Adigrat University: Welay G

ADIGRAT UNIVERSITY
STREAM: DESIGN
NAME IDNO.
TSEGAU HAGOS RET 4358/07
YEMANE ZEREAY RET 4445/07
ZENEBE TADELE RET 4518/07
SUBMITTED TO INS. WELAY G.
SUBMITION DATE: 14/5/2010EC

DESIGN OF PEDAL POWERED WATER LIFTING MACHINE
ABSTRACT
this project is important for people that living in dry areas such as pastorals
and farmers of dry areas. Man power can be good alternative tofulfill the
energy requirements for performing many activities like ground water
lifting.
Pedaling is the most efficient way of utilizing power from human muscles.
Keeping these things in mind a pedal powered water lifting can is
developed.
The machine system comprised of three subsystems namely:
1. Energy Unit: Comprising of suitable peddling mechanism and Flywheel
conceptualized as
Human Powered Flywheel (HPF)
2. Suitable torsion and power transmission shaft and
3. Water contain unit (bucket).
Though human capacity is 0.1hp continuous duty, the processes needing
the minimum power even up to 20w can be energized by this machine
concept to safe human power operating this machine.
This is a water lift which is run by rotating the pedal of a cycle and rotating
the rope on the flywheel that is connected with full of water bucket.
This mechanism lift the water about 10 gallons per one complete cycle
from 10m deeps of hole by extending the rope.
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DICLARATION
This project is entirely our own work. It is clear that any work has owner.
We would like to make clear that this project is done by us. All theories and
analysis except that we have taken from the reference materials and from
internet are our own suggestions and descriptions. We have spent full of
our effort and time to work this project. We believe that we are human
beings in general we are neither absolutely right nor absolutely wrong.
There may be error or any other possible problems in this project. We hope
all readers will play their own role in correcting those problems.
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ACKNOWLEDGEMENT
First of all, we would like to thank the almighty God for blessing us with
strength, aptitude and patience for successfully completing our project.
Our special appreciation goes to our IN; WELAY.G for giving us the
opportunity to work with him and directing us to design this project. His
inseparable follow up of our progress of day to day is really very
interesting and we come up with this accomplish through his effort at all.
We have been able to compile and complete this project report on
comprehensive manner due to guidance, support and counseling that he
has provided to us. Next, we would also have thanks for mechanical
engineering department that given us such fascinating course to solve
society’s problem through designing. Finally yet importantly, our sincere
thanks go to each and every one who has helped and supported us in
writing, searching, analyzing data significantly indifferent stages to
accomplish this project.
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Contents
ABSTRACT...............................................................................…1
DICLARATION.......................................................................….2
ACKNOWLEDGEMENT .......................................................…3
CHAPTER ONE .......................................................................…9
INTRODUCTION...................................................................... 9
1.1 PEDAL POWERED WATER LIFTING.......……...................9
1.2 PROBLEM STATEMENT.................................................... 9
1.3 OBJECTIVE OF THE PROJECT......................................... 9
1.3.1 GENERAL OBJECTIVE................................................... 9
1.3.2 SPECIFIC OBJECTIVE.................................................... 9
1.4 SCOPE……….....................................................................10
1.5 LIMITATI............................................................................10
1.6 METHODOLOGY .............................................................10
1.7 ORGANIZATION OF THE PROJECT ..............................11
CHAPTER TWO ............................................................….......12
LITERATURE RIVEW ............................................................12
2.1 TYPES OF WATER LIFTING DEVICES..........................12
2.1.1THE SHADUF..................................................................12
2.1.2BUCKET AND WINDLASS ...........................................12
2.1.3BUCKET PUMP...............................................................12
2.1.4 PEDAL POWERED WATER LIFTING MACHINE .....13
CHAPTER THREE...................................................................16
RESULT AND DISCUSSION .................................................16
3.1 DATA COLLECTION .......................................................16
3.2 GEOMETRICAL ANALYSIS ...........................................17
3.3 MATERIA SELECTION FOR COMPONENT DESING ..18
3.3.1 MATERIAL SELECTION FOR SHAFT.........................18
3.3.2 MATERIAL SELECTION FOR FLYWHEEL ...............18
3.3.3 MATERIA SELECTION FOR CLUTCH .......................19
3.3.4 MATERIA SELECTION FOR PEDAL ..........................19
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3.3.5 MATERIA SELECTION FOR WIRE ROPE...................19

3.3.6 MATERIAL SELECTION FOR LEVER.........................20
3.3.7 MATERIAL SELECTION FOR PIPE ............................20
3.3.8 MATERIAL SELECTION FOR KEY ........................….20
3.3.9 MATERIAL SELECTION FOR BUCKET.................….20
3.3.10 MATERIAL SELECTION FOR TANKER .................21
3.4 FORCE ANALYSIS.....................................................……21
3.4.1 FORCE RIQUIRED FOR THE SYSTEM ......................21
3.4.2 SHAFT AREA.................................................................22
3.4.3 PRESSURE REQUIREMENT FOR THE SYSTEM.......22
3.4.4 ENERGY INPUT FOR SYSTEM ...................................23
3.5 PART DESIGN...............................................................….24
3.5.1 SHAFT DESIGN .........….................................................24
3.5.2 FLYWHEEL DESIGN ....................................................29
3.5.3 CLUTCH DESIGN...............................…........................31
3.5.4 LEVER DESIGN ............................................................34
3.5.5 PEDAL DESIGN ............................................................40
3.5.6 KEY DESIGN.................................................................43
3.5.7 PULLY DESIGN ............................................................47
3.5.8 BUCKET DESIGN..........................................................51
3.5.9 DISCHURGING PIPE DESIGN .....................................54
3.5.10 ROPE DESIGN..........................................................….57
3.5.11 FRAME DESIGN FOR MACHINE COMPONENT ...59
3.5.12 WELDING DESIGN ....................................................59
3.5.13 BEARING SELECTION ..............................................63
3.5.14 DESIGN FOR FASTENERS.........................................63
3.6 OUTPUT ENERGY.........................................................…64
3.7 MANUFACTURING PROCESS ......................................65
3.8 COST ANALIYSIS ........................................................…66
3.9 GENERAL ASSEMBLY...................................................67
CHAPTER FOUR................................................................….69
CONCLUSION AND RECOMMONDATION.......................69
4.1 CONCLUSION................................................…...............69
4.2 RECOMMONDATION.................................................….70
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4.3 FUTUR WORK ..........................................................…...71

REFERANCE..................................................….....................72
APPENDIX.............................................................................73
LIST OF FIGURE PAGE

Fig 2.1 pedal powered water lifting machine .………..….......13
Fig 3.1 geometrical analysis………………….........................17
Fig 3.2 shaft………………………………………………......24
Fig 3.3 bending moment diagram……………………….....…26
Fig 3.4 flywheel………………………………………………29
Fig 3.5 clutch……………………………………………..…...31
Fig 3.6 lever…………………………………………………...35
Fig 3.7 pedal…………………………………………………...40
Fig 3.8 key…………………………………………………..…43
Fig 3.9 pulley………………………………………………......49
Fig 3.10 bucket………………………………………………...51
Fig3.11 sectioned part………………..…………………….......53
Fig 3.12 welding……………….…..………….………………..60
Fig 3.13 bearing…………………..….………………………….63
Fig 3.14 fasteners…………..…………………………………....64
Fig 3.15 manufacturing method….……………………………...65
Fig 3.16 assembly drawing….………………………………..….68
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CHAPTER ONE
INTRODUCTION
1.1 PEDAL POWERED WATER LIFTING
Pedal powered water lifting is machine used for the farmers to lift
atones of water from any depth and apply for irrigation crops. This
machine lifts the water from any depth by extending the rope. When it is
rains the water level is high the farmers can be stored at well and can be
lift with less effort. So the water can be stored in a container for future
use especially during drought period of time. The stored water in a
tanker can be piped in farm land for irrigation by pipe. A single machine
can be used for many farmers. Farmers will buy the machine for less
than $500(when mass produced) or rent it on an hourly basis. The pedal
powered water lifting machine that we are going to design is lift up to 38
liters per minute when pedaled by singled by single person. Two or more
people may pedaling at the same time to proportionally increase its
lifting capacity. PPWLM is require almost no maintenance, no requiring
more cost, is more reliable locally serviceable in case of manufacturing,
low noise, no pollution and high weight. The PPWLM need not only lift
the entire water needed for irrigation but also it needs for lift the water
for drinking.
1.2 COMPONENTIS OF PEDAL POWERED WATER LIFTING MACHINE
1.2.1 SHAFT
A shaft is a rotating machine element which is used to transmit power

from one place to another. The power is delivered to the shaft by some
tangential force and the resultant torque (or twisting moment) set up
within the shaft permits the power to be transferred to various
machines linked up to the shaft. In order to transfer the power from one
shaft to another, the various members such as pulleys, gears etc., are
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mounted on it. These members along with the forces exerted upon them
causes the shaft to bending. In other words, we may say that a shaft is
used for the transmission of torque and bending moment. The various
members are mounted on the shaft by means of keys or Splines.
1.2.2 FLY WHEEL
Flywheel used in machines serves as a reservoir which stores energy

during the period when the supply of Energy is more than the
requirement and releases it during the period when the requirement of
energy is more than supply. Flywheel is a rotating body acts as reservoir
of the energy.
1.2.3 Gearbox
The most common use is in motor vehicles, where the transmission

adapts the output of the internal combustion engine to the drive wheels.
Such engines need to operate at a relatively high rotational speed, which
is inappropriate for starting, stopping, and slower travel. The
transmission reduces the higher engine speed to the slower wheel speed,
increasing torque in the process. Generally, gearboxes are used to
increase torque while reducing the speed of a prime mover output shaft
(e.g. a motor crank shaft). This means that the output shaft or a gearbox
rotates at a slower rate than the input shaft, and this reduction in speed
produces a mechanical advantage, increasing torque. A gearbox can be
set up to do the opposite and provide an increase in shaft speed with a
reduction of torque. For example lathe machine.
Functions of a Gearbox
 A gearbox is precisely bored to control gear and shaft alignment.

