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CHAPTER 1
INTRODUCTION

1.1 PROBLEM DEFINITION

In spite of the advances in robotics and its wide spreading applications, interior
wall painting has shared little in research activities. 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. These factors motivate the development of an autonomous
mechanism for painting.

1.2 SOLUTION
Wall painting robot is a simple device that carries the entire paint application set
up from one end to other end of pipe and simultaneously applies a uniform spray coat of
paint on the wall pipe.
This machine easily solves the above problem which otherwise is really difficult
without such aid. The machine needs compressed air supply for movement of the robot
and painting operation.

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CHAPTER 2
LITERATURE REVIEW
Despite the advances in robotics and its wide spreading applications, interior wall
painting has shared little in research activities. 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. These factors motivate the development of an automated robotic
painting system. There have been few research projects in the literature but they did not
produce a mature system acceptable by the market yet. Warszawsky

and Kahane

,developed a robot for interior finishing tasks named TAMIR, and was used in four
interior finishing tasks namely; painting, plastering, tiling and masonry. The robot has 6
DOF (Degrees Of Freedom) with an average reach of 1.7m and end effector payload of 30
kg. It is mounted on 3 wheeled mobile robots which gives another 3 DOF. The platform
moves between workstations and at each one it deploys four stabilizing legs. The robot
arm used is theS-700 model made by General Motors, of 500 Kg weight. Also a
methodology for human-robot integration in construction site has been developed claimed
to be profitable of introducing robots in finishing tasks with promising numbers.
In case of wall painting, a reduction in total painting time of about 70% was
reached. A scaled down robot setup for interior wall painting together with spraying end
tool were implemented by Naticchia and claimed to work in full scale without reduction
in performance. The robot named Pollock#1 had 6 DOF, a nominal reach of 0.4 m and a
maximum payload of 4kg. It should be fixed on a 2 DOF hexapod for horizontal
movement but was not actually used in experiments. A full scale mechanism for ceil
painting was introduced by Aris. It had 3DOF without considering those of the platform, a
working envelope of (84cm by 72 cm by 122 cm). Significant improvement in painting
time and cost had been reached where 46 m2 of ceil were painted in 3.5 hours which is 1.5
times faster than manual painting. The implemented robot cant be used in residential
buildings due to its heavy weight that is over 500 kg. The robot is huge, has small work
space and paints only the ceiling. Spray painting used will result in increased system
weight which will impair the system portability. Therefore, we believe that the current
state of the art in wall painting robots is not matured and a need for a light weight and
simple system still exists to attract potential construction and service companies together
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with regular house owners. Moreover all of the previously conducted researches have
focused only on spray as the main painting tool. Spray painting was preferred over roller
painting, due to two reasons, namely the speed of spray is fast compared to roller and
using roller will require force feedback which complicates the control. In this work, a full
scale robot is described consisting of a 2 DOF robotic painting arm and a 3 DOF mobile
platform. Light weight is achieved here by using a light weight two link robotic arm with
new joint actuation mechanism. This mechanism is inspired from hydraulic cylinder
actuation in heavy machinery and has decreased the overall robot weight significantly. It
has the advantage of strong and accurate actuation due to the use of ball screw-nut. Also, a
four wheeled mobile platform with a new idle wheel attachment have been introduced and
claimed to be easier in control.

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CHAPTER 3
CONSTRUCTION AND WORKING
3.1 CONSTRUCTION
3.1.1.BASIC CONSIDERATION
3.1.1.1. Base Frame:
The Primary base frame is the base element provided with castor wheels, the

primary

base is made of mild steel square tube and mild steel plate. It supports the entire assembly
of the spray paint system.
3.1.1.2. Vertical Motion System:
The vertical motion system comprises of the screw and nut, lifter screw held in two ball
bearings and nut connected to the carrier. Rotation of screw is converted to translation of
the spray paint system up or down.
3.1.1.3. Paint Storage:
Paint storage is done in a small tank of 0.8 to 1.2 liter capacity mounted on the structure.
The compressed air is supplied through the chamber to carry the paint to the spray rotor
end.
3.1.1.4.. Paint Application:
Paint application is done by means of a spray which is reciprocated in linear guide by
crank and connecting rod mechanism operated by motor.
3.1.1.5. Control Circuit:
The paint quality i.e., the thickness of paint will be controlled by the control the speed of
the motor, so also the speed of the translation of the setup will be controlled by the speed
of translation.
3.1.1.6. Frame with castor wheels:
This is base of the machine which enables transportation of the set-up or when applied
with motorized motion can enable automatic translation While wall painting.

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3.1.2. MECHANICAL COMPONENTS

3.1.2.1. Motor:
Motor is a 12 volt DC motor, with following specification:
Voltage: 12 Volt DC
Power = 50 watt
Speed = 500 rpm
Mounting: Foot mounted

Fig 3.1 Motor

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3.1.2.2. Pinion shaft

Pinion shaft is mounted at its square end on the worm gear box output side, where as the
pinion is held on the other side of the pinion shaft.

3.1.2.3. Main shaft:

Main shaft is held at one end in ball bearing 6201zz in the main bearing housing which is
welded to the base frame. Whereas the side stand is welded at other end of shaft.

3.1.2.4. Holder bracket:

Holder bracket is an standard forged part which hinges the side stand at one end, and
spring arrester pin-1 is welded at the other end. This pin holds one end of the helical
tension spring. The holder bracket is welded to the boom.

