct stress
Bending stress = – 6/ 2

So our design is safe
Design of the crankshaft when the crank is at an angle of maximum twisting moment
The twisting moment on the crankshaft will be maximum when the tangential force on the
crank is maximum. The maximum value of tangential force lies when the crank is at angle
of to 30º from the dead center for a constant volume combustion engines (i.e., petrol
engines) and 30º to 40º for constant pressure combustion engines (i.e., diesel engines).in our
design we have constant volume and we select angle of inclination (θ) is 35°
We know that piston liquid load/force,
We know that thrust in the connecting rod,
Tangential force acting on the crankshaft,
Radial force,

Due to the tangential force t), there will be two reactions at bearings 1 and 2, such that
Due to the radial force there will be two reactions at bearings 1 and 2, such that
(a) Design of crankpin
Let = Diameter of crankpin in mm
We know that the bending moment at the center of the crankpin,
Twisting moment on crank pin
Equivalent twisting moment (Te)
3
if the maximum shear stress of steel is
Say 1 is the diameter of the crank pin we have to use.

(b) Design of shaft at the juncture of right hand crank arm
Let Diameter of the shaft at the juncture of the right hand crank arm.
We know that the resultant force at the bearing 1,
Bending moment at the juncture of the right hand crank arm,
4.7 Design of coupling

Figure 4. 23 coupling
Since the shaft from motor is coupled with the crank shaft it need to couple for similar motion to
transfer. The material we selected gray cast iron for flange and carbon steel for pins (bolts)
which have permissible shear stress
From the calculated shaft of pinion which means we have the standard table
property of pin and bush flexible coupling in appendix A (from table 9):
 Diameter of shaft
 Diameter of hub
 Pitch circle diameter of bolts on flange
 Diameter of bolts
 Outer diameter of flange
 Length of hub
 Thickness of larger protective
 Length of bush in the flange
 Number of bolts
 Diameter of bush
 Clearance
We know that:
Where, is power used for piston pump
is number of revolution in which is equal to pinion shaft.
From this parameter, where, is torque for piston pump
I. Design of hub
Since the shear stress of the hub is less than the permissible shear
stress therefore the design for hub is safe.

II. Design of key

We know that, length of key,
Width of key,
Height of key
Check for shearing,
Since shear stress of key is less than the permissible stress value
therefore it is safe.
Check for crushing
Since the crushing stress of key is less than allowable crushing stress
Therefore, the design is safe.
III. Design of flange

We have, the formula:
Since shearing stress of flange is less than permissible stress value

therefore it is safe.
IV. Design of bolts

From the formula, we have
Where (shearing bolt)
( is diameter of bolt)
say

Check for bolt (pin)

Bearing load on pin
Direct stress due to pure torsion in coupling …………….. (1)
Maximum bending moment on the pin
Bending stress …………………………………………… (2)

3 3
From the equation (1) and (2), we have maximum principle stress and maximum shear stress.
Maximum principal stress √ √
is the maximum principal stress
Maximum shear stress = √ = √
is the maximum shear stress
Since, the maximum principal stress and maximum shear stress with in limit. So it safe.
Check for crushing
Since the crushing stress is less than permissible stress. Therefore, it is safe.
V. Design for bush

Length of bush
Bearing stress

Since the bending stress is less than permissible stress
4.8 Bearing selection
Bearing is a stationary machine part which supports rotating shaft and axles and confines their
motion naturally. A bearing will be required to offer frictional resistance. Ball bearings also
resist thrust, and a unit of thrust does different damage per revolution than a unit of radial load,
so we must find the equivalent pure radial load that does the same damage as the existing radial
and thrust loads. Bearing can be radial or thrust based on types of load acting on the shaft, and
also depends on the nature of contact it can bed sliding or rolling and, it is specified by its static
load rating ( and dynamic load rating For relatively small radial and thrust forces deep
groove ball bearing and angular contact ball bearing are preferable due to the reason of
low cost, easy to maintenance, easy to assembly and smaller axial length. A bearing is a
machine element which supports another moving machine element (known as journal). It permits
a relative motion between the contact surfaces of the members, while carrying the load.
Figure 4. 24 Bearing
Selection of bearing for pinion shaft
This bearing is the supports of the shaft at one end and another also support by motor, it is
subjected to axial and radial load. For the selection of this bearing we have the following
parameters from the table and calculation:
 Expected life of bearing, ,(from table we selected for 8hr)