It is used as a housing/container for gear oil.
It is a metal casing for protecting gears and lubricant from water,
dust and other contaminants.
Use of Gearbox
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A variety of gearboxes find applications in a number of industries

depending on the end use. Some of the industries using gearboxes
include Agricultural, Industrial, and Construction, Mining,
Petrochemicals and Food processing
1.2.4 CLUTCH
A clutch is a machine member used to connect a driving shaft to a driven

shaft so that the driven shaft maybe started or stopped at will, without
stopping the driving shaft. The use of a clutch is mostly found in
automobiles. A little consideration will show that in order to change
gears or to stop the vehicle, it is required that the driven shaft should
stop, but the engine should continue to run. It is, therefore, necessary
that the driven shaft should be disengaged from the driving shaft. The
engagement and disengagement of the shafts is obtained by means of a
clutch which is operated by a lever.
1.2.5 LEVER (HANDLE AT THE SIDE OF CLUTCH)
A lever is a rigid rod or bar capable of turning about a fixed point called
fulcrum. It is used as a machine to lift a load by the application of a small
effort. The ratio of load lifted to the effort applied is called mechanical
advantage. Sometimes, a lever is merely used to facilitate the
application of force in a desired direction. A lever may be straight or
curved and the forces applied on the lever (or by the lever) may be
parallel or inclined to one another. We use this clutch to break the
power, lock the driving shaft and to change the direction of rotation. The
principle on which the lever works is same as that of moments.
1.2.6 HANDLE (SUPPORTIG BEAM)
A handle is component of PPWLM which is used to support the operator

during pedaling for lifting water by the machine.
1.2.7 FRAME
Frame is the bathe of the machine which is used to support the

components.
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1.2.8 TANKER
A water tank is a container used to store the water. The need for water
tank is as old as civilization, providing storage of water for drinking water,
irrigational agriculture and other application.
1.2.9 BUCKET
The bucket is the material used contain the water for lifting from the
ground and discharge to the tanker.
1.2.10 WIRE ROPE
The wire ropes are extensively used in hosting Hal slag and material
handling equipment. They are also used in stationary application; such
as guy wire and stays. When a large amount of power is to be
transmitted over long distances from one pulley to another (i.e. when
the pulleys are up to 150 meters apart), then wire ropes are used. The
wire ropes are widely used in elevators, mine hoists, cranes, conveyors,
hauling devices and suspension bridges. The wire ropes run on grooved
pulleys but they rest on the bottom of the grooves and are not wedged
between the sides of the grooves. The wire ropes are made from cold
drawn wires in order to have increase in strength and durability. It may
be noted that the strength of the wire rope increases as its size
decreases. The various materials used for wire ropes in order to
increasing strength of wrought iron, cast steel, extra strong cast steel,
plough steel and alloy steel. For certain purposes, the wire ropes may
also be made of copper, bronze, aluminum alloys and stainless steel
1.3 WORKING PRINCIPLE
The principle of operation of the machine is very simple and requires

only one man to operate. To operate the machine first tied the rope on
the bucket, then after rotate the lever to return the bucket to the
ground water. To fetch the water the bucket will sick on the water by
itself due to its spherical shape and we design the bucket sectioning on
the tope surface to sink in the water easily. After it fetches the water the
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operator will drive the pedal to lift the water from the well. When it
reaches at the suitable level rotate the lever to the opposite direction in
order to stop the movement of the bucket. After the mechanism will
stop, direct the pipe of the bucket to the tanker and by opining the
check valve that found on the bucket and makes the flow of the water to
the tanker.After the tanker will be full of water, by opining check valve
at the bottom of the tanker and watering the crop by applying pipe.
1.4 OBJECTIVE OF THE PROJECT

This project has two objectives.The general objective which include
about the general objective of the project and the specific objective
which express about the entire parts of the project.
1.4.1 GENERAL OBJECTIVE

 To design pedal powered water lifting machine.
1.4.2 SPECIFIC OBJECTIVE

 To design shaft
 To design flywheel
 To design gear box
 To design a clutch
 To design pedal
 To design frame for the mechanism
 To design lever
 To design pipe
 To design rope
 To design bucket
 To design pulley
1.5 SCOPE This pedal powered water lifting machine design paper is
aimed to design a pedal powered water lifting machine which is used to
lift the water from the well. This project is focused on the purpose of
irrigation to minimize the shortage of water during dry season. This
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paper also uses for mechanical engineering students as a reference to be

used for academic purpose and to be stored as a document for
mechanical engineering.
CHAPTER TWO
LITERATURE RIVEW
2.1 TYPES OF WATER LIFTING DEVICES
Many people throughout the world rely an underground water
supply for clean drinking water. Also in hot regions where rain fall is low
or unreliable, water is often lifted from rivers, channeled and also from
the dams and wells in to field to water or irrigate the crops. Different
device have been invited over the ages to raise water. Most of them are
still in use. Such as;
 The shaduf
 Bucket and windlass
 Bucket pump
 The Persian wheel
 The rope pump
 The pedal powered flywheel motor
 Pedal powered water pump
2.1.1THE SHADUF
The Shaduf is a simple water lifting device that has been used for the
past 4500 years and also used in the Middle East. It is made of an upright
past on whish is balanced along thin pole. A rope and bucket are fixed at
one end, and heavy counter balanced weight is attached to the other
end to balance the bucket. Then it is only necessary to pull on rope
lower bucket to the water. The weight can then lift up the full bucket.
2.1.2BUCKET AND WINDLASS

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In many parts of Africa and Middle East, the bucket and windlass
device is widely used as means of raising water from well. This is a type
of wheel and axels on the right are diagrams of two buckets and
windlass machine.
2.1.3BUCKET PUMP
There are three parts to the pump
 The pump stands including footings and windlass.

 The bucket and chain.
 The PVC (plastic) casing which sits in the well.
The bucket pump has a cylindrical still bucket with simple none return
valve at its base so that the water can flow in but not out. The bucket is
connected to the windlass through the length of chain. The bucket is
raised or lowered through a PVC casing which is either mounted in a
hand drilled tube well or wide diameter well.
2.1.4 PEDAL POWERED WATER LIFTING MACHINE

PPWLM is the machine which is used to lift the water from above 10
gallons per minute from wells and bored above 10 meter of depth or
from any depth by extending the rope to provide irrigation and drinking
water where the electricity is not available. From the other water lifting
mechanism we have to select and to design the pedal powered water
lifting machine for the following reason. Pedal powered water lifting
machine:
 Can lift the water from any depth. Just extending the rope.
 Cheap to product
 More reliable, no electrical parts
 Works 24 hours a day
 Less risk of theft. Machine have less weight, can be dissembled
within a short period of time and taken a home after completion
the purpose.
 No more maintenance for components
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 We may goat some materials for production in a simple way.

 It is simple mechanism comparing to the others.
Fig. pedal powered water lifting machine
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CHPTER 3
METHODOLOGY AND PROPLEM STATMENT
3.1 METHODOLOGY
To achieve the goal of our project we used the primary and secondary
data analysis.
Primary data collection:
We collected data for project analysis we observe some method from
the existing water lifting systems.
Secondary data collection:
It is expected to do this project by using different resources; such as
Internet access, different books
and our concept. The reference books that we used are:
 Text book of machine design
 Machine element of second edition
 Use Internet
 Interview and observation
3.2 PROBLEM STATEMENT

It is known that there is a shortage of water on the land surface of most
desert rural areas; especially in the low land area of our country. No
loose of water in the developed country easily like in our country. They
can use either the rain fall or ground water properly by applying
technology. That is why the government of our country forces farmers
and pastorals to construct wells and dams around their location. But
they did not care to use the water properly. It is mean that; the
population gets risk while they are fetching water and they will be tiered
when they fetch water. That is why we forced to design this project
which is known as pedal power water lifting machine that is used for
water lifting from underground.
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3.3 LIMITATION
This project entirely concerned with the pedal powered water lifting
machine that is used lift the water from the ground in order to minimize
the problem due to the shortage of the water at the dry area. But this
project has the following limitations:
 The mechanism has no on and off system.

 Operating by man power mechanically, not automatically.
 If the operator tiered during operating the bucket of water turns
to the well.
 Because it has no automatic connected system.
 The mechanism has no the application of the pump system.
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CHAPTER 4
DESIGN ANALYSIS
4.1MATERIAL SELECTION FOR COMPONENT DESING
4.1.1 MATERIAL SELECTION FOR SHAFT
Since the shaft is a rotating machine element used to transmit power
from one part to the other. So to safe operation from risk and shaft from
damage we have to select carbon steel of grade 50C12. Because it has
the following property:
 It has high strength
 It has good mach inability
 It has low notch sensitivity factor
 It has high wear resistance property
 It has good heat treatment
4.1.2 MATERIAL SELECTION FOR FLYWHEEL

Flywheel is a heavy rotating body that acts as reservoir of energy. The
energy is stored in the flywheel in the form of kinetic energy. We select
the cast iron for this component by considering the following property:
 It is cheap
 It can be any complex shape without involving machine
operation
 It has an excellent ability to damp vibration
4.1.3 MATERIA SELECTION FOR CLUTCH
A clutch is a machine member used to connect a driving shaft to a driven
shaft’s that the driven shaft may be started or stopped at the will of
operator, without stopping the driving shaft. We select alloy steel
material for this component. Because of the following property:
 It has high heat conductivity
 It has high wear resistance
 It has the ability to stand high temperature that caused by
slippage
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 It is not affected by moisture and oil

4.1.4 MATERIAL SELECTION FOR PEDAL
Pedal system is any foot operated lever or other device which is used to
rotate the shaft. We select aluminum alloy material for this component.
Because of the following property:
 It is light in weight or mass
 It has high resistance to corrosion
 High reflection to both heat and light
4.1.5 MATERIAL SELECTION FOR WIRE ROPE
Since, the wire rope is made of cold drawing wires in order to have a
greater strength and durability. We select the wrought iron. Because of
the following property:
 It is tough, malleable and ductile material
 It has higher durability from the fiber rope
ADVANTAGES OF WIRE ROPE OVER FIBER ROPE
The wire ropes have the following advantages as compared to fiber
ropes.
 These are lighter in weight,
 These offer silent operation,
 These can withstand shock loads,
 These are more reliable,
 These are more durable,
 They do not fail suddenly,
 The efficiency is high, and
 The cost is low. Has high strength to weight ratio
 Has greater reliability
 Silent operation even at high velocity
 Has high strength to weight ratio
4.1.6 MATERIAL SELECTION FOR LEVER
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Lever is a component used to engage and disengage the clutch for

process of opening and closing the operation. We select cast iron for this
component. Because of the following property:
 Cheapest or low cost
 High wear resistance
 Good machinability
4.1.7 MATERIAL SELECTION FOR PIPE
The pipes are used for transporting various fluids like water, steam,
different types of gases, oil and other chemicals with or without
pressure from one place to other place. We select polyethylene plastic
material for this component. Because of the following property:
 Relatively low cost per unit weight
 Good corrosion resistance
 Principally low weight
 Generally has excellent plastic property
4.1.8 MATERIAL SELECTION FOR KEY
We use key to prevent relative motion or rotation between shaft and
flywheel. There are different types of key. From them we select sunk.
Also the sunk key can be classified as many type depend on the shape of
keys. So by considering the shearing and crushing of the key we select
rectangular sunk steel material that has the same property with shaft
material which is carbon steel of grade 50C12.Because it may be
minimize the crushing and shearing of the key as the key material has
the following the same property with the shaft materials.
 It has good machinability
 It has low notch sensitivity factor
 It has high wear resistance property
 It has good heat treatment
4.1.9 MATERIAL SELECTION FOR BUCKET
Bucket is a material which has a circular cone shape that used to contain
the water when we are fetch the water from the ground or from the well.
This material can always contact with moisture in case it is used to
contain the water. As we know if the most materials can contact with
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water or moisture rusting or corrosion of the component will be form.