3.1.2.5. Base frame:

Base frame comprises of the base plate, boom, motor plate and the gear box plate. These
are support members that hold the assembly together.

3.1.2.6. DP/DT switch:

The DP/DT switch is an electrical direction control switch which changes the direction of
rotation of the motor and there by controlling the motion of the side stand.

3.1.2.7 Air Compressor

All air tools, spray guns, sanders, etc, must be supplied with air which is elevated
to higher pressures and delivered in sufficient volume. The air compressor compresses air
for use in this equipment and is a major component of a spray painting system. This
chapter will examine the various types available. Compressed air is measured on the basis
of volume supplied per unit of time (cubic feet per minute or cfm) at a given pressure per
square inch or psi), referred to as delivery. This is the actual air output of the compressor
after its efficiency is taken into account. Displacement is the output of air by a compressor
at zero pressure, or Free Air Delivery. This is the theoretical air output of the compressor
before its efficiency is taken into account.

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3.1.2.8 Spray Painting Gun

The spray gun is the key component in a finishing system and is a precision
engineered and manufactured instrument. Each gun type and size is specifically designed
to perform a certain, defined range of tasks. As in most other areas of finishing work,
having the right tool for the job goes a long way toward getting professional results.

Fig 3.2 Gravity Spray Painting Gun

This design uses gravity to flow the material from the cup, which is mounted above
the gun, into the gun for spraying. No fluid pickup tube is used, since the fluid outlet is at
the bottom of the cup. This cup has a vent hole at the top of the cup that must remain open.
The cup is normally limited to approximately 600 cc capacity due to weight and balance.
Gravity feed guns are ideal for small applications such as spot repair, detail finishing or
for finishing in a limited space. They can utilize smaller quantities of material and feed
more viscous liquids than suction guns.
HVLP and Compliant type Suction and Gravity guns generally generate less
venturi effect than their conventional counterparts and therefore give lower fluid flow
rates. Therefore it is usual to increase the fluid tip size by one or two sizes. However,
remember that HVLP and Compliant gun have a greater transfer Efficiency than
conventional guns and therefore a slightly lower fluid flows not necessarily a problem.

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3.2. WORKING
DP/DT switch has a central OFF position, when operated to one of the ON
position, the motor will rotate in clockwise direction, operating the worm gear box and
thereby the pinion shaft. The pinion rotates to rotate the gear and thereby the main shaft
and stand in clockwise direction taking the stand to close position.
When other ON position is operated the motor will rotate in counter clockwise
direction, operating the worm gear box and thereby the pinion shaft. The pinion rotates to
rotate the gear and thereby the main shaft and stand in counter clockwise direction taking
the stand to open position.

3.2.1. Paint Preparation

Todays finishes are extremely complex chemical formulations. They include both
solvent and waterborne types as well as more specialized formulations for special
applications. Some only require the addition of solvents to give the proper spraying
viscosity while others require the addition of a second component at a prescribed ratio to
obtain sprayable consistency. Many modern coatings have hardeners or other chemicals,
added to them to insure correct colour match, gloss, hardness, drying time or other
characteristics necessary to produce a first class finish. Make sure you are familiar with
the specific Product Data Sheets accompanying each material. Do not mix materials from
various manufacturers. Read and follow directions carefully.

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Fig 3.3 Assembly of Machine

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CHAPTER 4
ADVANTAGES AND APPLICATION
4.1. ADVANTAGES
1. The painting process is virtually impossible without the painting robot set up.
2. The painting robot saves on time required for painting.
3. The painting robot saves on the labor cost.
4. As robot is automatic, it reduces human effort.
5. Easy to maintain.
6. Cost effective.
4.2. APPLICATIONS
1. Wall painting
2. Painting internal and external surfaces of storage tanks
3. Painting process industry installations
4. Painting oil refinery installations

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CHAPTER 5
WORK ACTION PLAN
5.1. PROJECT ACTION PLAN (APPROXIMATE ESTIMATE 4 MONTHS)
5.1.1. PHASE 1: DATA COLLECTION (DURATION: 1 WEEK)
Data collection phase involves the collection of reference material for project concept; the
idea is taken from book ingenious mechanisms for designers and inventors
5.1.2. PHASE 2: SYSTEM DESIGN (DURATION: 2 WEEKS)
The system design comprises of development of the mechanism so that the given concept
can perform the desired operation. The system design also determines the system
components and their shape and overall dimensions, the parts are as shown in part list
above.
5.1.3. PHASE 3: MECHANICAL DESIGN (DURATION: 3WEEKS)
The parts mentioned above in the part list will be designed for stress and strain under the
given system of forces, and appropriate dimensions will be derived. The standard parts
will be selected from the PSG design data handbook.
5.1.4. PHASE 4: PRODUCTION DRAWING PREPARATION (DURATION: 2
WEEKS)
Production drawings of the parts are prepared using Auto Cad, with appropriate
dimensional and geometric tolerances. Raw material sizes for parts are also determined.
5.1.5. PHASE 5: MATERIAL PROCUREMENT & PROCESS PLANNING
(DURATION: 2 WEEKS)
Material is procured as per raw material specification and part quantity. Part process
planning is done to decide the process of manufacture and appropriate machine for the
same

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5.1.6. PHASE 6: MANUFACTURING (DURATION: 2 WEEKS)

Parts are produced as per the part drawings.
5.1.7. PHASE 7: ASSEMBLY TEST & TRIAL (DURATION: 1 WEEK)
Assembly of device is done as per assembly drawing, and test and trial is conducted on
device for evaluating performance.
5.1.8. PHASE 8: REPORT PREARATION (DURATION: 2 WEEKS)
Report preparation of the activities carried out during the above phases is done.