 Shaft diameters,
 Rotational speed,
The equivalent load at A for pinion shaft, =√
√ =
1/3
We know that, where, is dynamic load rating
is life in revolution
Therefore,
Therefore, from [the Appendix C-2 table 3], we selected which is single deep groove ball
bearing.
From the above, the first underline from the table we have,
 Bore diameter
 Outside diameter
 Width
 which is greater than the calculated load, it suit for selection.
Selection of bearing for main shaft
This bearing is the supports of the shaft at one end and another also support by motor, it is
subjected to axial and radial load. For the selection of this bearing we have the following
parameters from the table and calculation:
 expected life of bearing, ,(from table we selected for )

 Shaft diameters,
 Rotational speed
The equivalent load at A for pinion shaft, =√
=√

6 1/3
We know that where, is dynamic load rating
is life in revolution
Therefore,
Therefore, from [Appendix A-1 table 8], we selected which is single deep groove ball bearing.
From the table, the coloured form, from the table we have,
 Bore diameter
 Outside diameter
 Width
 Which is greater than the calculated load, therefore, it suit for selection.
4.9 Frame design and analysis
Figure 4. 25 Wall painting machine frame.

In our design we take the room/class with length of 3m, width of 1m, and height of 2.8m as a
sample. Designed frame is detachable at half of its parameters (i.e at height of 1.4m and length of
1.5m) except on its width because, its width is applicable for any types of room. It carries all our
parts of machine safely and moves from one location/area to another by using tires. Also it has T
section like ways, through which the table which contains brush is moved. For our frame we
selected structural steel (ASTM-A36) [from the Appendix A-1 table11], we have Modulus of
elasticity ) and assumption we take
 Height of the column is

 Width of frame is 1m
 Length of frame is 3m
 Assume that the critical load and each column can carry
and safety factor
We know that, from the Euler’s formula we have
Where, is critical load can carry
4
(is moment of inertia) = = / since,
(is effective length) for both end fixed
Figure 4. 26 legs of frame
where, is the load applied on column.
Rearrange the above equation and can be written

CHAPTER FIVE
5.1 Manufacturing procedure
The manufacturing procedure for the each component with the required specification in the table
below:
No Components to Manufacturing procedure

be manufacturing
1 Frame We cut two parts of structural steel with length of 3m, width of
200mm, and height of 200mm. then to make detachable cut its
length into two parts by 1.5m. make hole/boring on one of these
parts with diameter of 90mm and depth of 200mm. do turning on
the other parts with the dimension of the previous part, because as it
assembled to the bored one. do internal cutting way in the form of T
section by the length of 2700mm on one parts, drills/ bores with
30mm diameter on both parts through which the rope passes, make
the rolled way on which the circular shape material rolls to reduce
the contacting surface of the rope with the holes tip. Make small
vertically assembled parts to the frame ends to support the free
rolling of the rope with the diameter of 30mm and length of
50mm. add bearing on its end. Cut 100mm width with 90mm height
at the end of each legs/supports for the tires assembly. We done T
section cut only on one parts and the others is as it is. Finally weld
the four parts at 90 degree to others.

2 Casing Bend steel sheet with the thickness of 18mm in rectangular form
with the length of 172mm and decrease the width from 1000mm
into 300mm with the height of 180mm to carry the pinion shaft.
Make the bearing house at 172mm from the tip to the center for
main shaft with diameter of 80mm. After we decrease the width we
make bearing house at 362mm with the diameter of 62mm to
support the pinion and gear shaft.
3 Main shaft From our material selected facing 40mm diameter and turning
1000mm length.
4 Pinion Shaft From our material selected facing 30mm diameter and turning
300mm length.
5 Gear Gears diameter is 280mm and 100mm with a face width of 60mm
get the appropriate shaft and then by the help of milling machine we
do the gears.
7 Crank shaft Do the same processes with shaft but after we go 40mm from its
tips make slot center to center like shape with 175.5mm length and
81mm diameter of main end journal. Do the same processes with
the left parts.
8 Piston Make facing with the diameter of 103mm and turning with 54mm
length, then decrease to connecting rod diameter also due the some
processes for connecting rod by its parameters.
9 Cylinder From the sheet metal bend to form circular shape with length of
202mm and 121mm diameter which have 18mm thickness. Finally
weld it together.
10 Tank Do the same processes with cylinder with 700mm length and
500mm diameter and make two hole at bottom dead center of the
tanker.
Table 5.1: manufacturing procedure

5.2 Cost Estimation
Cost of analysis include the cost of material, cost of manufacturing, cost of standard materials
available in market like bearing, bearing house ,block support and etc. and cost of
manufacturing.
5.2.1 Cost of materials
The cost of the materials is bought and sold in . For example the steel material is
for commercial for internal work/company itself. The formula of the cost analysis
is as follows:-
I. is the cost of raw material before it proceeds into the

machine/as it is. To calculate we must now the dimensions or the weight of the
raw material.
Example, 1) let us calculate the cost of the pinion shaft. Shaft has circular shape and it
has the following dimension: -Length
Diameter
To calculate the mass of the shaft we must calculate the volume from the given
dimensions.
We know that the shaft material is steel and the density of steel is
where is mass of material
is volume of the material