Due to this reason to prevent or minimize the corrosion of this
component we select the aluminum alloy with aluminum number 2017
that has the following properties;
 Yield strength(𝑌𝑠 )=70Mpa
 Tensile strength(𝑆𝑢 )=179Mpa
 Fatigue(𝑆𝑓 )=90Mpa
 Elongation in 2in%=22
 Hardiness=45 HB
 Specific gravity=2.7
We select this material for the following reason
 High corrosion resistance
 Ease of fabrication
 High specific gravity than water
4.1.10 MATERIAL SELECTION FOR GEAR BOX
The materials of most of the gears used for transmitting reasonable
torque and speed mainly need to be mechanically strong in shear and
bending, sufficiently tough and resistant to wear, fatigue and chemical
degradation. Many factors influence the selection of materials for gears,
and the relative importance of each can vary. These factors include:
 Mechanical Properties
 Grade and Heat Treatment
 Cleanliness
 Dimensional Stability
 Availability and Cost
 Harden-ability and Size Effects
 Mach-inability and Other Manufacturing Characteristics.
Generally, the gears may be manufactured from metallic or non-metallic
materials. The metallic gears with cut teeth are commercially obtainable
in cast iron, steel and bronze. The non-metallic materials like wood,
rawhide, compressed paper and synthetic resins like nylon are used for
gears, especially for reducing noise. The cast iron is widely used for the
manufacture of gears due to its good wearing properties, excellent
mach-inability and ease of producing complicated shapes by casting
method. The cast iron gears with cut teeth may be employed, where
smooth action is not important.
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The steel is used for high strength gears and steel may be plain carbon
steel or alloy steel. The steel gears are usually heat treated in order to
combine properly the toughness and tooth hardness.
4.1.11 MATERIAL SELECTION FOR TANKER
A water tank is a container used to store the water. The need for water
tank is as old as civilization, providing storage of water for drinking water,
irrigation for agriculture and other application. Various materials are
used for making water tank such as plastic, steel, stone and fiber glass.
From these materials we select the fiber glass. Because of the following
property
 Light in weight
 Can weather resistance
 Both stiff and strong in tension and comparison
 Cheapest in cost
4.2 FORCE ANALYSIS
4.2.1 FORCE RIQUIRED FOR THE SYSTEM
From the gravitational force analysis:
F=mg because our force applied due to gravity. So;
𝐹1 =𝑚1 g=50kg*9.81=490.5N 𝐹2 = 𝑀2 55kg*9.81𝑚⁄ 2
𝑠
Gravity(in
No of masses Mass ( in kg) No of forces Force(in N)
m/s )
2
9.81
m1 50 F1 490.5
9.81
m2 55 F2 539.55
9.81
m3 60 F3 588.6
9.81
m4 65 F4 637.65
9.81
m5 70 F5 686.7
9.81
m6 75 F6 735.75
9.81
m7 80 F7 784.8
Table 4.1 force required to apply on the pedal
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4.2.2 SHAFT AREA

Since the shaft circular in shape
𝑑2
A =π
4
(12.5𝑚𝑚)2
𝐴1= π =126.67
4
No of diameters Diameter( in mm) No of areas Area(in mm2)

d1 12.7mm A1 126.67
d2 25.4mm A2 506.71
d3 38.1mm A3 1140.09
d4 50.8 A4 2026.82
Table 4.2 area of the shaft on which the force is applied
4.2.3 PRESSURE REQUIREMENT FOR THE SYSTEM

𝐹
p= from the pressure analysis formula
𝐴
𝐹1 490.5𝑁
P= =126.67𝑚𝑚2 =3.869*106pa
𝐴1
Area(in Pressure(in Area(in Pressure(in

𝐹1 (in N) 𝐹3 (in N)
mm2) N/mm2) mm2) N/mm2)
126.67 3.869 126.67 4.647
506.71 0.986 506.71 1.126
490.5 588.6
1140.09 0.430 1140.09 0.516
2026.82 0.242 2026.82 0.315
Area(in Pressure(in Area(in Pressure(in
mm2) N/mm2) mm2) N/mm2)
126.67 4.259 126.67 5.034
506.71 1.065 506.71 1.258
539.55 637.65
1140.09 0.473 1140.09 0.559
2026.82 0.266 2026.82 0.315
𝐹5 Area Pressure( Area Pressure( 𝐹7 Area Pressure(

𝐹6 (in
(in (in in (in in (in (in in
N)
N) mm2) N/mm2) mm2) N/mm2) N) mm2) N/mm2)
686. 126.67 5.691 735.7 126.67 5.808 784. 126.67 6.189
FINAL PROJECT 22
7 506.71 1.355 5 506.71 1.452 8 506.71 1.549

1140.0 0.602 1140.0 0.645 1140.0 0.688
9 0.339 9 0.363 9 0.387
2026.8 2026.8 2026.8
Table 4.3 pressure distribution when the force is

applied on the area of the mechanism.
3.4.4 ENERGY INPUT FOR SYSTEM
The energy input for the mechanism is the potential energy because the
force applied is the force due to gravity. So estimate the input energy we
have to consider the height of the operator to perform the mechanism. As
we have taken the height in design specification; H= (140-170). So;
PE=mgh
PE1 = F1h1=490.5N*1.4m=686.7j
Height (in Energy (in Height (in Energy (in
m) J) m) J)
1.4 686.7 1.4 824.04
1.45 711.225 1.45 853.47
1.5 735.75 1.5 882.9
490.5 1.55 760.275 588.6 1.55 912.33
1.6 784.8 1.6 941.75
1.65 809.325 1.65 971.19
1.7 833.85 1.7 1000.12
Height (in Energy (in Height (in Energy (in
𝐹2 (in N) 𝐹4 ( in N)
m) J) m) J)
1.4 755.37 1.4 892.71
1.45 782.4375 1.45 924.5925
1.5 809.325 1.5 956.475
539.55 1.55 836.28 637.65 1.55 988.3575
1.6 863.28 1.6 1020.24
1.65 890.2575 1.65 1052.1225
1.7 917.235 1.7 1084.005
Energy Energ
𝐹5 (in Height Energy 𝐹6 (in Height 𝐹7 (in Height
(in y
N) (in m) (in J) N) (in m) N) (in m)
J) (in J)
686.7 1.4 961.38 735.75 1.4 1030.05 784.8 1.4 1098.7
FINAL PROJECT 23
1.45 995.72 1.45 1066.83 1.45 1137.9

1.5 1030.1 1.5 1103.62 1.5 1177.2
1.55 1064.4 1.55 1140.41 1.55 1216.4
1.6 1098.7 1.6 1177.2 1.6 1255.6
1.65 1133.1 1.65 1213.98 1.65 1294.9
1.7 1167.4 1.7 1250.77 1.7 1334.1
Table 4.5 energy input for the system to operate the

machine.
3.5 PART DESIGN
3.5.1 SHAFT DESIGN
The shaft should be designed on the basis or on the consideration of
strength and rigidity. We select carbon steel
Grade 50C12
Ultimate tensile strength (δu) =700Mpa
Yield strength (𝑌𝑠 ) =390Mpa
F=637.7=638N
D=31.8mm=0.0318m
L=1.4m
Fig 3.2 shaft

Shaft subjected to the combination of both twisting moment and bending
moment. When shaft is to combined twisting moment and bending
moment, then the shaft must be designed on the basis of the two moment
simultaneously. The following two theories are important from the
subject point of view.
Maximum shear stress theory
Maximum normal stress theory
But we use the formula of maximum shear stress theory since the material
we selected for this
shaft material is ductile material.
𝜏𝑚𝑎𝑥 =√δ2b − 4τ
FINAL PROJECT 24
we have the following equation when shaft is subjected to twisting

moment
𝑇 τ
= …………………………….………..………….eq (1)
𝐽 𝑟
Where T =twisting moment acting up on the shaft
J =polar moment of inertia of the shaft about the axis of
rotation
τ =torsional shear stress and
𝑑
r =distance from the neutral axis to the outer most fiber or r=
2
We know that for round solid shaft polar momentum of inertia (J)
𝜋
J= *𝑑 4
32
So the eq (1) may be written as the following

𝑇 τ
𝜋 =
∗ 𝑑4 𝑑
32 2
𝜋
T= *τ*𝑑 3 …………………………………..…….…………………eq
16
(2)
So, the torque of the shaft when the force 637.6N is applied on the shaft
of 31.8mm in diameter having 7.94𝑚2 is calculated as the following.
𝜋
T= *τ*𝑑 3
16
𝐹
We know that τ= but A=𝜋𝑑 2 /4=794.2𝑚𝑚2
𝐴
638𝑁
=
7.942∗10−4 𝑚2
𝑁
= 0.8 2
𝑚𝑚
=0.8Mpa
𝜋 𝑁
T= *0.803293756 *(31.8𝑚𝑚)3
16 𝑚𝑚2
=5072N.mm
We the following equation when the shaft is subjected to bending
FINAL PROJECT 25
𝑀 δ𝑏
= 𝑦 ……………………………………………….eq (1)
𝐼
Where M=bending momentum
I=momentum of inertia of cross-sectional area of the
shaft about the axis of the shaft.
δ𝑏 =bending stress
Y=distance from neutral axis to the outer most fiber
It is known that for a round solid shaft momentum of inertia (I),
𝜋 𝑑
I= ∗ 𝑑 4 𝑎𝑛𝑑 𝑦 = ………………………………….eq (2)
64 2
Fig 3.3 bending momentum diagram

