DESIGN AND FABRICATION OF PEDAL OPERATING WATER PUMPING SYSTEM

A MINI PROJECT REPORT

Submitted by

R.GOGULARAJAN

S.JAYAPRAKASH

M.KODIYARASU

M.VINAYAGAM

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

SRI RANGAPOOPATHI COLLEGE OF ENGINEERING

ANNA UNIVERSITY:CHENNAI 600 025

APRIL – 2012

SRI RANGAPOOPATHI COLLEGE OF ENGINEERINGANNA UNIVERSITY: Chennai 600 025

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BONAFIED CERTIFICATE

Certified that this project report “PEDAL OPERATING WATER PUMPING

SYSTEM” is the bonafied work of

R.GOGULARAJAN 47309114004

S.JAYAPRAKASH 47309114006

M.KODIYARASU 47309114313

MVINAYAGAM 47309114333

Project report submitted for the viva-voice examination held on …………………

SIGNATUREHEAD OF THE DEPARTMENT SIGNATURE SUPERVISORMr. S.RAMESH. M.E K.SUNDARAVINAYAGAM. B.E., sri rangapoopathi college of engineering sri rangapoopathi college of engineering

Gingee T.K Gingee T.K

INTERNAL EXAMINER EXTERNAL EXAMINER

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ACKNOWLEDGEMENT

We would like to express our gratitude to the almighty for being with us everywhere

and every time. Not only for the successful completion of our project but for our

successful life also.

First and foremost our sincere gratitude moves to our respected

Chairman Mr. R.POOPATHI. B.Sc., B.L., sri rangapoopathi college of

Engineering Allampoondi , Gingee T.K.

We are obliged to Principal Dr. RAMACHANDRAN MANIKANDAN M.Tech., Phd., NITT., AMICHE., MISTE.,sri rangapoopathi college of Engineering Allampoondi , Gingee T.K., for permitting

us to our bachelor of engineering academic project.

And our H.O.D Mr. S.RAMESH. M.E sri rangapoopathi college of Engineering

Allampoondi,

We would like to express profound senses of our sincere heart-felt gratitude thanks

to Mr. R.MATHIAZGHAN. B.E., Our Internal Project Guide , sri rangapoopathi

college of Engineering Allampoondi , Gingee T.K.

for his encouraging words of appreciation and suggestion for the successful

completion of this project work with motivation guidance.

We also express our sincere and incomparable gratitude to

Our DepartmentStaffs.

Mr. V.KUMARAN. M.E., Mr. S.ARULKUMAR. M.E.,

Mr. S.PANNERSELVAM. M.E., Mr. G.VIGNESH. B.E.,

Mr. M.SANTHOSH KUMAR . B.E.,

Finally, we thanks, Our Parents and Family Members for their blessing and

encouragement they gave us throughout this project.

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LIST OF CHAPTER

CHAPTER PAGENO

1. Abstract 1

2. Introduction 3

3. Requirements 5

I. Flow chart 6

4. Construction 7

I. Bicycle 8

II. Stand 9

III. Alternator 10

IV. Battery 13

V. Inverter 18

5. Working principle 22

6. Sketch 25

7. Design calculation 27

8. Photocopy 30

9. Cost estimation 32

10. Advantages 35

11. Conculsion 37

12.Referance 39

LIST OF FIGURES4

FIGURE NO

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

TABLES NO

TITLE

Bicycle

Stand

Alternator

Section view

Battery

Battery Test

Inverter circuit diagram

Connection diagram

Cycle with stand

Model sketch

LIST OF TABLES

PAGE NO

8

9

11

12

15

16

20

23

24

26

5

2.12.2

TITLE

List of materials

List of materials cost

PAGE NO

34

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Chapter -1

INTRODUCTION

Water plays an important role in the material, social and cultural life of

mankind. The water needs are increasing day by day. This is the result of

population growth and increase in the standard of living which is directly

proportional to water consumption. The lifting of water for drinking or irrigation

purposes is of great importance in widely distributed villages with little or no rural

electrification and where underground water is available. This moving to works, like

all the bicycle machines, with the force of your legs (which are 5 times stronger than

your arms). It’s a self-sufficient form of technology that doesn’t require fuel or

electricity.

Chapter -2

REQUIREMENTS

SL.NO MATERIALS SPECIFICATION QUANTITY

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1. cycle STD 1

2. centrifugal pump ½ HP 1

3. stand STD 1

4. l-angle STD 1

5. pipes 30mm dia 2

6. food valve 30mm dia 1

7.

Chapter -3

3. ConstructionMethod

The construction of the bicycle powered water pump. It also shows the

tools required and time taken to build each part. Since the workshop consists of hand

tools, a few vices, a bench grinder, an arc welder, a chop saw and a drill press,

significant modifications will need to be made to the design before it can be

manufactured in workshop. The frame and cylindrical connectors pose a signify

cant problems they require the use of milling equipment, a lathe and boring tools – 8

none of which are available to workshop without an expensive and time consuming

trip to the machine shop in the hardware.