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CHAPTER 6
DESIGN AND DRAFTING
Design consists of application of scientific principles, technical information and
imagination for development of new or improvised machine or mechanism to perform a
specific function with maximum economy & efficiency.
Hence a careful design approach has to be adopted. The total design work has been
split up into two parts;

System design

Mechanical Design.

System design mainly concerns the various physical constraints and ergonomics,
space requirements, arrangement of various components on main frame at system, man +
machine interactions, No. of controls, position of controls, working environment of
machine, chances of failure, safety measures to be provided, servicing aids, ease of
maintenance, scope of improvement, weight of machine from ground level, total weight of
machine and a lot more.
In mechanical design the components are listed down and stored on the basis of
their procurement, design in two categories namely,

Designed Parts

Parts to be purchased

For designed parts detailed design is done & distinctions thus obtained are
compared to next highest dimensions which are readily available in market.

This

amplifies the assembly as well as postproduction servicing work. The various tolerances
on the works are specified.

The process charts are prepared and passed on to the

manufacturing stage.
The parts which are to be purchased directly are selected from various catalogues
& specified so that anybody can purchase the same from the retail shop with given
specifications.

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6.1. SYSTEM DESIGN

In system design we mainly concentrated on the following parameters: 1. System Selection Based on Physical Constraints
While selecting any machine it must be checked whether it is going to be used in a largescale
industry or a small-scale industry. In our case it is to be used by a small-scale industry.
So space is a major constrain. The system is to be very compact so that it can be adjusted
to corner of a room. The mechanical design has direct norms with the system design.
Hence the foremost job is to control the physical parameters, so that the distinctions
obtained after mechanical design can be well fitted into that.

2. Arrangement of Various Components

Keeping into view the space restrictions the components should be laid such that their easy
removal or servicing is possible. More over every component should be easily seen none
should be hidden. Every possible space is utilized in component arrangements.

3. Components of System
As already stated the system should be compact enough so that it can be accommodated at
a corner of a room. All the moving parts should be well closed & compact. A compact
system design gives a high weighted structure which is desired.

4. Man Machine Interaction

The friendliness of a machine with the operator that is operating is an important criterion
of design. It is the application of anatomical & psychological principles to solve problems
arising from Man Machine relationship.

5. Chances of Failure
The losses incurred by owner in case of any failure are important criteria of design. Factor
safety while doing mechanical design is kept high so that there are less chances of failure.
Moreover periodic maintenance is required to keep unit healthy.

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6. Servicing Facility
The layout of components should be such that easy servicing is possible. Especially those
components which require frequents servicing can be easily disassembled.

7. Scope of Future Improvement

Arrangement should be provided to expand the scope of work in future. Such as to
convert the machine motor operated; the system can be easily configured to required one.
The die & punch can be changed if required for other shapes of notches etc.

8. Height of Machine from Ground

For ease and comfort of operator the height of machine should be properly decided so that
he may not get tired during operation. The machine should be slightly higher than the
waist level, also enough clearance should be provided from the ground for cleaning
purpose.

9. Weight of Machine
The total weight depends upon the selection of material components as well as the
dimension of components. A higher weighted machine is difficult in transportation & in
case of major breakdown; it is difficult to take it to workshop because of more weight.

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6.2. MECHANICAL DESIGN

Mechanical design phase is very important from the view of designer .as whole
success of the project depends on the correct deign analysis of the problem.
Many preliminary alternatives are eliminated during this phase. Designer should
have adequate knowledge above physical properties of material, loads stresses,
deformation, and failure. Theories and wear analysis, He should identify the external and
internal forces acting on the machine parts.

These forces may be classified as;

1. Dead weight forces
2. Friction forces
3. Inertia forces
4. Centrifugal forces
5. Forces generated during power transmission etc

Designer should estimate these forces very accurately by using design equations .If
he does not have sufficient information to estimate them he should make certain practical
assumptions based on similar conditions which will almost satisfy the functional needs.
Assumptions must always be on the safer side.
Selection of factors of safety to find working or design stress is another important
step in design of working dimensions of machine elements. The correction in the
theoretical stress values are to be made according in the kind of loads, shape of parts &
service requirements.
Selection of material should be made according to the condition of loading shapes
of products environment conditions & desirable properties of material. Provision should
be made to minimize nearly adopting proper lubrications methods.
In, mechanical design the components are listed down & stored on the basis of
their procurement in two categories

Design parts

Parts to be purchased

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For design parts a detailed design is done & designation thus obtain are compared
to the next highest dimension which is ready available in market.
This simplification the assembly as well as post production service work. The
various tolerances on the work are specified. The processes charts are prepared & passed
on to the work are specified.
The parts to be purchased directly are selected from various catalogues &
specification so that anybody can purchase the same from the retail shop with the given
specifications.