Take ΣMA=0
RB*1400mm-638N*700mm=0
638𝑁∗700𝑚𝑚
RB= =319N
1400𝑚𝑚
Again taking Σ 𝐹𝑌 =0
𝑅𝐵 +𝑅𝐴 -F=0
𝑅𝐴 =F- 𝑅𝐵
𝑅𝐴 =638N-319N
=319N
Σ𝑀𝐵 = 𝑅𝐵 *1.4 + F*0.7
=319*1.4 + 638*0.7
=893.2N.m
𝑀𝑇 = 0+893.2=893.2N.m
𝑀 δ𝑏
=𝑦
𝐼
𝜋 𝜋
I= ∗ 𝑑4 = ∗ 324 =51471.85𝑚𝑚4
64 64
𝑑 32
y= = = 16𝑚𝑚
2 2
From the above
FINAL PROJECT 26
𝑀 δ𝑏 𝑀𝑦 893200𝑁.𝑚𝑚∗16𝑚𝑚
= , δ𝑏 = = =277.65Pa
𝐼 𝑦 𝐼 51471.85𝑚𝑚4
𝜏𝑚𝑎𝑥 =√δ2b − 4τ =√2.7765𝐾𝑃𝑎2 − 4 ∗ 0.8𝑀𝑃𝑎 =2.132kpa
Factor of safety
τs
F.S=
τall
𝑌𝑠
But τs= 2 =390𝑀𝑃𝑎
2
=195Mpa and
τall =0.18𝑆𝑢 =0.18*700Mpa =126Mpa
S0 safety factor of the shaft will be:
τS 195𝑀𝑃𝑎
F.S= = =1.5
τall 126𝑀𝑃𝑎
Mass of shaft
M=ƍ*v
𝑘𝑔
Where mass density of steel is 7850 ⁄ 3 and volume shaft is area of
𝑚
shaft multiplied by lengthof shaft (the shaft is solid)
V=794.2𝑚𝑚2 *1400mm
=1111880𝑚𝑚3 =0.001111880𝑚3
So, mass of shaft will be:
𝑘𝑔
M=7850 ⁄ 3 *0.001111880𝑚3 =8.73kg
𝑚
Weight of shaft
W=mg =8.73kg*9.8=85.6N
Angular velocity of shaft
𝜋𝐷𝑁 𝜋∗32𝑚𝑚∗60𝑟𝑝𝑚
V= = =100𝑚𝑚⁄𝑠
60 60
3.5.2 FLYWHEEL DESIGN

Specification
Selected material is cast iron having
Tensile strength=100Mpa
Compressive strength=400Mpa
Shear strength=120MPa
Mass of flywheel=20kg (our assumption)
𝑘𝑔
Density of cast iron=7200 ⁄ 3
𝑚
FINAL PROJECT 27
The flywheel should be designed based on the consideration of

Cross-sectional area dimension of the flywheel rim Diameter and length
of hub
Fig 3.4 flywheel

3.5.2.1 CROSS-SECTIONAL AREA OF THE RIM
A=b*t
=2𝑡 2
Where t=thickness of the flywheel rim
b=width of the flywheel rim and b=2t
Assume mass of the flywheel rim is 20kg diameter of the flywheel is
150mm
Mass (m) =density*volume
=A*𝜋D*ρ
Where A=area of the rim=2𝑡 2
D=diameter of the flywheel
𝑘𝑔
ρ=density of the cast iron=7200 ⁄ 3
𝑚
Because the material that we selected for this purpose is cast iron
𝑘𝑔
So 20kg=2𝑡 2 *π*0.15m*7200 ⁄ 3
𝑚
2 𝑘𝑔⁄
10kg=𝑡 *π*0.15m*7200
𝑚3
2 2
𝑡 =0.002947𝑚
t=√0.002947𝑚2 =0.054289m=54.289mm=54mm
Area of the rim
A=2𝑡 2 =5832m𝑚2
Volume of the flywheel
V= A*π D
FINAL PROJECT 28
=3.14*5832m𝑚2 *120mm
=2197497.6𝑚𝑚3
Width of the flywheel rim (b)
b=2t =2*54mm=108mm
3.5.2.2 DIAMETER AND LENGTH OF THE HUB

Let, d=diameter of the hub= 2𝑑1
𝑑1 =diameter of the shaft
l=length of the hub
We know the shaft diameter before d1 (31.8mm)
The diameter of hub (d) is twice of the shaft diameter (d1)
d=2𝑑1 =2*31.8mm =63.8mm=64mm and
Length of the hub (l) is twice of the width of the rim (b)
L=2*b =2*108mm=216mm
Weight of the flywheel=m*g =20kg*9.81𝑚⁄𝑠 2 =196.2N
Angular velocity
𝜋𝐷𝑁 𝜋∗120𝑚𝑚∗60𝑟𝑝𝑚
V= = =376.8mm⁄s
60 60
3.5.3 CLUTCH DESIGN
Selected material is alloy steel 35Ni1cr60
Mass of clutch=15kg (assumption)
We design the clutch by considering the two friction surfaces maintained
in contact by an axial thrust (W) as shown in the figure
below.
Fig 3.5 clutch

Where: p=intensity of axial pressure with which the contact surface
are haled together
r1and r2 =mean radius of the friction face
μ=coefficient friction
W=an axial thrust.
Consider an elementary ring of radius (r) and the thickness diameter (dr)
in the fig. 3.5
We know that area of the contact surface or friction surface
A=2𝜋r*dr
Therefore: normal or axial force on the ring
δW=pressure*area
FINAL PROJECT 29
=p*2𝜋r*dr and
The frictional force on the ring acting tangentially at radius (r):
Fr=μ*δW=μ*p*2𝜋r*dr
Therefore: frictional torque (TR) acting on the ring will be
TR=Fr*r=μ*p*2𝜋r*dr*r
TR=2𝜋𝑟 2 *μ*p*dr
The pressure is uniformly distributed over the entire area of the friction
face as shown in the fig. (a), then the intensity of pressure will be:
𝑤
P= 2 2
𝜋[𝑟1 −𝑟2 ]
Where: W=axial thrust with which the friction surfaces are haled
together.
We have discussed above that the frictional torque on the elementary ring
of radius (r) and thickness (dr) is:
TR = 2π𝑟 2 *μ*p*dr
Integrating this equation within the limits from 𝑟1 and 𝑟2 for total
frictional torque.
Therefore: total frictional force acting on the friction surface or on the
clutch is:
𝑟 3 𝑟1 𝑟2 𝑟2
T=∫𝑟 1 2π𝑟 2 ∗ μ ∗ p ∗ dr =2πμp [𝑟 ⁄3]𝑟 =2πμp[ 1 − 2 ]
2 2 3 3
𝑤 𝑟12 𝑟22 𝑟 3 𝑟 2
=2πμ* 2 2 *[ − ] =2⁄3 [ 12 − 22] π w
𝜋[𝑟1 −𝑟2 ] 3 3 𝑟1 𝑟2
=N*W*R
𝑟3 𝑟2
Where: R=2⁄3 [ 12 − 22]
𝑟1 𝑟2
R=mean radius of the friction surface.

The plate clutch having a single driving plate with contact surface on
each side is required to 20 w at 60 rpm. The outer diameter of the contact
surface is to be 35mm. the coefficient of friction is 0.4 and the uniform
pressure is 2.06𝑁⁄ and the outer diameter of the contact surface (d1)
𝑚𝑚2
is 35mm.
Then we have to determine the inner diameter (d2) of the contact surface.
We know that the torque transmitted by the clutch.
𝑝∗60 20∗60
T= = =3.1Nm=3100Nmm
2𝜋𝑁 2𝜋∗60
Axial thrust with which the contact surfaces are held together is:
W= Pressure*Area =p*π*[𝑟12 − 𝑟22 ] =2.06*[(17.5mm)2 -(𝑟22 )]
W=1982[1-𝑟22 ]……………….……………eq (1)
FINAL PROJECT 30
And mean radius of the contact surfaces for the uniform pressure
condition is:
𝑟3 𝑟2
R=2⁄3 [ 12 − 22]
𝑟1 𝑟2
17.53 𝑟2
R=2⁄3 [ 3 − 22]…………………….....eq (2)
17.5 𝑟2
We know the torque transmitted by the clutch
T=ɳ*μ*w*R…………………………………………..eq (3)
By substituting eq (1) and eq (2) in eq (3) we will gate
𝑟3 𝑟2
T= ɳ*μ*6.5*[(17.5mm)2 -(𝑟22 )*2⁄3 [ 12 − 22]
𝑟1 𝑟2
𝑟3 𝑟2
=2*0.4*6.5*[(17.5mm)2 -(𝑟22 )*2⁄3 [ 12 − 22]
𝑟1 𝑟2
2 3
= ⁄3*2*0.4*6.5*[(17.5mm) -(𝑟2 )] 3
=3.5*[(17.5mm)3 -(𝑟23 )]
But the torque transmitted by the clutch is 3.1Nm or 3100Nmm from the
privies calculation.
T=ɳ*μ*w*R
3100N.mm=3.5*[(17.5mm)3 -(𝑟23 )]
3100N.mm
= [(17.5mm)3 -(𝑟23 )]
3.5
885.7=5359.4-𝑟23
𝑟23 =4473.7𝑚𝑚3
3
𝑟2 =√4473.7𝑚𝑚3
𝑟2 =16.477mm, 𝑑2 =33mm
Weight of clutch
W=m*g =15kg*9.81𝑚⁄ 2 =147N
𝑠
3.5.4 LEVER DESIGN
We design the lever for operating the clutch to connect and disconnect the
operation. The lever can be operated either by a single person or by two
persons. The maximum force in order to operate the lever may be taken
as 400 N and the length of handle as 300 mm. In case the lever is
operated by two persons, the maximum force of operation will be doubled
and length of handle may be taken as 500 mm. The handle is covered in a
pipe to prevent hand scoring. The end of the shaft is usually squared so
that the lever may be easily fixed and removed. The length (L) is usually
from400 to 450 mm and the height of the shaft Centre line from the
ground is usually one meter.
FINAL PROJECT 31
In order to design such levers, we have to put the following in to

consideration.
The diameter of the handle (d)
The cross-section of the lever arm is usually rectangular having
uniform thickness through out.
The induced shear stress in the section of the lever
arm near the boss, caused by the twisting moment
checking the maximum principal or shear stress
The diameter journal of the shaft.
SPECIFICATION
We select cast iron having