From the internship knowledge, we get that
2) Calculate the cost of the main shaft. Shaft has circular shape and it has the following
dimension: -Length
Diameter (
To calculate the mass of the shaft we must calculate the volume from the given
dimensions.
We know that the shaft material is steel and the density of steel is
where is mass of material
is volume of the material
From the internship knowledge, we get that
II. - is the cost of technicians/machinist that operates the

materials into the required shape or designed. Office workers and the person who see the
finished material is not the . For the labors the birr is paid by hours they stay/done.
Man
salary is average of all the machinist say and lastly it comes in in
the shops. To finish the given shaft 48hrs.and

III. - is the cost of the covered material example box for embracing
bullet, wood pattern, nail, and etc. assume there is no direct expense in our design.
IV. is indirect cost like cost of machine
depreciation, cost of materials used for our machine that operates our work pieces like
rag, coolant (grease, oil and) and etc. Manufacturing overhead cost is always greater or
equal to the direct labor cost.
The total cost of the shaft is the summation of above calculated birr
Birr for pinion shaft and
Birr for main shaft
All the part of our improved machine is calculated in this form. The summary of the cost as
follows:
No Material Specifications Material Quantit Total Cost

. name selected y estimation
1 Tire D = 300mm, b = 100mm 4 2000
2 Dc motor Power=11.3kw 1 15000
N= 900 rpm
3 Pinion shaft d=28mm, L=300mm mild steel 1 1227.064
4 Main shaft d=40mm, L=1m, density mild steel 1 2157.816
=7850kg/m3
5 Pinion (gear Pd = 90mm, T=18 Cast iron 1 2500
1) ordinary
6 Gear 2 Pd = 270mm, Cast iron 1 3000
T = 54 medium
7 Sheave D = 180mm Cast iron 4 600
medium
8 Pulley D = 20mm Aluminum 4 400

alloy
9 Rope and d=6mm, L=9.8m Wire rope 1 300
end joint
10 Table hold? L=100mm, Steel 6 800
W = 50mm,
H = 100mm
11 Arm D= 3mm, L=100mm Aluminum 2 150
alloy
13 Circular L=300mm, d = 20mm 2 220
brush
14 Flexible L = 3m, Plastics 4 400
pipe d = 13.35mm
15 Cylinder Diameter=108mm Sheet metal 1 800
Piston rod diameter=103mm
Stroke =175.5mm
14 Crank shaft Dc = 11mm r = 175.5mm Mild steel 1 800
15 Coupling D2 = 112mm, L = 32mm Cast iron 2 1000
16 column L = 2.8m, Structural steel 4 6400
(frame) w = b=55mm
17 Beam L = 2.5m, Structural steel 2 3000
W = b = 55mm
18 Key1 L=45mm, b=8mm Steel 1 50
h=6mm
19 Key2 L=63, b=12mm h=8mm Steel 3 180
20 Bearing 1 OD = 62mm b = 16mm Deep grove 2 500
21 Bearing 2 OD = 80mm b = 18mm Deep grove 2 550
22 Casing L = 1m, h = 360mm, Cast iron 1 500
Thickness = 18mm
23 Bolts and Steel 4 150
nuts

Total sum = 37554.8
Table 5.2: table of cost for each materials
5.2.2 Manufacturing cost (CM) Estimation
1) Relaxation (Rest) Allowance: is commonly 5% to 10% (of normal time)
Fatigue allowance: enable the operator to recover from the physiological and psychological
effects which occurs due to continuous doing of the work (monotony etc.).
1) Process Allowance: to compensate for enforced idleness of the worker. Generally 5% of the
normal time is provided
2) Interference Allowance: when one worker is working on several machines.
3) Contingency Allowance: delays (e.g. waiting for raw materials, tools). Contingency
allowance is 5% (maximum) or Normal Time.
Therefore , for no interference
allowances.
Then
As summarized the manufacturing cost
NO. Item No. of Workers Per day salary No. of Amount in

days birr
1 Machinist 1 181.82 30 5454.55
2 Cutting 1 90 1 90
3 Boring 1 90 1 90
4 Welding 1 90 1 90
Total sum = 5724.55
Table 5.3: table cost of manufacturing
Total initial expense of the machine will be the summation of the above two, total cost of
the parts and manufacture cost.