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6.2.1. MOTOR SELECTION

Selection of motor is done from standard motors available in geared motors form:
The Geared motors are basically DC motors 12 Volt DC coupled to planetary gear
set to amplify the torque available at the shaft end. Motor selected for above application is,
Motor: 12 Volt DC motor, 40 rpm, 20watt---1:20 RATIO GEARED

Fig 6.1 Motor Specification

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6.2.2. DESIGN OF WORM AND WORM WHEEL (WORM GEAR BOX)

The pair of worm and worm wheel used in the machine is designated as
1/20/10/1
The worm is made of case hardened steel 14C6 where as the worm wheel is made of Cast
iron.
Zw = 1
Zg = 20
q= 10
m=1
I = Zg/Zw =55
Nw = 800 rpm
Ng = 800/20 =40 rpm
Dg = m x Zg =1 x 55 =55
Tan = Zw/q = 5.71 0
b = 2m sq.rt (q+ 1) = 9.94
daw = m(q+2) =12
C= 0.2 m cos = 0.3
Lr ={ daw+2c} sin-1[ b/(daw+2c)]
Lr = 632
For case hardened steel Sb =28.2
For BRASS, Sb =6.2
Xb1 = 0.25
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Xb2 =0.48
Mt1 = 17.65 Xb1 Sb1m lr d2 cosU
= 4.694 x 106N-mm
Mt2 = 17.65 Xb2 Sb2m lr d2 cosU
= 1.98 x 106 N-mm
The lower value of torque is on the wheel = 1.98 x 106 N-mm
Kw = 2 n2 Mt/60 x 106
Kw =7.46 Kw
As the drive is capable of transmitting 7.46 Kw and we intend to transmit 0.08Kw the
drive is safe.

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6.2.3. DESIGN OF GEAR FOR SCREW

Power = 20 watt
Speed = 40 rpm
b = 10 m
No. of teeth on pinion (Zp) = 14
No. of teeth on Gear (Zg) = 24
Reduction ratio (i) = 24/14 = 1.71
Gear speed = 40/1.71 = 24 rpm
Material of pinion and gear is High grade steel, EN24 having,
Tensile strength = 720 N/mm2
Sut pinion = Sut gear = 720/3 = 240 N/mm2
Service factor (ka) = 1.5
Power =

2 NT
60

T=

60 x P
2xxN

T=

60 x 20
2 x x 24

T = 8 N-m
Assuming 20 degree full depth involutes tooth system,
Hence, Yp = 0.484 2.87/Zp
= 0.484 2.87/14
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= 0.279
bp x Yp = 240 x 0.279
= 66.96 N/mm2
Now bending force,
Fb = bp x m x b x Yp
= 240 x m x 10m x 0.279

.As (b = 10m)

= 669.6 m2, N
Now, Feff =

Ka x Ft
Kv

As, Ft = P/V
Where, V =

x dp x np
60 x 1000

x 14 m x 40
60 x 1000

= 0.0293 m
Ft = 20 / 0.02932 m
= 682.09/m, N
Feff =

1.5 x 682.09
m

Where Kv is neglected as speed is very less.

Feff = 1023.13/m
Now Fb = Nf x Feff
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= 1 x 1023.13/m
= 1.15
GEAR DATA
No. of teeth on pinion = 10
No. of teeth on gear = 30
Module = 1.5

x
C
s
=
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6.2.4. DESIGN OF GEAR FOR CRANK

Power = 20 watt
Speed = 40 rpm
b = 10 m
No. of teeth on pinion = 14
No. of teeth on Gear = 70
Reduction ratio (i) = 70/14 = 5
Gear speed = 40/5 = 8 rpm
Material of pinion and gear is High grade steel, EN24 having,
Tensile strength = 720 N/mm2
Sut pinion = Sut gear = 720/3 = 240 N/mm2
Service factor (ka) = 1.5
Power =

2 NT
60

T=

60 x P
2xxN

T=

60 x 20
2x x8

T = 23.87 N-m
Assuming 20 degree full depth involutes tooth system,
Hence, Yp = 0.484 2.87/Zp
= 0.484 2.87/14
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= 0.279
bp x Yp = 240 x 0.279
= 66.96 N/mm2
Now bending force,
Fb = bp x m x b x Yp
= 240 x m x 10m x 0.279

.As (b = 10m)

= 669.6 m2, N
Now, Feff = Ka x Ft
Kv
As, Ft = P/V
Where, V =

x dp x np
60 x 1000

x 14 m x 40
60 x 1000

0.0293 m

Ft = 20 / 0.02932 m
= 682.09/m, N
Feff =

1.5 x 682.09
m

Where Kv is neglected as speed is very less.

Feff = 1023.13/m
Now Fb = Nf x Feff
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669.6 = 1 x 1023.13/m
= 1.15
GEAR DATA
No. of teeth on pinion = 14
No. of teeth on gear = 70
Module = 1.5

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6.2.5. DESIGN OF GEAR SHAFT

MATERIAL SELECTION: -Ref: - PSG (1.10 & 1.12) + (1.17)
Designation

Ultimate Tensile Strength

Yield Strength N/mm2

N/mm2
EN 24

800

680

Table 6.1 material selection of Gear Shaft

ASME code for shaft design.