Tension and compression =80Mpa
Shear stress =50Mpa
Length of the handle=300mm
Length of the arm=400mm
Overhang of the journal=100mm
Mass of lever=2kg (assumption)
Fig 3.6 lever
NB: - It is assumed that the effort (p) applied on the handle acts at
2⁄ of the length. The permissible bending stress for the lever material
3𝑟𝑑
may be taken as 50Mpa and shear stress for shaft material as 40Mpa. The
lever is acted by single a person.
3.5.4.1 HANDLE DESIGN
FINAL PROJECT 32
Since the force applied acts at a distance of 1⁄ 𝑟𝑑 length of the handle

3
from its free end, thereforethe maximum bending momentum is:
M= (1 - 1⁄3) p∗ l =2⁄3p*l
=2⁄3*400∗300 =80*103 N-mm
Section modulus (Z)
Z=𝜋⁄32*𝑑 3
Z=0.0982*𝑑 3 …………………………….…………eq (1)
Resisting bending momentum
M=δ𝑏 *Z =50*0.0982*𝑑 3
M=4.91𝑑 3 N-mm……………………………..……eq (2)
From equation 1 and 2 we will gate the diameter of the handle

So the diameter is
80∗103
𝑑3= =16.3*103
4.91
3
= √16.3
=25mm
Area of the handle
𝜋𝑑 2
A=
4
=490.6𝑚𝑚2
Volume of the handle
V=A*L =490.6𝑚𝑚2 *300mm
=147187.5𝑚𝑚3
3.5.4.2 LEVER ARM DESIGN

Assume the lever arm is designed for 25% more bending momentum, so
the maximum bending
Momentum of the lever is:
M=1.25p*l =1.25*400*400
=200*103 N-mm
The section modulus (Z), since the lever is rectangular section:
Z=1⁄6*t*𝐵2
Where: t=thickness of the lever arm in mm and
B=width of the lever arm near the boss, in mm
Assume B=2t
Z=1⁄6*t*𝐵2 =1⁄6*t*(2𝑡)2
=0.667𝑡 3
From the bending stress (δ𝑏 )
FINAL PROJECT 33
𝑀 50∗200∗103 50∗200∗103
δ𝑏 = = , 50=
𝑍 0.667𝑡 3 0.667𝑡 3
300∗10 3
𝑡 3=
50
3 3 3
𝑡 =6*10 = √6000 =18.2=20mm
B=2t=2*20=40mm
Area of lever arm
A=2𝑡 2
=800𝑚𝑚2
Volume of lever arm
V=A*h =800𝑚𝑚2 *400mm
=320000𝑚𝑚3
T0tal volume
Vt=320000𝑚𝑚3 +147187.5𝑚𝑚3
=467187.5𝑚𝑚3
Including bending and shear stress we have to check the lever arm
Bending momentum on the lever arm near the boss
(Assuming that the length of the arm existed up to center of the shaft) is
given by:
M=p*l =400*400
=160*102 N-mm
Section modulus (Z)
Z=1⁄6*t*𝐵2 = 1⁄6*20*402 =5333𝑚𝑚2
𝑀 160000
δ𝑏 = = =30Mpa
𝑍 5333
Therefore: Included bending stress is within safe limits.

The twisting momentum:
T=2⁄3p*l =2⁄3∗ 400 ∗ 300
=80*103 N-mm
From twisting momentum
T=2⁄9B*𝑡 2 *τ 80*103 N-mm =2⁄9*40*202 *τ
80000𝑁−𝑚𝑚
So, τ= =22.5Mpa
3556
Check the cross-section of the lever arm for maximum principal or shear
stress maximum principal stress
𝛿𝑏(max) = 1⁄2[δ𝑏 (+ √(δ𝑏 2 +4τ2 )]
= 1⁄2 [30+√(302 +22.52 )] =42Mpa

FINAL PROJECT 34
Maximum shear stress

τ (max) =1⁄2+√(δ𝑏 2 +4τ2 )
τ (max) = 1⁄2+√(302 +22.52 ) =27Mpa
Therefore the maximum principal and shear stresses are also within safe
limit.
3.5.4.3 SHAFT JOURNAL DESIGN

Since the journal of the shaft is subjected to twisting momentum and
bending momentum, therefore: its diameter is obtained from equivalent
twisting momentum, so Equivalent bending momentum is:
2𝑙
Te=𝑝√[( + 𝑥)2 + 𝑙 2 ]
3
2∗300
=400√[( + 100)2 + 4002 ]
3
From the equivalent twisting momentum (Te)
200*103 =𝜋⁄16∗ τ∗ 𝐷3
200*103 =𝜋⁄16∗ 40∗𝐷3
200000
𝐷3 =
7.86
3
D=√25.445 ∗ 103 𝑚𝑚3 =30mm
Weight of lever
W=mg =2kg*9.81𝑚⁄ 2 =19.6N
𝑠
3.5.5 PEDAL DESIGN

The pedal is used to rotate the shaft when the force is applied on it. When
we design the pedal for this mechanism we essentially consider the
following.
FINAL PROJECT 35
Fig 3.7 pedal

Let l=length of rod of pedal
y=height of foot
D=diameter of the pedal
h=total length of the pedal
x=length of foot
l+y=43mm+24mm=67mm
x=26mm
t=20
From the measurement of pedal of bicycle we assume the total length (h)
of the pedal is equals to 100mm.
h=D+l+y
D=h-(l+y)
D=100mm-(43mm+24mm) =33mm
Total area
AT=A1+A2+A3
𝐴2 =𝜋⁄4 𝐷2 =𝜋⁄4*(33𝑚𝑚)2
=855𝑚𝑚2
𝐴2 =t*l
=20mm*43mm =860𝑚𝑚2
𝐴3 =x*y
=26mm*24mm𝑚𝑚2 =624𝑚𝑚2
AT= A1+A2+A3=855𝑚𝑚2 +860𝑚𝑚2 +624𝑚𝑚2 =2339𝑚𝑚2
Volume of the pedal
V=AT*h =2339𝑚𝑚2 *100mm
FINAL PROJECT 36
=233900𝑚𝑚3 =0.0002339𝑚3
Mass of the pedal
M=ƍ*v
Where ƍ=density of the pedal
V=volume of the pedal
𝑘𝑔
But the volume the pedal is 2700 ⁄ 3 because the material that
𝑚
we selected is aluminum
𝑘𝑔
So, M= ƍ*v =2700 ⁄ 3 *0.002339m3
𝑚
=0.63153kg
Weight of the pedal
W=m*g =6.21kg*9.81𝑚⁄ 2
𝑠
=6.1953093N =6.2N
For four pedal w=6.2*4=24.8N
Stress of the pedal

𝐹 6.2𝑁
δ= = =0.0267𝑁⁄
𝐴𝑇 2339𝑚𝑚2 𝑚𝑚2
3.5.6 KEY DESIGN
Key is the component used to prevent the relative motion or rotation
between the shaft and the flywheel when we connect them to transmit the
torque due to the applied force. When a key is used in transmitting torque
from the shaft to a rotor or hub, there are two types of forces acts on the
key.
Force (F1) due to fit of the key in in its key way, as in a tight fitting
straight key or in tapered key driven in place. These forces produce
compressive stresses in the key which are difficult to determine in
magnitude.
Force (F) due to the torque transmitted by the shaft. These forces
produce shearing and compressive (or crushing). The distribution of the
force along the length of the key is not uniform because the forces are
concentrated near the torque-input end. The non-uniformity of
distribution is caused by the twisting of the shaft within the hub. In
designing a key, forces due to fit of the key are neglected and it is
assumed that the distribution of forces along the length of key is uniform.
FINAL PROJECT 37
Fig 3.8 key

Let T=torque transmitted by the shaft
F=tangential force acting at the circumference of the shaft
d=diameter of the shaft
L=length of key
h=thickness of key
b=width of key and
τ &𝛿𝑐 =shear and crushing stress for the material of key
τ1=shear stress for shaft material.
The rectangular sunk key parameters have the following proportion:
b=𝑑⁄4
h=2𝑑⁄3 =𝑑⁄6
Consider that due to the power transmitted by the shaft, the key may fail
due to shearing or crushing. Considering shearing of the key, the
tangential shearing force acting at the circumference of the shaft:
F=area of resisting shearing*shear stress
=L*b*τ
Therefore torque transmitted by the shaft will be:
T=F∗𝑑⁄2
=L*b*τ*𝑑⁄2………………………..eq (1)
Considering crushing of the key, the tangential crushing force acting at
the circumference of the
Shaft:
F=area of resisting crushing*crushing stress
=L*ℎ⁄2*𝛿𝑐
Therefore torque transmitted by the shaft will be:
T= F∗𝑑⁄2
= L*𝑑⁄2*ℎ⁄2*𝛿𝑐 …………….…eq (2)
Consider that the strength of key will be equal both in shearing and
crushing.
FINAL PROJECT 38
So L*b*τ*𝑑⁄2= L*𝑑⁄2*ℎ⁄2*𝛿𝑐
𝑏 𝛿
=2τ𝑐 …………………….....eq (3)
ℎ
In order to find the length of the key to transmit full power of the shaft,
the shearing of the key is equal to the torsional shear strength of the shaft.
We know that shearing strength of the key
T= L*b*τ*𝑑⁄2……………………………...eq (4)
Torsional shear strength of the key
T=𝑑⁄2*τ1*𝑑 3 ………….………….…………eq (5)
From eq (4) & eq (5) we will gate
L*b*τ*𝑑⁄2=𝜋⁄16*τ1*𝑑 3
τ
L=1.571d 1 since, we select the same material for
τ
shaft and key τ=τ1
L=1.571d…………………………...………………… eq (6)
Length of key
L=1.571d we have shaft diameter (d=32mm)
=1.571*32mm
=50.272mm
Width of key
32𝑚𝑚
b=𝑑⁄4 = =8mm
4
Thickness of key
32𝑚𝑚
h=2𝑏⁄3=𝑑⁄6= =5.3mm
6
Volume of key
V=h*b*L =50.272mm*8mm*5.3mm
=2131.5𝑚𝑚3
Shear stress (τ)
Since we select the materials for shaft and key they have equal shear
stress.
τ=τ1 we have shear stress of shaft (τ1=803293.756𝑁⁄ )
𝑚𝑚2
=803293.756𝑁⁄
𝑚𝑚2
Crushing stress (δc)
𝑏 𝛿
We know that = 𝑐 from eq (3) so,
ℎ 2τ
𝛿𝑐 =3τ
=3*803293.756𝑁⁄ =2409881.268𝑁⁄
𝑚𝑚2 𝑚𝑚2
3.5.7 PULLY DESIGN
We have design the pulley by adapting the following procedure.
Dimension of the pulley
FINAL PROJECT 39
Dimension of the arms