1, bicycle

2 stands

3, centrifugal pump

4, l-clamp

5, inlet& outlet tube

6, food valve

3.1BICYCLE

Bicycle often called a bike is a human power pedal drive or single track

vehicle having two wheels attached to aframe one behind the other. A person who

rides a bicycle is called a cyclist.Bicycle were introduced in the 19 th century and now

number about one billion worldwide twice as many as automobiles.They also

provide apopular of recreation and have been adapted for such uses as children’s

toys, adult fitness, military and police application and bicycle racing.The basic shape

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and configuration of atypical upright bicycle has changed little since the first chain-

drive model was developed around 1885.

HISTORY

The DRAISIENNE, LAUFMASCHINE, DANY horse was the first

human means of transport to use only two wheels in tandem and was inverted by the

German baron Karl von dais. It is regarded as the fortunes of the modern bicycle and

in 1817and in Paris in 1818.it’sride sat astride a wooden frame supported by two in –

line wheels and pushed the vehicle along with her feet while steering the front

wheel.The first mechanically-propelled 2-wheel vehicle may have been built by

Kirkpatrick Macmillan, a Scottish blacksmith in 1839.The several invention of rear

wheel drive the best known being the rod-driven velocipede by Scotsman

ThomasMcCall in 1869.the French creation made of iron and wood developed into

the penny-farthing.Further innovation increased comfort and ushered in a second

bicycle craze, the 1890s’ Golden Age of bicycles. In 1888, Scotmanjohn boy Dunlop

introduced the first practical pneumatic tire, which soon becomesuniversal.

FEMALE CYCLE

The female bicycle is a safety bicycle gave women unprecedented

mobility contributing to their emancipation in Westonnations. The bicycle was

recognized by 19th-century feminists and suffragists as a freedom machine for

women. American Susan b.antony said in New York world in February 2 in 1896.

3.1 BYCYCLE TYPES

Utility bicycle

Mountain bicycle

Racing bicycle

Touring bicycle

Hybrid bicycle

Cruiser bicycle10

Unicycles

Tricycles

Quadra cycles

Tall bikes

Fixed gear bicycles

3.1 BY CYCLE

Bicycle is designed to converthuman energy into mechanical energy to

transportation purpose.

The mechanical energy is then transferred in rear wheel the friction

energy converted into kinetic energy through the use of drive and pumping the water.

The bicycle is one of the most efficient uses of human body existing

musculature.

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It is consist of parts frame, chain, and rim, and rope, tire.

Fig (3.1)

3.2 STAND

The L-channel cut the length of the frame, in length 450mm and width

is250mm.Thehigh of the axel is 500mm. it is weld to join in the A-frame.

The end of the A-frame drill to attach the axil, the end A-frame welded to the square

bold in 35mm.

The outer diameter of the axle griper guide in attached in the frame, it is

M16 threaded bold use the axial griper guide.

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The axial griper adjustment type. It is drill to the side of the frame. It is

fixed in the pump.

The stand fixed in the cycle rear axial, it is freely move to use the stand

and it is use to career of the cycle.

Fig (3.2)

3.3 PUMP

A pump is a device used to move fluid such as liquids; the pump is

displacinga volume by physical or mechanical action. Pumps fall into three major

groups in direct lift, displacement and gravity pumps. Their names describe the

method for moving a fluid.

Types of pumps:

1.Dynamic pressure pump

Centrifugal pump

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Jet pump

2.displacement pump

Reciprocating pump

Rotary pump

3.Reciprocating pump

Piston pump

Plunger pump

Diaphragm pump

4.Rotary pump

Gear pump

Lube pump

Vane pump

Screw pump

Rotary plunger pump

3.4. PUMP TYPES

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3.4 HISTORY OF PUMP

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According to rate, the BRAZILIAN SOLIDER and historian of science

the first machine that could be characterized as acentrifugal pump was amud lifting

machine which appeared as early as 1475 in a treatise by the Italian renaissance

engineer FRANCESCO DI GIORGIO MARTINI. True centrifugal pump were not

developed until the late 17th century, when DENIS PAPIN made one with straight

vanes. The curved vane was introduced by British inventor JOHN APPOLD in 1851.

3.4 HOW TO WORK

Like most pumps, a centrifugal pump converts mechanical energy from

a motor to energy of a moving fluid; some of the energy goes into kinetic energy of

fluid motion, and some into potential energy, represented by a fluid pressure or by

lifting the fluid against gravity to a higher level.The transfer of energy from the

mechanical rotation of the impeller to the motion and pressure of the fluid is usually

described in terms of centrifugal force, especially in older sources written before the

modern concept of centrifugal force as a fictitious force in a rotating reference frame

was well articulated. The concept of centrifugal force is not actually required to

describe the action of the centrifugal pump.