Since the loads on most shafts in connected machinery are not constant, it is
necessary to make proper allowance for the harmful effects of load fluctuations.
According to ASME code permissible values of shear stress may be calculated
from various relations.
(max) = 0.18 Sut
= 0.18 x 800
= 144 N/mm2
OR
(max) = 0.3 Syt
= 0.3 x 680
= 204 N/mm2
Considering minimum of the above values
(max) = 144 N/mm2
Shaft is provided with key way; this will reduce its strength. Hence reducing above
value of allowable stress by 25%
(max )= 0.18 Sut x 0.75
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= 108 N/mm2
This is the allowable valve of shear stress that can be induced in the shaft material
for safe operation.
Assuming 100 % efficiency of transmission
2 NT

Power =

60
T=

60 x P
2xxN

T=

60 x 20
2 x x 24

T = 10.23 N-m
T design = 8 N-m
CHECK FOR TORSIONAL SHEAR FAILURE OF SHAFT.
Assuming minimum section diameter on input shaft = 19 mm
d = 19 mm
Td = /16 x (act) x d3
(act) =

16 x Td
xd3

16 x 31.8 X10 3
x (19) 3

(act) = 8.29 N/mm2

As
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6.2.6. DESIGN OF CRANK PIN

We know that
T = force x radius
8000 = force x 100
Force =

8000
100

Force = 80 N
Assuming pin diameter =10 mm
MATERIAL SELECTION
Designation

Ultimate Tensile Strength

Yield Strength

N/mm2

N/mm2

800

680

EN 24

Table 6.2 material selection of Crank Pin

Check for direct shear of crank pin

Shear stress

shear force
Shear area

80
/4 x (d2)

318 x 4
x (10) 2

Shear stress =

1.0185 N/mm 2

Shear stress = 1.0185 N/mm 2 < 144 N/mm 2, Design of crank pin is safe.
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6.2.7. DESIGN OF SLIDER PIN

We know that
T = force x radius
8000 = force x 100
Force =

8000
100

Force = 80 N
Assuming pin diameter =10 mm
MATERIAL SELECTION
Designation

Ultimate Tensile Strength

Yield Strength

N/mm2

N/mm2

800

680

EN 24

Table 6.3 material selection of Crank Pin

Check for direct shear of crank pin

Shear stress

shear force
Shear area

80
/4 x (d2)

318 x 4
x (10) 2

Shear stress =

1.0185 N/mm 2

Shear stress = 1.0185 N/mm 2 < 144 N/mm 2, Design of slider pin is safe.
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6.2.8. DESIGN (SELECTION OF BALL BRG) FOR CRANK

In selection of ball bearing the main governing factor is the system design
of the drive i.e.; the size of the ball bearing is of major importance; hence we shall
first select an appropriate ball bearing first select an appropriate ball bearing first
taking into consideration convenience of mounting the planetary pins and then we
shall check for the actual life of ball bearing.
BALL BEARING SELECTION.
Series 62
Brg.No.

Do

Co

6003

17

35

10

6.05 kN

3.25 kN

Table 6.4 Bearing selection of Crank

Pe = (X V Fr + Y fa)
Where;
Pe = Equivalent dynamic load, (N)
X = Radial load constant
V = 1 (Here inner race is rotating)
Fr = Radial load (H)
Y = Axial load contact
Fa = Axial load (N)

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In our case;
Radial load Fr = 80 N
Axial load (Fa)
Fa = 0
Pe = X x Fr
Pe = 1 x 80 = 80 N
No of revolutions of bearing
L10 =

Lh10 x n x 60
106

L10 = 60 x 18 x 4000
106
L10 = 5.76 Millions Of Revolution
L10 = (C/pe) a
5.76 = (C/80) a
C = 143.40 N
C = 0.1434 kN < 6.05 kN
.As; required dynamic of bearing is less than the rated dynamic capacity of
bearing;
Bearing is safe.

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6.2.9. DESIGN (SELECTION OF BALL BRG) FOR SCREW

In selection of ball bearing the main governing factor is the system design
of the drive i.e.; the size of the ball bearing is of major importance; hence we shall
first select an appropriate ball bearing first select an appropriate ball bearing first
taking into consideration convenience of mounting the planetary pins and then we
shall check for the actual life of ball bearing.
BALL BEARING SELECTION.
Series 62
Brg.No.

Do

Co

6004

20

42

12

9.36 kN

5 kN

Table 6.5 Bearing selection of Screw

Pe = (X V Fr + Y fa)
Where;
Pe = Equivalent dynamic load, (N)
X = Radial load constant
V = 1 (Here inner race is rotating)
Fr = Radial load (H)
Y = Axial load contact
Fa = Axial load (N)

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In our case;
Radial load Fr = 80 N
Axial load (Fa)
Fa = 0
Pe = X x Fr
Pe = 1 x 80 = 80 N
No of revolutions of bearing
L10 =

Lh10 x n x 60
106

L10 =

60 x 18 x 4000
106

L10 = 5.76 Millions of Revolution

L10 = (C/pe) a
5.76 = (C/80) a
C = 143.40 N
C = 0.1434 kN < 9.36 kN
.As; required dynamic of bearing is less than the rated dynamic capacity of
bearing;
Bearing is safe.

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6.2.9. DESIGN (SELECTION OF BALL BRG) FOR CRANK AND SLIDER

PIN
BALL BEARING SELECTION.
Series 62
Brg.No.

Do

Co

6000

10

26

4.26 kN

1.9 kN

Pe = (X V Fr + Y fa)

Table 6.5 bearing selection of Crank and Slider pins

pins

Where;
Pe = Equivalent dynamic load, (N)
X = Radial load constant
V = 1 (Here inner race is rotating)
Fr = Radial load (H)
Y = Axial load contact
Fa = Axial load (N)

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In our case;
Radial load Fr = 80 N
Axial load (Fa)
Fa = 0
Pe = X x Fr
Pe = 1 x 80 = 80 N
No of revolutions of bearing
L10 =

Lh10 x n x 60
106

L10 = 60 x 18 x 4000
106
L10 = 5.76 Millions Of Revolution
L10 = (C/pe) a
5.76 = (C/80) a
C = 143.40 N
C = 0.1434 kN < 4.62 kN
As; required dynamic of bearing is less than the rated dynamic capacity of
bearing;
Bearing is safe.