Dimension of the hub
DIMENSIONS OF THE PULLEY
The dimension of the pulley may be obtained either from velocity ratio
consideration or centrifugal stress consideration. We know that the
centrifugal stress induced in the rim of the pulley (δt):
𝛿𝑡 =ƍ*v2
Where: ƍ=density of rim material
=7200𝑁⁄ 3 since the selected material is cast
𝑚
iron
𝜋𝐷𝑁
V=velocity of the rim=
60
𝜋∗200𝑀𝑀∗60𝑟𝑝𝑚
=
60
𝑚
=628 ⁄ 2
𝑠
D=diameter of the pulley and
N=speed of the pulley
DIMENSIOM OF THE ARMS
We have taken four arms for the pulley diameter (𝑑𝑃 =200mm)
The cross-section of the arm is usually elliptical with major axis is equal
to twice of the minor axis. The cross-section is obtained by considering
the arm as cantilever that mean fixed at the hub and carrying can center
led loaded at the rim end. The length of cantilever is taken equal to the
radius of the pulley. It is further assumed that any given time the power is
transmitted from the hub to the rim or vice verse through only halve the
total number of the arms.
Assume: T=torque transmitted
R=radius of pulley
ɳ=number of arms
Therefore: Tangential load per arm is (WT)
𝑇 2𝑇
WT= 𝑛 =
𝑅∗ ⁄2 𝑅∗𝑛
Maximum bending momentum on the arm at the hub end:
2𝑇 2𝑇
M= *R=
𝑅∗𝑛 𝑛
DIMENSION OF HUB
The diameter of the hub (d1) may be fixed by the following relation:
d1=1.5d + 25mm
FINAL PROJECT 40
Where: d1=hub diameter

d=shaft diameter (take d=50mm)
L=hub length so,
d1=1.5d + 25mm
=1.5*50mm+25mm
=100mm
The diameter of the hub should not be greater than 2d.
The length of the hub (l)
L=𝜋⁄2*d
=𝜋⁄2∗ 50mm
=78.54mm=79mm
Fig 3.9 pulley

The selected material is cast iron. Pulley transmits 20w at 60rpm, we take
the diameter of the pulley (𝑑𝑃 =100mm) and the pulley has four straight
arms of elliptical cross-section in which the major axis is twice the minor
axis. The allowable bending stress is 1Mpa. Then we have to find the
dimension of the arm and mention the plan in which the major axis of the
arm should be lie.
We know that the torque transmitted by the pulley:
𝑝∗60
T=
2𝜋𝑁
20∗60
=
2𝜋∗60
=3.1Nm
Therefore: the maximum bending per arm at the hub end is:
2𝑇
M=
𝑛
FINAL PROJECT 41
2∗3.1𝑁𝑚
=
4
=1.5Nm and
Section modulus (Z)
Z = 𝜋⁄32 ∗ 𝑏1 ∗ 𝑎12
Where: b1=minor axis and

a1=major axis=2b1 so
Z=𝜋⁄32 ∗ 𝑏1 ∗ 2𝑎12
Z=𝜋⁄32 ∗ 4𝑏15
𝜋𝑏3
Z= 1
8
We know that the bending stress (𝛿𝑏 )
𝑀
𝛿𝑏 =
𝑍
𝑀
But Z=
δb
1.5𝑁𝑚
= 𝑁
1 ⁄
𝑚𝑚2
1500𝑁𝑚
= 𝑁
1 ⁄
𝑚𝑚2
=1500𝑚𝑚2
So from the above result we have to calculate the minor and major axis.
The minor axis:
𝜋𝑏13
Z=
8
𝜋𝑏13
1500𝑚𝑚3 =
8
so
1500𝑚𝑚3 ∗8
=𝑏13
𝜋
𝑏13 =3821.7𝑚𝑚3
3
𝑏1 =√3821.7𝑚𝑚3
b1=15.6mm =16mm and
The major axis (a1) is equal to twice of minor axis (b1)
a1=2b =2*16mm =32mm
3.5.8 BUCKET DESIGN

To design the bucket we have to consider:
The bucket area
The bucket volume
FINAL PROJECT 42
The mass of the bucket

The weight of the bucket
the circular sectioning part of the bucket
Volume of water per bucket
Mass of water
The weight of the water
We select the aluminum alloy number 2012 for this material that has the
yield strength (𝛿𝑠 =70Mpa), tensile strength (𝑠𝑢 =179Mpa), fatigue
(𝑠𝑓 =90Mpa), elongation in 2%in=22 and hardness=45HB. The specific
gravity of the aluminum is 2.7.
Fig 3.10 bucket

Where: R=the major radius (take, R=25mm)
r =the minor radius (take, r=15mm)
h=the height between the minor and the major radius
(take, h=40mm)
s=the length of the surface
BUCKET AREA
A=π(R+r) s or
= π (R+r)√)[ℎ2 + (𝑅 − 𝑟)2 ]
= (0.25m+0.15)√[0.40.42 + (0.25 − 0.15)2
=0.6407m2=640.7*103 𝑚𝑚2
BUCKET VOLUME
V=1⁄3 𝜋ℎ(R2+r2+r*R)
=1⁄3 𝜋 *0.04m (0.0252 + 0.0152 + 0.025*0.015)
=0.000513𝑚3
=0.0005𝑚3
MASS OF BUCKET
FINAL PROJECT 43
To determine the mass of the bucket, it is known that the specific gravity
of the aluminum that is
2.7.
𝜌
S.G= 𝐴
𝜌𝑤
Where: S.G=specific gravity of aluminum
𝜌𝐴 =density of aluminum
𝜌𝑤 = density of water
So, the density of bucket is:

𝜌𝑏 =𝜌𝐴 =S.G*𝜌𝑤
𝑘𝑔
=2.7*1000 ⁄ 3
𝑚
𝑘𝑔⁄
=2700
𝑚3
Then mass of the bucket will be: 𝜌𝐴
𝑚
𝜌𝐴 = 𝐴
𝑣𝐴
Mb=𝜌𝐴 *𝑣𝐴
𝑘𝑔
=2700 ⁄ 3 *0.0051𝑚3 =1.4kg
𝑚
WEIGHT OF THE BUCKET
𝑊𝑏 =𝑚𝑏 *g
=1.4kg*9.8𝑚⁄ 2
𝑠
=14N
CIRCULAR SECTIONING PARTS OF THE BUCKET
Take D=20mm
Fig 3.11 sectioning part

Let A=area of sectioned part
G=location of centroid
Ix=∫ 𝑦 2 dA=2𝑛𝑑 moment of area about x axis
𝐼𝑦 =∫𝑥 2 dA=2𝑛𝑑 moment of area about y axis
𝐼𝑋𝑌 =∫ xydA= max.moment of area about x and y axis
JG=∫𝑟 2 dA=∫(𝑥 2 +𝑦 2 ) dA=Ix +𝐼𝑦 =2𝑛𝑑 polar moment area
about axis th.r G
FINAL PROJECT 44
Ix
𝐾 2 x= =squared radius of gyration about x axis
𝐴
𝜋𝐷2 𝜋(20𝑚𝑚)2
So, A= = =314.159𝑚𝑚2
4 4
Ix=𝐼𝑌 = = =7853.98
64 64
𝐼𝑋𝑌 =0
JG= = =15707.96
32 32
VOLUME OF WATER TO OBTAIN FOR 10 GALLON

We decide that the amount of water to take up per one complete cycle is
10 gallons.
So, 1gallon=0.003785𝑚3 =0.0038𝑚3

10 gallons=x
By cross multiplication we gate x=0.038𝑚3
So, the volume of water to obtain per one cycle is 0.038𝑚3 .
MASS OF WATER FOR 10 GALLON

We know the density of fluid is:
𝑚
ρ=
𝑣
𝑘𝑔
Where: 𝜌𝑊 =density of water=1000 ⁄ 3
𝑚
𝜌𝑊 =volume of water
Mw=mass of the water
𝑘𝑔
Mw= ρ*v=1000 ⁄ 3 *0.03=38kg
𝑚
WEIGHT OF WATER
The weight of water for 10 gallon will be:
W=Mw*g
=38kg*9.81𝑚⁄ 2 =372.78N
𝑠
3.5.9 DISCHURGING PIPE DESIGN
The design of the pipe involves the determination of inside diameter of
the pipe and its wall thickness.
INSIDE DIAMETER OF THE PIPE

The inside diameter of the pipe depends on up on the quantity of fluids to
be deliver
Where: D=inside diameter of the pipe
V=velocity of fluid flowing per minute
Q=quantity of fluid carried per minute
t=thickness of the pipe
FINAL PROJECT 45
It is known that the quantity of fluid flowing per minute is:

Q=Area*velocity
𝑚3 𝑚3
Assume that the flow rate is 3 and the velocity of the fluid is 30 then,
𝑠𝑒 𝑠𝑒
Q=A*V
𝑚3
𝑄 3
A= = 𝑠𝑒𝑚 0.1𝑚2
𝑉 30
𝑠𝑒
So the internal diameter of the pipe will be
𝜋𝐷2
A=
4
2 4𝐴
𝐷 =
𝜋
4𝐴
d=√
𝜋
4∗0.1𝑚2
=√ =0.36m
𝜋
WALL THICKNESS OF THE PIPE

The thickness of the wall (t) in order to withstand the internal pressure (p)
may be obtained by using a thin cylinder formula. Because the fluid
transported is water. According to the thin cylinder formula the wall
thickness of the pipe will be:
𝑃∗𝑑
t=
2𝛿𝑡
Where: 𝛿𝑡 =tensile strength of the pipe
P=pressure flow of the fluid
d=internal diameter of the pipe
The tensile strength of polyethylene material is 38Mpa from the property
of selected thermoplastic of material science of fourth edition. And
pressure is 2.06𝑁⁄ from the force analysis. So the thickness of the
𝑚𝑚2
pipe will be:
2.06𝑁⁄ ∗0.36𝑚
𝑚𝑚2
t=
2∗38𝑁⁄
𝑚𝑚2
t=0.0098m=9.8mm
For the thin cylinder the internal diameter divided by the wall thickness
𝑑
must give greater than twenty (i.e. >20).
2
𝑑 0.36𝑚
Therefore: = =36.7=37
𝑡 0.0098𝑚
37>20 it is safe
FINAL PROJECT 46
VOLUME OF THE PIPE