3.4 VERTICAL CENTRIFUGAL PUMPS

Vertical centrifugal pumps are also referred to as cantilever pumps.

They utilize a unique shaft and bearing support configuration that allows the volute

to hang in the sump while the bearings are outside of the sump. This style of pump

uses no stuffing box to seal the shaft but instead utilizes a "throttle Bushing". A

common application for this style of pump is in a parts washer.

3.4 MULTISTAGE CENTRIFUGAL PUMP

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A centrifugal pump containing two or more impellers is called a

multistage centrifugal pump. The impellers may be mounted on the same shaft or on

different shafts. If we need higher pressure at the outlet we can connect impellers in

series.If we need a higher flow output we can connect impellers in parallel. All

energy addedto the fluid comes from the power of the electric or other motor force

driving the impeller.

3.4 FORTH PUMPS

In the mineral processing industry, or in the extraction of oils and, froth

is generated to separate the rich minerals or bitumen from the sand and clays. Forth

contains air that tends to block conventional pumps and cause loss of prime. The

industry over the years has developed different ways to deal with this problem. One

approach consists of using vertical pumps with a tank. Another approach is to build

special pumps with an impeller capable of breaking the air bubbles. In the pulp and

paper industry holes are drilled in the impeller. Air escapes to the back of the

impeller and a special expeller discharges the air back to the suction tank. The

impeller may also feature special small vanes between the primary vanes called split

vanes or secondary vanes. Some pumps may feature a large eye, an inducer or

recirculation of pressurized froth from the pump discharge back to the suction to

break the bubbles.

3.4 CENTRIFUGAL PUMP DIAGRAME

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FIG (3.4)

3.5 CENTRIFUGALPUMP

A centrifugal pump is rot dynamic pump that uses a rotating impeller to

create flow by the addition of energy to fluid. Centrifugal pump are commonly used

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to move liquids through piping. The fluid enters the pump impeller along or near to

the rotating axis and is accelerated by the impeller flowing readily outwardinto a

diffuser or casing from where it exits the downstream piping. Centrifugal pumps are

used for large discharge through smaller heads.

The centrifugal pump parts Brocken to the coils and removes to the

armature in the pump. The pump flat plates join to the nut and bold, it is connected

to the L-plate in the centrifugal pump. It is joined to the stand. The L-clamp is

adjustment type. The opposite side is supporting of the bearing became shacking is

absorbed in bearing,

3.5 pump specification

Pump capacity = 0.5 HP

Pump power(p) = 0.37 kw

Pump speed = 2500 rpm

Pump duty = S1

Pump class = ‘B’

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3.6 DISMANDLING OF PUMP

After dismantling the pump a reverse engineering exercise was

conducted to find out the function of each part and establish whether it would be

suitable for use in the bicycle model was created to aim in visulation of the different

parts and they fit in fig (4.1), the armature friction to tire in the pump shaft.

Fig (3.6.1)

CENTRIFUGAL PUMP CUT SECTION MODEL:

Fig (3.6.2)

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3.7 L –CLAMP

The L- clamp is used to attach to the pump, it is fixing to the stand it is

adjustment type. The L-clamp material is cast iron. It is drill toholes in the clamp.

Fig (3.7.1)

3.7 INLET AND OUTLET PIPE

The inlet tube is joined to the suction and another end is connected to

the food valve. The outlet tube is joined to the delivery valve. The inlet and outlet

tube material is plastic.

Fig (3.7.2)

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Chapter-4

4. WORKING PRINCIPLE

The “PEDAL OPERATING WATER PUMPING SYSTEM” use to

pumping the water. The stand is use to adjust to clamping pump, it is tire friction to

armature shaft in the pump. The pipe joined to the pump. The man is pedaling to the

cycle the rear wheel is rotated. The rear wheel is friction to the pump shaft. The

friction energy converted into kinetic energy. The pump is vacuum is created in to

the casing in suction valve suction to deliver to the water. The centrifugal pump is

suction from 15 feet deliver to 40 feet above the highest.

4.1 GEAR TRAIN ANALYSIS

The performance of a pump is directly related to the speed at which the

impeller spins. The centrifugal pump has arated operating speed of 2800rpm.in order

to obtain maximum performance; the bicycle powered pump should run as close to

this speed as possible.it has been proposed that the armature of the motor, which has

a diameter of 46.5mm, should be used as a driving roller for the pump. It is possible

to calculate whether this will drive the pump at the right speed by analyzing the gear

train. Using a friction drive on the rear tyre means that thegear trains has 4 sections,

the bicycle front chain rings(1),rear sprockets (2) and rear wheel (3) and the pumps

driving roller(4).