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6.2.10. DESIGN OF SCREW

Power screw is mechanical device meant for converting rotary motion into
translation motion and for transmitting power.
The main application of power screw is;
To raise load, e.g. Screw jack.
To clamp a work piece e.g. Vice, etc.
Power screws are simple to design, easy to manufacture and give smooth &
noiseless service. They provide large mechanical advantage and highly accurate
motion. Square thread profile is favorably used in applications like vices; clamps
etc, due to its property of maximum efficiency and minimum radial or bursting
pressure on nut. We shall design a screw jack having a single start, square threads
screw with no collar friction.

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Data:Tmotor = 4.7 N-m

Torque at screw = 4.7 x 1.25 x 24/14
= 10.23 N-m
Initially assuming dimensions of screw, which we shall check under the given
system of forces
SELECTING MATERIAL COMBINATION FOR SCREW AND NUT
(Ref: Pg. No.170, Design of Machine elements, V. B. Bhandari
Material

Coefficient of

Coefficient of

Combination

friction(starting)

friction(running)

Soft steel-

0.10

0.08

Bronze

Table 6.6 selection of material combination of screw and nut

BASIC DIMENSIONS FOR SQUARE THREADS

(Ref: Pg. No. 5.69, PSG-Design Data)
Nominal

Major

Major

Minor

Dia.

Dia.(bolt)

Dia.(nut)

Dia.

21 mm

21 mm

21.5 mm

17 mm

Table 6.7 Basic Dimensions of Square Thread

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Pitch

6 mm

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Design Check
D = Nominal /outer diameter (mm) = 21 mm
dc = core / inner diameter (mm) = 17 mm
dm = mean diameter (mm) = 19 mm
T (screw) = W x (dm/2) tan ( +)
Where, W= Axial load.
= friction angle.
= Helix angle.
Helix angle:tan = L
dm
For the single start sq. thread lead is same as pitch=6
tan =

6
x 19

= 5.740

Friction Angle:
Coefficient of friction under different condition
C

Condition

Ref: - R.S.Khurmi (Table17.5)

Average coefficient of friction

Starting

Average quality of material

0.18 &
workmanship & average running
conditions

Running
0.13

0.18

Table 6.8 Coefficient of friction under different conditions

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0.13

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Hence Friction Angle,

= tan
0.18 = tan
= 10.20
T = W x (dm/2) tan ( +)
10.23 = W X 19/2 x tan (10.2 + 5.74)
W =3770.29 N
W = 3770/9.81
W = 384.30 Kg
This is lifting capacity of screw using the motor specifications
MATERIAL SELECTION
Ref :-( PSG 1.12)

For Screw
Designation

Tensile Strength, N/mm2

Yield Strength, N/mm2

EN9

600

380

Table 6.9 Material selection of Screw

1) Direct Tensile or Compressive stress due to an axial load: (act) =

W
(/4) x dc2

(act) =

3770
(/4) x (17)2

(act) = 16.60 N/mm2

As (act) < (max);
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Hence screw is safe in compression.

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2) Torsional shear stress:T = (/16) x (act) x dc3

10.23 x 10 3 = (/16) x (act) x (17)3
(act) = 10.60 N/mm2
As (act) < (max);
Hence screw is safe in torsion.
3) Bearing Pressure:Pb =

W
(/4) (do2-dc2) n

Where; P b = Bearing pressure (N/mm2)

N = No of threads in contact.

Limiting values of bearing pressure

Application of screw

Ref: - V B Bhandari. (Table 6.3)

Material

Safe bearing

Rubbing speed

pressure(N/mm2)

Screw jack

Screw

Nut

Steel

Bronze

11-17

Table 6.10 Limiting values of bearing pressure

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Pb =

W
(/4) (do2-dc2) n

11 =

3770
(/4) (212-172) n

n = 4.99
n=5
4) Shear stress due to axial load: (act) =

W
n dc t

t = thread width = p/2

t = 3 mm
(act) =

3770
x 5 x 17 x 3

(act) = 4.70 N/mm2

As (act) < (max);

Hence screw threads are safe in shear.

5) Stresses due to buckling of screw: According to Rankine formula,

Where;
Wcr =

fc x A
1 + a(le/k) 2

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Where;
Wcr = Crippling load on screw (N)
A = Area of c/s at root (mm2)
a= constant
Le= Equivalent unsupported length of screw (mm)
Decided by end conditions.
K= Radius of gyration = dc/4 (mm)
Fc= Yield stress in compression (N/mm2)
le = 0.707L;as one end of screw are considered to be fixed and other free
(Ref. PSG Design Data Pg. No. 6.8)
Here transverse of the screw jack is 210 mm, and length of nut approximately 30mm
therefore length of crew can be assumed to be 180 mm.
le = 0.707 x 180 = 127.6 mm
300 x (/4 x 172)

Wcr =

1+ (1/7500) (127.6/ (17/4)) 2

Wcr = 60.78 kN As, The critical load causing buckling is high as compared to actual
compressive load of 3.770KN the screw is safe in buckling.