Conclusion
The painting machine used in a world is difficult to applicable for painting the room. But it has
the problem on the respiratory system damaged, complicity of component, expensive, etc. To
solve above problem we design wall painting machine in this paper. Most part of the machine
designed from a material which available in country i.e. mild steel is a material used for most
part. Geometric shape of each part can be manufactured simply in small work shop which can
produce rectangular and circular surface finish. The design and manufacturing of this machine in
our country has also an advantage of reducing foreign currency and increase quality of grain.
This project helped us in widening our knowledge of designing machines and machine elements.

Recommendation
Wall painting machine which was done previously has many defects like hand painting/gun
spraying, low time management, needs high human power, and has effect on human respiratory
due to spray the chemicals. In designing the machine for our country’s standard and demand, it’s
recommended that the enterprise should be trained and needs encouragements and motivations to
manufacture the machine. The government and the university should give attention on such type
of project to enhance the technology.
Also we recommended that the contractor should be encouraged to buy the machine, since the
budget for this project was not enough. The prototype of the machine was not developed on the
workshop. So, the university should give critical attention to encourage the creativity and
innovation.
Wall painting machine has many parts and improved with the defects of before designed
machine. Any industrial company/private company can produce this machine to save their cost,
time, reduce labor force, and increase the quality of painting. When we use this machine wisely
start the motor also disassemble the frame and lubricate the parts as needed. Place the
reserved/protected area to increase the life span of our machine. Control the motion of the motor
direction we have to use carefully hand switch system. If there is unconditional sound/vibration
can be there during the operation we have to stop the motor and see the problems
occurred/reports to more specialized machinist.

REFERENCE
1. R.S. Khurmi, J.k.Gupta (2005), text book of machine design, first multicolor edition,
Eurasia publishing house (pvt.) ltd.
2. Shigley’s Mechanical Engineering Design, Eighth Edition Budynas−Nisbett.
3. Standard Handbook of Machine Design 3rd edition- Shigley, Mischke.
4. Design of machine element G.K.Vijayaraghavan and S.Vishnupriyan.
5. Design and developement an automated paint mixing machine by tapas rajashirvad Jena.
6. Design & development of Semi- Automatic exterior Wall Painting Machine by
Prof.Jayendra Patel.
7. Engineering Design a systematic Approach G. Pahl and W. Beitz J. Feldhusen and K.-H.
Grote.
8. Mechanics of materials fourth edition by Fernand P. Beer, Erussiel Johnston. Jr. john
Dewolf.
9. Crankshaft Design Methodology for Diesel Engines, K.Pandiyan, Dr. Ashesh Tiwari.
10. Alternatives to natrosol asthickener in the production of emulsion paint, akpa jackson
gunorubon and uku misel

Appendix
Appendix A -1 List of Tables Required
Table 1 the application wire rope
Standard designation Application

6 × 7 rope It is a standard coarse laid rope used as haulage rope in mines,
. tramways, power transmission.
6 × 19 rope It is a standard hoisting rope used for hoisting purposes in

mines, quarries, cranes, dredges, elevators, tramways, well
drilling.
6 × 37 rope It is an extra flexible hoisting rope used in steel mill laddles,
cranes, and high speed elevators.
8 × 19 rope It is also an extra flexible hoisting rope
Table 2 the safety factor of our rope
Application of wire rope Factor of Application of wire rope Factor of

safety safety
Track cables 4.2 Derricks 6
Guys 3.5 Haulage ropes 6
Mine hoists : Depths Small electric and air hoists 7
Up to 150m 8 Overhead and gantry cranes 6
300-600m 7 Jib and pillar cranes 6
600-900m 6 Hot ladle cranes 8
Over 900m 5 Slings 8
Miscellaneous hoists 5

Table 3 the property of wire rope, nominal diameter and weight of rope
Type of rope Nominal Average Average tensile strength (N)

diameter weight
Tensile strength of wire
(mm) (N/m)
1100– 1250–
1250MPa 1400MPa
6 × 19 6, 8, 10, 12, 14, 0.0383 d2 385 d2 435 d2

16, 18, 20, 22, 25
6 × 37 8, 10, 12, 14, 16, 0.034 d2 355 d2 445 d2

18, 20, 22, 25
Table 4 the diameter of wire and area of wire
Type of wire 6×8 6×19 6×37 8×19

rope
Wire diameter 0.106 d 0.063 d 0.045 d 0.050 d
(dw)
Area of wire rope 0.38 d2 0.38 d2 0.38 d2 0.35 d2

(A)