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4.2 GEAR TRAIN ARRANGEMENT

The gear train can be described using formula:

= Wheelpumpwheelpedal =

frictionrollerfriction tyre

The test bicycle has a tyre diameter of 614mm and the armature of the

electronic motor that will be used as the pump driving roller has a diameter of

46.5mm. A number of sources have suggested that 80rpm is the optimum clearance

for comfortable pedaling. As the bicycle uses a variable gearing system, a number of

different gear ratio is possible for the first section of gear train.

1 2 3 4

Fig (4.2.1)

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4.2.2 TYRE AND ROLLER CONTACT FRICTION

In order for smooth operation and maximum power transfer to occur the

roller must not slip as it is driven by the tyre. The inflation pressure of the tyres and

their grip pattern both significantly alter the contact friction between the two

components making analytical modeling .if this is the case then the contact friction

could be increased by applying grip tape to the roller outside.

TYRE

SPROCKET

PUMP SHAFT

Fig(4.2.2)

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5.0 CADMODELING SKETCH

The cad model of the bicycle as shown in figure (6.1) was created to help

of the design, both as individual parts and to show the interaction between the

assembly diagrams.

3D Visualizations

AxleGripTightenersfor Lateral

Adjustment

OutletHose

InletHose

AxleGrips

Bicycle Rear Tyre

HoseClip

PumpAssembly-driving roller

-Cylindricalbracket-pump head

Radial Adjustment

Slots SupportingFrame

Key-Bicycle-Manufacturedparts-Parts oforiginalpump- Otherpurchased parts

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Fig (5.1)

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Chapter -6

CALCULATION

SPEEDRATIO

Speed ratio = pump shaft speed

cycle rear wheel speed

Speed ratio (i) = 2000150 = 14.5

I =speed ratio

VELOCITY

v =π ×D×N60

v =π × .03×2000

60 = 3.3 m/s

N= pump speed

D = diameter of impeller

V = velocity

FOR HORIZONTAL FLOW

Suction = 15 feet

Delivery = 40 feet

Discharge (q) =1000 lit/ hour

FOR VERTICAL FLOW

Suction = 10 feet

Delivery = 20 feet

Discharge (q) = 600lit/hour

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7. PHOTOCOPY

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Chapter -8

COST ESTIMATION

ELAMENT OF COST

Direct material cost

Direct labor cost

Direct expenses cost

Direct material cost:

All the material from which the product is manufactured is known as

direct material cast.

Direct labor cost:

The labor actually spend by workers to manufacture product is known

as direct labor cost.

Direct expanses:

These are expenses Cost of special tools, jigs and fixtures.Cost of

drawing, designs, etc.

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8.1 LIST OF MATERIALS

The following components are used

SI.NO NAME OF COMPONENT SIZE QUANTITY

1 BYCYCLE STD 1

2 STAND STD 1

3 CENTRIFUGAL PUMP 0.5 HP 1

4 PIPE 1 1

8.2 DIRECT MATERIAL COST

SO.NO DESCRIPTION QUANTITY AMOUNT OF COST

1 BY CYCLE 1 1000

2 CENTRIFUGAL PUMP 1 800

3 L-ANGLE 8m 500

4 PIPE 5m 150

5 WELDING COST - 500

6 NUT &BOLD 10 150

7 OTHER COST - 900

8 REPORT COST - 1000

TOTAL 5000

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Chapter -9

ADVANTAGES

Cost is low.

Must be easy to use.

Must be cheap and easy to maintain by local people.

Must be hygienic if used for drinking water.

Should be self-priming.

High efficiency.

Must not require electricity or fuel

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Chapter -10

APPLICATIONS:

Agricultural purpose used.

Domestic purpose used.

Industrial Applications.

Pumping and traveling used.

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Chapter -11

CONCLUSION

We thing that this project will give a best satisfaction to public for it

by legs. It can be used for good pumping system. It is demand of source in fuel and

electricity is do not used in pedal operating water pumping system. This system

used to water pumping to fill in the water storage tank. It is used for all domestic

applications. The finally this project is completed.

The next stage of implemented to in pump shaft speed is increase to

discharge the long length.

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Chapter -12

REFERENCES

TEXT BOOK OF FLUIED MECHANICS ( DR.R.K.BANSAL)

SIDEWELLS, C-BIKE REPAIR MANUAL.

WWW.MAYAPEDALS.COM

WWW.GOOGLE.COM

WWW.RECYCLING GUIDE.COM

WWW.PEDAL POWER.COM

WWW.STUFFWORK.COM

WWW.ALIBABA.COM

WWW.ENGINEERING TOOL BOX.COM

WWW.PUMPWOULD.COM

www.wikipedia.com

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