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6.2.11. DESIGN OF NUT

In design of nut the major dimension is the height or length of the nut. It is decided
by considering the bearing criterion. Nut is also required to be safe under shearing. The
failure of nut in shearing takes place at its core diameter and the area of core diameter of
screw resisting shear is less than the area at the core diameter of nut.
Secondly the materials for nut & screw are different to avoid greater friction at
contacts.
MATERIAL SELECTION
Material

Allowable tensile stress

N/mm2

Phosphor bronze

400
Table 6.11 Material selection of Nut

P(bearing)

W
/4 (d2 dc2) x n

n =

3770
(/4) (212-172) x 11

n=

As; n = no of the threads in contact.

ln = length of nut.
P = Pitch.

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Allowable shear stress

N/mm2
210

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n = Ln/p
Ln = n x p
=5x6
Ln = 30
Normally it is recommended that ratio of length or height of nut (n) to core diameter (dc)
should be between 1.2 to 2.5 for solid nuts.
Ln = 1.2 x 30
= 36 mm
Considering length of nut = 36 mm

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CHAPTER 7
PROCESS CHART AND DRAFTING FOR PARTS
7.1. Operation performed
Following operations will go to perform on component sequentially:
1. Facing
2. Turning
3. Step turning
4. Grooving
5. Drilling
6. Boring

7.2. Components of Machine

7.2.1. Screw Top Bearing Housing

7.2.2. Screw Bottom Bearing Housing
7.2.3. Screw
7.2.4. Left .Hand Pillar and Right Hand pillar
7.2.5. Top Arm
7.2.6. Bottom Arm

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7.2.1. Screw Top Bearing Housing

Fig 7.1 Screw Top Bearing Housing

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PART NAME: - SCREW TOP BRG. HOUSING

MATERIAL SPECIFICATIONS :- EN9
RAW SIZE :- 70X16X50
FINAL SIZE (mm): 50x12x40
Sr.
Operation
Tool used
no.
1

Clamp stock

On milling

Face milling all

Form milling

sides

Initial size

QUANTITY :- 01 NOS
Operation
Final size
Time (Min)

70x16x50

10

tool

70x16x50

20

50x12x40

Clamp stock

On lathe

20

Drilling

Twist drill

20

Drilling 25

Boring tool

20

Boring 28

Boring tool

20

Boring 35

Boring 28
5

through thickness
Counter boring

35 through 10 mm
thickness

Table 7.1 process chart of Screw Top bearing Housing

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7.2.2. Screw Bottom Bearing Housing

Fig 7.2 Screw Bottom Bearing Housing

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PART NAME: - SCREW BOTTOM BRG. HOUSING.

MATERIAL SPECIFICATIONS :- EN9
RAW SIZE :- 70X16X50
FINAL SIZE (mm): 50x12x40
Sr.
Operation
Tool used
no.
1

On milling

Clamp stock

Initial size

QUANTITY :- 01 NOS
Operation
Final size
Time (Min)

70x16x50

10

Face milling all

Form milling

sides

tool

70x16x50

20

50x12x40

Clamp stock

On lathe

20

Drilling

Twist drill

20

Drilling 25

Boring tool

20

Boring 28

Boring Tool

20

Boring 35

Boring 28
5

through thickness
Counter boring

35 through 10 mm
thickness

Table 7.2 process chart of Screw Bottom bearing Housing

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PART NAME: - SCREW

MATERIAL SPECIFICATIONS :- EN24
RAW SIZE :- 22X550
FINAL SIZE (mm): 20X541

QUANTITY :- 01 NOS

Sr.
no.

Operation

Tool used

Initial size

Operation
Time (Min)

Final size

Clamp stock

On lathe

20

Facing

Facing tool

550

541

15

Turning OD
20 mm

Turning OD 20
mm through length
Step turning OD to
17 mm through
length 50
Step turning OD to
17 mm through

Threading M16 x
2 pitch length
482mm

Turning tool

Turning tool

Turning tool

Threading tool

22

20

Table 7.3 process chart of Screw

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10

10

126

Turning OD
17 mm

Turning OD
20 mm

Threading
M16 X 2

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PART NAME: - LEFT HAND PILLAR AND RIGHT HAND PILLAR

MATERIAL SPECIFICATIONS :- EN24
RAW SIZE :- 20X510
FINAL SIZE (mm): 12X500
Sr.
Operation
Tool used
no.

Initial size

QUANTITY :- 01 NOS EACH

Operation
Final size
Time (Min)

Clamp stock

On lathe

20

Facing

Facing tool

510

500

Turning OD 12
mm through length

Turning tool

20

Table 7.4 process chart of Left and Right Pillar

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15

Turning OD
12 mm

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7.2.5. Top Arm

Fig 7.3 Top Arm

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PART NAME: - TOP ARM

MATERIAL SPECIFICATIONS :- EN9

RAW SIZE :- 345X22X22

FINAL SIZE (mm): 340x20x20

Sr.

Operation

Operation

Tool used

Initial size

Clamp stock

On milling

345X22X22

15

Face milling all

Form milling

sides

tool

345X22X22

20

340x20x20

no.