Table 5 the sheave diameter of wire rope
Type of wire Recommended sheave diameter (D) Uses

rope Minimum sheave Preferred sheave
diameter diameter
6×7 42 d 72 d Mines, haulage tramways.
6×19 30 d 45 d Hoisting rope.
60 d 100 d Cargo cranes, mine hoists.
6×37 20 d 30 d Derricks, dredges, elevators,
Cranes, high speed elevators and
6×37 18 d 27 d small shears.
Extra flexible hoisting rope.
8×19 18 d 31 d
Table 6 the table of allowable static stress
Material Allowable static stress

Cast iron, ordinary 56
Cast iron, medium grade 70
Cast iron, highest grade 105
Cast steel, untreated 140
Cast steel, heat treated 196
Forged carbon steel-case hardened 126
Forged carbon steel-untreated 140 to 210
Forged carbon steel-heat treated 210 to 245
Alloy steel-case hardened 350
Alloy steel-heat treated 455 to 472
Phosphor bronze 84
Non-metallic materials
Rawhide, fabroil 42

Bakelite, Micarta, Celeron 56
Table 7 the table of elastic coefficient of gear
Table 8 the table of deep groove and angular contact ball bearing

Table 9 The table of flexible coupling

Table 10 the table of hose (pipe)
Table 11 Material property of the given for structure (frame).

Table 12 the formula for beam and column.

Table 13 specified motor selection.
Table 14 the application of motor

Table 15 table of the constant value
Table 16 selection of pinion gear teeth
No. Systems of gear teeth Minimum number of teeth on the pinion

1 14.5° Composite 12
2 14.5° Full depth involute 32
3 20° Full depth involute 18
4 20° Stub involute 14

Table 17 uniform load factor
Table 18 reliability factor
Table 19 Physico-chemical properties of produced paints

Appendix A – 2) The Graph We Used
Chart 1: The graph of geometer factor

Chart 2: the bending strength and pitting resistance stress cyclic factor

Appindex B: Detail of part drawing.

1) The pinion shaft drawing (2D)

2) The main shaft drawing (2D)

3) Bearing drawing (2D)

4) Frame drawing (2D)

5) The flange coupling drawing (2D)

6) The pinion drawing (2D)

7) Gear drawing in (2D)

8) Casing drawing (2D)

9) Tanker

10)Bush holder drawing (2D)

10) Gear box drawing (2D)

Appindex C: Assemble of wall painting machine (3D)
10

1.wallpainting Machine

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JIMMA UNIVERSITYJIMMA INISTITUTE OF TECHNOLOGY 6/5/2017

DESIGN OF WALL PAINTING MACHINE I

DESIGN OF WALL PAINTING MACHINE II

DESIGN OF WALL PAINTING MACHINE III

No Name of Peer Group ID No Sign

1. Obsinan Girma 01519/05 --------------

1) Main advisor: Dr. Anil (PHD) ----------------

DESIGN OF WALL PAINTING MACHINE IV

DESIGN OF WALL PAINTING MACHINE V

2.4 The conclusion from literature review................................................................................................ 9

DESIGN OF WALL PAINTING MACHINE VI

5.2 Cost Estimation ................................................................................................................................. 69

DESIGN OF WALL PAINTING MACHINE VII

DESIGN OF WALL PAINTING MACHINE IX

NOMENCLATURE AND ABBREVIATIONS

Design load for wire rope

Area of wire rope

Diameter of wire rope

Number of tooth on pinion

A fraction by which standard addendum of the wheel should be multiplied

Gear ratio or velocity ratio

Equivalent bending load

Pressure angle or angle of obliquity

Angular speed on shaft

Pitch line velocity

Angular speed on sheave

Speed of wire rope

DESIGN OF WALL PAINTING MACHINE X

Tangential tooth load

Additional load due to acceleration

Velocity factor for cut tooth

Impact load during starting

Tooth form factor for pinion

Effective load during normal working on the wire rope

Tooth form factor for gear

Actual safety factor during normal working

Effective load on rope during starting

Actual safety factor during starting

Bending factor of safety

Allowable bending stress

DESIGN OF WALL PAINTING MACHINE XI

Fillet radius at root

Pitch line velocity

Number of revolution in rpm

Face load distribution factor

Rim thickness factor

Bending strength geometry factor

Hardness ratio factor

Stress cycle factor

Crushing tensile strength

DESIGN OF WALL PAINTING MACHINE XII

t Thickness of the paint

Diameter of the pipe

Pressure in the pipe

Motion of piston in the cylinder or length of stroke

Thickness of cylinder head

Force acting on studs

Resistance force offered by stud

Mass of connecting rod

Maximum bending moment

Diameter of crank pin

Twisting moment on the crankshaft