V=A*t
Where: A=area of the pipe
t=thickness of the pipe
So, the volume of the pipe will be:
V=0.1𝑚2 *0.0098m=0.00098𝑚3
MASS OF THE PIPE
Mp=𝜌𝑃 *VP
Where: 𝜌𝑃 =density of the pipe
VP=volume of the pipe
𝑘𝑔
We select the polyethylene material having the density 960 ⁄ 3 from
𝑚
the scienceand engineering of the material selection fourth edition.
𝑘𝑔
Therefore: Mp=960 ⁄ 3 *0.00098𝑚3
𝑚
=0.941kg
WEIGHT OF THE PIPE
𝑊𝑃 =𝑀𝑃 *g
Where: 𝑀𝑃 =is mass of the pipe
g=gravity of the pipe
So, the weight of the pipe will be:
𝑊𝑃 =0.941kg*9.81𝑚⁄ 2
𝑠
=9.23N
3.5.10 ROPE DESIGN

Specification
Height of the frame to support the component from the ground=1m
Height of the pulley to flywheel=3m
Height of the pulley to the top of the well=4m
Depth of the well=10m
To design the rope we have to consider the depth of the well, the distance
from the top of the well up to the flywheel (the height of the pulley from
the flywheel and from the top of the well), the weight of the discharging
pipe, the weight of the bucket.
LENGTH OF THE ROPE
Length of the rope (𝐿𝑟𝑃 ) is the sum of (the height of the pulley flywheel
+the height of the pulley from the top of the well + the depth of the well).
𝐿𝑟𝑃 =1m+3m+4m+10m
=18m
FINAL PROJECT 47
STRENGTH OF THE ROPE
We have to consider the rope have to be lift the load or lift the weight of
the (bucket +pipe+water). So the strength of the rope will be calculated as
the following.
𝑊𝛿𝑡 =𝑊𝑏 +𝑊𝑃 +𝑊𝑤
Where: 𝑊𝛿𝑡 =strength of the rope
𝑊𝑏 =weight of the bucket
𝑊𝑤 =weight of the water
Therefore: 𝑊𝛿𝑡 =15N + 9.23N +372.8N=396.03N
DIAMETER OF THE ROPE
We wire rope of the rope type from the rope property of machine design
second edition and its tensile strength 1800Mpa is 595𝑑 2 .
Where (d) is the diameter of the wire rope.Equating this tensile strength
to design load.
𝑊𝑟 = 595𝑑 2
396.03N=595𝑑 2
396.03𝑁
𝑑2 = 𝑁
595 ⁄
𝑚𝑚2
𝑑 2 =0.665𝑚𝑚2
d=√0.665𝑚𝑚2
d=0.816mm
AREA OF THE WIRE ROPE
𝐴𝑟𝑃 =0.38 𝑑2
Where: d is the diameter of the wire rope. But the coefficient of
diameter (d) is 0.38 that have taken from the machine design second
edition.
Therefore: the wire rope area is:

𝐴𝑟𝑃 =0.38(0.816mm)2
=0.31m𝑚2
WEIGHT OF THE ROPE
FINAL PROJECT 48
To find the weight of the rope we have taken the weight coefficient
(0.0363𝑁⁄ ) from the type rope of machine design of second
𝑀𝑚𝑚2
edition. So,
𝑊𝑟 =0.0363𝑑 2 *length of the rope.

=0.0363(0.816mm)2 *18M
=0.0363𝑁⁄ *0.6659𝑚𝑚2 * 18M
𝑀𝑚𝑚2
=0.4351N
Weight of operator must be greater than the sum lift up of the weight of
(rope +discharge pipe + bucket + water).
Therefore:
𝑊𝑜𝑟 > 𝑊𝑟 +𝑊𝑃 +𝑊𝑤
Where: 𝑊𝑜𝑟 =weight of the operator
𝑊𝑃 =weight of the pipe
𝑊𝑏 =weight of bucket
𝑊𝑤 =weight of water
So, 637.7>0.4351N+14N+372N+9.23N
637.7>395.7N It indicate that the operator will operate
easily.
3.5.11 FRAME DESIGN FOR MACHINE COMPONENT

For frame metals we select gray cast iron 4.5%C ASIM A-48
Tensile strength =130Mpa
Yield strength=200Mpa
3.5.12 WELDING DESIGN
We use the welding in the process to join the frame metals, pulley
supporting metal bars and operator handle.
Specification
Considering the load capacity we select Single transverse fillet weld due
to its high concentration and has high tensile strength.
Load capacity =weight of component applied on the frame
P=weight of (operator + shaft + flywheel + clutch + lever +pedal + other)
= (85.6+196.2+147+19.6+24.8+638) N =1111.2N=1.5KN
Length of welding (L=100mm)
FINAL PROJECT 49
Fig 3.12 welding design

Assumption
Since the weld is weaker than the plate due to slag and blow holes
therefore the weld is given a reinforcement which may be taken as 10%
of the plate thickness.
In order to determine the strength of the fillet joint, it is assumed that
the section of the
fillet is a righted angle triangle with hypotenuse making equal angles with
other two sides.
Where, t=throat thickness
S=leg or size of weld
L=length of weld
t =S * sin450
A=t*L
F=A*𝛿𝑎𝑙𝑙
Yield stress
From table of fillet weld joint (table 10.5 stresses for welded joint), the
stress for all type (Tension,
Compression, and Shear) is given by 80Mpa.
𝛿𝑠 =80Mpa
The stress concentration factor for transverse fillet weld is given by 1.5.
But for static loading and any type of joint, stress concentration factor is
1.
Length of welding
L=100mm
Adding 12.5 for starting and ending
L=100mm+12.5mm
Throat thickness
In transverse fillet weld joint, the size of the weld S is equal to the
thickness of the plate (𝑡𝑃 )
S=𝑡𝑃
The throat thickness becomes
FINAL PROJECT 50
t = S * sin 450
Throat area
The minimum area of the weld or throat area is given by
A = Throat thickness * Length of weld
=t*l
= S * sin450 *32.5mm
= S*22.98mm
A = (22.98*S) mm
Since the weld is weaker than the plate due to slag and blow holes,
therefore the weld is given a reinforcement which may be taken as 10%
of the plate thickness.
A=S * sin450 *32.5mm+ S * sin450 *32.5mm
A=45.96*S𝑚𝑚2
The size of the weld
Case – 1 Static loading
The tensile strength of the joint for single fillet weld,
P=Throat area * Allowable tensile strength
P=45.96*S𝑚𝑚2 * 80Mpa
S= P / (45.96 * 80)
=1.5kN/ 3676.8
=0.40796mm
L=112.5mm
Case – 2 Fatigue loading
The tensile strength of the joint for single fillet weld
F = Throat area * Allowable tensile stress
Tensile stress for fatigue = Tensile stress of static loading / Stress
concentration factor
𝛿𝑠 = 80Mpa / 1.5
For fatigue 𝛿𝑠 = 53.3Mpa
P= (45.96*S𝑚𝑚2 * 53.3Mpa
S= (P/ (45.96*S𝑚𝑚2 * 53.3)
S= 1.5kN/ 2449.668
=0.612mm
We know that the size of the weld is less than or equal to the thickness of
the plate.
In the above two cases, the size of the weld are less than the thickness of
the plate.
Therefore, the dimension is safe.
Take the maximum of the two case (in fatigue loading) the weld size is
S=3
The stress developed
FINAL PROJECT 51
In order to have a safe welding portion, the permissible stress is must be

greater than the allowable stress.
Permissible stress
𝛿𝑓
Permissible stress =
𝐹.𝑠
200Mpa
=
2
=100Mpa
Allowable stress
Allowable stress= P / A but
2
The throat area = (45.96*S)𝑚𝑚
= (45.96*3)𝑚𝑚2
=137.88𝑚𝑚2
P = 1.5kN /137.88𝑚𝑚2
=10.87Mpa
The allowable stress is less than the permissible stress, so the design of
the frame is
S=3
3.5.13 BEARING SELECTION
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. A little
consideration will show that due to the relative motion between the
contact surfaces, a certain amount of power is wasted in overcoming
frictional resistance and if the rubbing surfaces are in direct contact, there
will be rapid wear. If bearing is necessary for the mechanism we select
from the following ball bearing. principal dimensions ball bearing.
Bearing no. 206
Bore diameter= 30mm
Outside diameter =62mm
Width of bearing= 16 mm
FINAL PROJECT 52
Fig 3.13 bearing

3.5.14 DESIGN FOR FASTENERS
Bolts, screws and nuts used to hold the container holder on the frame
have to carry the summation load acts on it this maximum load. This load
may shear the rivets when it is not the rivets do not resist this load.
Washers are used to protect the outer surface of the connected
material from damage as the bearing or gear was torqued or turned with
respect to the shaft.
Fig 3.14 fasteners

3.6 OUTPUT ENERGY
Output energy is the energy out or exposed during due to the work is
done. So, for our mechanism is potential energy the result from the
process of pedaling motion at 60 rpm and transmitting power by shaft,
flywheel, pulley and rope to achieve the out put.so,
𝑂𝑃𝐸 = (𝐵𝑊 +𝑊𝑊 +𝑃𝑊 +𝑅𝑊 )*𝐷𝐻
Where 𝑂𝑃𝐸 =output energy
𝐵𝑊 =bucket weight
𝑊𝑊 =water weight
𝑃𝑊 =pipe weight
𝑅𝑊 =rope weight
𝐷𝐻 =height from the water level to discharge
𝑂𝑃𝐸 = (14N+372.78N+9.23N+0.4351N)*14m
FINAL PROJECT 53
=396.4455N*14m
=5550kJ
𝐸𝑛𝑒𝑟𝑔𝑦 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡
Efficiency =1 –
𝐸𝑛𝑒𝑟𝑔𝑦 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑚𝑒𝑐ℎ𝑛𝑖𝑠𝑚
𝑖𝑛𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦
=1 – but we minimum input energy (988.9KJ)
𝑜𝑢𝑡𝑡𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦
989𝑘𝐽
=1 −
5550𝑘𝐽
=0.82*100
=82%
So the operation is safe.
3.7 MANUFACTURING PROCESS

Manufacturing is the use of machines, tools and labor to produce goods
for use or sale. The term may refer to a range of human activity, from
handicraft to high tech, but is most commonly applied to industrial
production, in which raw materials are transformed into finished goods
on a large scale. Such finished goods may be used for manufacturing
other, more complex products, such as aircraft, household appliances or
automobiles, or sold to wholesalers, who in turn sell them to retailers,
who then sell them to end users the "consumers". Manufacturing is a
collection of interrelated activities that includes product design and
documentation, material selection, planning, production, quality
assurance, management and marketing of goods. The fundamental goal of
manufacturing is to use these activities to convert raw materials in to
finished goods on a profitable base. The ability to produce this conversion
efficiently determines the success of the enterprise. The five inputs
required are raw materials, equipment, tooling and fixtures, energy and
labor.
FINAL PROJECT 54
,
Fig 3.15 manufacturing method
The manufacturing process for our machine is the following process:

We prepare the flywheel, lever handle, lever arm, pulley and beam for
supporting by cast molding process. We produce the shaft, clutch, pedal
and bucket by molding process. We produce the rope wire drawing
process. We use lath machine turning, tapering, treading, and surface
finishing of components; like shaft, flywheel, clutch, pulley, pedal, key
and lever. We use the drilling machine for boring and drilling the hole of
the components: like the hole on the pedal ring, on the shaft, on the lever
parts, on the clutch, on cover of the shaft and on beam metals for frame
We use the electrical cutting ax sow for cutting the components; like
shaft, lever parts, beam or bar metals for frame and pedals. We use
welding machine for joining the component; like beam for frame.
3.8 COST ANALIYSIS

Cost analysis include the total cost expend on the machine to design the
machine components, manufacturing (to buy) the machine components,
to assemble the machine components and the payment for operator.
FINAL PROJECT 55
Table 3.6 cost analysis
Design cost in birr= 40,000

Machining cost in birr=2000
Assembling cost including welding in birr=1000
Salary cost per employment per month if the machine is used for
community=3000
But if the machine used by individual the user by obtain the operator or
may operate by himself.
Total cost = component cost + design cost + machining cost + assembling
cost + salary cost.
=11200+40,000+6000
=57,200 birr
3.9 GENERAL ASSEMBLY
Assembling is the process of arranging the components at their
appropriate location for function able operation. After the selection of
material for components, analysis and design the components and
manufacturing the components we have to be assemble each component
to get the available operation of the mechanism. So, we assemble our
design components of pedal powered water lifting machine as the
following stapes.
1. First adjust the metal bars of frame to support and hold the body of the
machine component, pulley supporting metal and handling metal to
support the operator.
2. Inter the shaft in the pedals ring. Then fixing the pedal ring with shaft
by bolt;
3. Locating the shaft on the frame at its supporting point.Putting the
internal rotary ball bearing if it is necessary to reduce the friction between
FINAL PROJECT 56
the shaft and the supporting metal. Join the above cover of the shaft to
frame by bolt.
4. Adjust the clutch at one end-side the main shaft and meshing its fixed
side with shaft. Then fix the external part of clutch on the frame by bolt.
5. Adjust the lever and mesh it with driven shaft, fix the above holding
shaft to the frame by bolt. The handle of the lever can be supported with
lever arm by bolt and the lever arm mesh with lever boss by treed or fixed
by wilding. Then the shaft and the lever boss can be joined by spline the
rectangular shape (journal) at the end of the shaft and the rectangular
shape inside of the boss.
6. Adjust the flywheel on the other end-side of the main shaft and join the
flywheel with shaft by bolt.
7. Fix one end-side of rope with flywheel
8. Adjust the pulley on the pulley supporting metal.
9. Extend the rope on pulley
10. Fix the other end of rope with bucket arm.
11. Lastly site the tanker at appropriate position of bucket side.
Fig 3.16 assembly drawing
CHAPTER FOUR
CONCLUSION AND RECOMMONDATION
4.1 CONCLUSION
FINAL PROJECT 57
The primary focus of this project is to create the equipment with the
capability to lift up the water from the ground or well by the means of
energy generated by human-muscle. The main purpose is to build the
pedal powered water lifting machine with a mechanism to convert
mechanical energy created during the machine will operated. The human
body has the potential to create an enormous amount of energy if we are
able to channel it in the right way. Will considering the human energy our
project study how to generate power through the use of human energy
and to promote awareness of the belief that the human energy is an
untapped resource can aid in solving society’s escalating energy.
The benefits relating with the access to use the ground water provide a
strong agreement to increase resource allocations to interventions aimed
at further improving the current shortage of water situation, as a key entry
point for achieving much wider livelihood benefits.
Generally, most of farmers and pastorals this pedal powered water lifting
machine is one of the most advantageous type of water lifting machine
used to help them during the dry season and gate better revenues from
agriculture and indirectly it is better to came up for sustainable
development for our country.
4.2 RECOMMONDATION
Our project included almost all design procedures and has full
performance to operate the mechanism with functional. We design all the
main machine components properly and due to time limitation we cannot
conclude some related components but we put into consideration to
design in the future. But for design procedure due to the limitation we
decide as the following to some components such as bucket, frame for the
machine and stand bar for the pulley.
It decided to buy the tanker from the market with considering its
property to meet the performance.
It decided to buy the metal bars for frame.
It decided to buy the metal bars for used to support pulley
The frame metals, pulley supporting bars and the handle of operator by
appropriate welding process at appropriate position, length and height
have to be joining to give full function.
4.3 FUTUR WORK

Agriculture including cultivation, pastoral and farming is the back bone
of our country incomes. So to support such sectors we use agricultural
machinery like pedal powered water lifting machine. In this paper pedal
powered water lifting machine designed as the energy for operating is the
FINAL PROJECT 58
human muscle as much as possible. But in the future if other research will
be done on this paper or will be modified by our group member or by any
one, they have consider following alternative additional.
Weight of the machine
Design the alternative mechanism with bucket to fellow water
directly from ground well to tanker.
Design additional self operating mechanism to open the check
valve of the bucket and direct the fellow of water to tanker during the
bucket reaches at discharge point.
Increase the adaptability of the machine at every place where
the shortage of water is available.
Instead of human muscle use alternative energy sours like sun, wind
and other
REFERANCE
1. Shigley’s Mechanical Engineering Design, Eighth Edition

2. R.S Khurmi and J.K Gubta, a text book of machine design, 2oo5, First
Edition.
3. S.L. Dixon, Fluid mechanics and Thermodynamics of Turbo
machinery, Fifth Edition
4. www.sharedasolutions.com
5. www.water in cyclopeda.com/Po-Ro/
6. Pump traditional.html
APPENDIX
Table of results and discussion
FINAL PROJECT 59
Angular velocity of shaft=100𝑚𝑚⁄𝑠Applied force=638N

Angular velocity flywheel=471𝑚𝑚⁄𝑠
Angular velocity pulley=628𝑚𝑚⁄𝑠
The 3D, 2D and section views of pedal powered water lifting machine
and its components.
FINAL PROJECT 60
Drawn by Checked Approved by date

group by
member W/GEBRIEL.G 14/5/2010
EC
Container
Bucket Scale 1:2
FINAL PROJECT 61

group by
EC
Direction controller
Clutch Scale 1:2
FINAL PROJECT 62

group by
EC
Lever parts
lever Scale 1:2
FINAL PROJECT 63

group by
EC
Rotor
Flywheel 1:2
FINAL PROJECT 64

group by
EC
Transmitter
Shaft Scale 1:2
FINAL PROJECT 65

group by
EC
Transmission shaft
Shaft Scale 1:2
FINAL PROJECT 66
FINAL PROJECT 67

group by
EC
2D Assemble drawing Assemble parts

Scale 1:2
FINAL PROJECT 68

group by
EC
3D Assemble drawing Assembly parts

Scale 1:2
FINAL PROJECT 69

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ADIGRAT UNIVERSITY

TSEGAU HAGOS RET 4358/07

YEMANE ZEREAY RET 4445/07

ZENEBE TADELE RET 4518/07

SUBMITTED TO INS. WELAY G.

SUBMITION DATE: 14/5/2010EC

3.3.5 MATERIA SELECTION FOR WIRE ROPE...................19

4.3 FUTUR WORK ..........................................................…...71

LIST OF FIGURE PAGE

1.2 COMPONENTIS OF PEDAL POWERED WATER LIFTING MACHINE

A shaft is a rotating machine element which is used to transmit power

1.2.2 FLY WHEEL

Flywheel used in machines serves as a reservoir which stores energy

The most common use is in motor vehicles, where the transmission

 A gearbox is precisely bored to control gear and shaft alignment.

A variety of gearboxes find applications in a number of industries

A clutch is a machine member used to connect a driving shaft to a driven

1.2.5 LEVER (HANDLE AT THE SIDE OF CLUTCH)

1.2.6 HANDLE (SUPPORTIG BEAM)

A handle is component of PPWLM which is used to support the operator

Frame is the bathe of the machine which is used to support the

1.2.10 WIRE ROPE

1.3 WORKING PRINCIPLE

The principle of operation of the machine is very simple and requires

1.4 OBJECTIVE OF THE PROJECT

1.4.1 GENERAL OBJECTIVE

1.4.2 SPECIFIC OBJECTIVE

paper also uses for mechanical engineering students as a reference to be

2.1.2BUCKET AND WINDLASS

 The pump stands including footings and windlass.

2.1.4 PEDAL POWERED WATER LIFTING MACHINE

 We may goat some materials for production in a simple way.

Fig. pedal powered water lifting machine

3.2 PROBLEM STATEMENT

 The mechanism has no on and off system.

4.1.2 MATERIAL SELECTION FOR FLYWHEEL

 It is not affected by moisture and oil

Lever is a component used to engage and disengage the clutch for

water or moisture rusting or corrosion of the component will be form.

Table 4.1 force required to apply on the pedal

4.2.2 SHAFT AREA

No of diameters Diameter( in mm) No of areas Area(in mm2)

4.2.3 PRESSURE REQUIREMENT FOR THE SYSTEM

Area(in Pressure(in Area(in Pressure(in

𝐹5 Area Pressure( Area Pressure( 𝐹7 Area Pressure(

7 506.71 1.355 5 506.71 1.452 8 506.71 1.549

Table 4.3 pressure distribution when the force is

1.45 995.72 1.45 1066.83 1.45 1137.9

Table 4.5 energy input for the system to operate the

Fig 3.2 shaft

we have the following equation when shaft is subjected to twisting

So the eq (1) may be written as the following

We the following equation when the shaft is subjected to bending

Fig 3.3 bending momentum diagram

𝜏𝑚𝑎𝑥 =√δ2b − 4τ =√2.7765𝐾𝑃𝑎2 − 4 ∗ 0.8𝑀𝑃𝑎 =2.132kpa

3.5.2 FLYWHEEL DESIGN

The flywheel should be designed based on the consideration of

Fig 3.4 flywheel

3.5.2.2 DIAMETER AND LENGTH OF THE HUB

Fig 3.5 clutch

R=mean radius of the friction surface.

In order to design such levers, we have to put the following in to

We select cast iron having