QUANTITY :- 01 NOS

Drilling 11.5 mm
through thickness

Boring 12 mm
through thickness
Drilling 7 mm
through thickness

Time (Min)

Final size

Drilling 11.5
Twist drill

20

mm

Boring 12
Boring tool

20

mm

Boring 28
Twist drill

20

mm
Tapping M8

Tapping 8 mm

Tapping tool

Table 7.5 process chart of Top Arm

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7.2.6. Bottom Arm

Fig 7.4 Bottom Arm

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PART NAME: - BOTTOM ARM

MATERIAL SPECIFICATIONS :- EN9

RAW SIZE :- 345X22X22

FINAL SIZE (mm): 340x20x20

Sr.

Operation

Operation

Tool used

Initial size

Clamp stock

On milling

345X22X22

15

Face milling all

Form milling

sides

tool

345X22X22

20

340x20x20

no.

QUANTITY :- 01 NOS

Drilling 11.5 mm
through thickness

Boring 12 mm
through thickness
Drilling 7 mm
through thickness

Time (Min)

Final size

Drilling 11.5
Twist drill

20

mm

Boring 12
Boring tool

20

mm

Boring 28
Twist drill

20

mm
Tapping M8

Tapping 8 mm

Tapping tool

Table 7.6 process chart of Bottom Arm

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7.3 Standard Part of Machine

7.3.1 Crank

Fig 7.5 Crank

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7.3.2 Nut for Guide

Fig 7.6 Nut for Guide

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7.3.3 Crank Gear

Fig 7.7 Crank Gear

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7.3.4 Details and Assembly of Frame

Fig 7.8 Details of Frame

Fig 7.9Assembly of Frame

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7.3.5 Nut

0
Fig 7.10 Nut

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CHAPTER 8
COST ESTIMATION
8.1. BILL OF MATERIALS

SR

PART CODE

DESCRIPTION

QTY.

MATERIAL

1.

SPR-01

CRANK MOTOR

01

STD

2.

SPR -2

GRIPPER SCREW

01

MS

3.

SPR -3

CRANK GEAR

01

STD

4.

SPR -4

CRANK

01

MS

5.

SPR -5

CONNECTING ROD

01

MS

6.

SPR -6

SCREW TOP HSG

01

EN9

7.

SPR -7

SCREW BOTTOM

01

EN9

NO.

HSG
8.

SPR 8

SCREW

01

EN24

9.

SPR 9

LH PILLAR

01

EN9

10.

SPR 10

RH PILLAR

01

EN9

11.

SPR 11

CRANK BRG

01

EN9

HOUSING
12.

SPR 12

LM BEARINGS

02

STD

13.

SPR 13

GM NUT

01

STD

14.

SPR 14

BASE PLATE

01

MS

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15.

SPR 15

LINEAR GUIDES

04

STD

16.

SPR 16

CASTOR

04

STD

17.

SPR 17

CIRCLIPS

08

STD

18.

SPR 18

LIVTER NUT

01

STD

19.

SPR -19

FRAME

01

MS

20.

SPR -20

BEARING 6002Z

02

STD

Table 8.1 Bill of Material

8.2. MATERIAL PROCUREMENT

Material is procured as per raw material specification and part quantity. Part
process planning is done to decide the process of manufacture and appropriate machine for
the same.
GENERAL MATERIAL USED
EN24- ALLOY STEEL
EN9- PLAIN CARBON STEEL
MS-MILD STEEL
STANDARD: - STANDARD PARTS SELECTED FROM PSG DESIGN
DATA/MANUFACTURER CATALOGUE.

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8.3. RAW MATERIAL COST

The total raw material cost as per the individual materials and their corresponding rates
per kg is as follows,
Total raw material cost = Rs 3770/8.4. MACHINING COST

OPERATION

RATE
Rs /HR

TOTAL TIME

TOTAL COST

HRS

IN Rs/-

LATHE

120

10

1200

MILLING

120

960

DRILLING

80

2.5

200
2360

TOTAL

Table 8.2 Machining Cost

8.5. MISCELLANEOUS COSTS

OPERATION

COST(Rs)

GAS CUTTER

300

SAWING

120

TOTAL

420

Table 8.3 miscellaneous costs

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8.6. COST OF PURCHASED PARTS

SR NO.

DESCRIPTION

QTY

COST IN Rs. /-

1.

MOTOR

02

2400

2.

CASTOR

04

440

3.

GRUB SCREW

09

30

4.

BEARINGS

02

380

5.

GEAR

02

1200

TOTAL

Rs 4450/-

Table 8.4 Cost of Purchased Part

8.7. TOTAL COST

TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost + cost of
Purchased Parts +Overheads
Hence the total cost of machine = Rs 11600/-

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CHAPTER 9
RESULTS
9.1. Result
9.2. Future Scope

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CHAPTER 10
CONCLUSION
A new actuating mechanism and a mobile platform were designed and
implemented. For mechanizing the process of painting a single wall was developed. The
implemented mobile platform was tested and succeeded in carrying the intended load
while enabling the plane degrees of freedom. The two link manipulator was tested and
succeeded in fulfilling the intended reachability, while maintaining low levels of vibration
and noise. Overall system have been successfully integrated and tested. The arm has
succeeded in moving along the trajectory intended while keeping distance between spray
gun and wall constant at all times.
A painting duration of 0.101 hour/ m2 is sufficient as targeted for domestic use.
Further enhancement by a mechanical programming can be done.

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REFERENCES

1. MACHINE DESIGN:-R S KHURMI

2. DESIGN OF MACHINE ELEMENTS: - V B BHANDARI
3. P S G DESIGN DATA
4. PRODUCTION TECHNOLOGY:- P C SHARMA

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