Design and Fabrication of an automatic shoe polishing machine
Submitted by Muhammad Bilal Asif Mahmood Muhammad Gulsher
Supervisor Co-supervisor
327-FET/BSME/F13 330-FET/BSME/F13 335-FET/BSME/F13
Engr. Muhammad Rizwan Engr. Noor Rahman
Department of Mechanical Engineering International International Islamic University Islamabad, Pakistan 2017
i
Design and Fabrication of an automatic shoe polishing machine
Submitted by Muhammad Bilal Asif Mahmood Muhammad Gulsher
327-FET/BSME/F13 327-FET/BSME/F13 330-FET/BSME/F13 330-FET/BSME/F13 335-FET/BSME/F13 335-FET/BSME/F13
A Thesis Presented in International Islamic University, Islamabad In partial fulfillment for degree requirement of Bachelor in Science in Mechanical Engineering 2017 Islamabad, Pakistan
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CERTIFICATE OF APPROVAL It is certified that we have checked the project presented and demonstrated by Muhammad Bilal (327-FET/BSME/F13), Asif Mahmood (330-FET/BSME/F13), Muhammad Gulsher (335-FET/BSME/F13) (335-FET/BSME/F13) and approve their project.
Supervisor Engr. Muhammad Rizwan
co-supervisor Engr. Noor Rahman
Dr. Saeed Badshah Head of Department Mechanical Engineering
Department of Mechanical Engineering Faculty of Engineering and Technology
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Declaration
We hereby declare that this project, neither whole nor as a part has been copied out from any source. It is further declared that we have developed this project and accompanied report entirely on the basis of our personal efforts. If any part of this project is proved to be copied out from any source or found to be reproduction of some other. We will stand by the consequences. No Portion of the work presented has been submitted of any application for any other degree or qualification of this or any other university or institute of learning.
Muhammad Bilal (327-FET/BSME/F13) Asif Mahmood (330-FET/BSME/F13) Muhammad Gulsher (335-FET/BSME/F13)
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Dedication
This thesis is dedicated to our parents for their love, endless support and encouragement.
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Acknowledgement
In the name of Allah, the Most Merciful, the Most Beneficent. It is with the deepest senses gratitude of the almighty that gives strength and ability to complete this thesis successfully. First and foremost, we have to thank our parents for their love and support throughout our life. Thank you both for giving us strength to reach stars and our dreams. We would like to sincerely thank our supervisor Engr. Muhammad Rizwan for his guidance and support throughout this project. We would like to sincerely thank our co-supervisor Engr. Noor Rahman for his guidance in this project.
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Abstract
In this work an attempt has been made to design and fabricate an automatic shoe polishing Machine which makes the shoe polishing process easy and time saving. This project focuses on automation of the shoe Polishing and shining process without any human involvement in the process. The main purpose to design the automatic shoe polishing machine is to reduce human effort to zero. The machine consists of three main units transportation, polishing operation section and control unit which controls the whole operation according to given instructions.
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Table of Contents Chapter 1 Introduction ........................................................................................ vi
1.1 Overview ...................................................................................................... 1 1.2 Problem Statement ...................................................................................... 2 1.3 Objective Statement .................................................................................... 2 1.4 Working Principle ......................................................................................... 2 Chapter 2 Literature Review ............................................................................... 4 Chapter 3 Design and Specifications .................................................................. 7 3.1 Microcontroller ............................................................................................. 8 3.2 Arduino ..................................................................................................... 10 3.3 Arduino UNO ............................................................................................ 10 3.4 Stepper motor ............................................................................................ 11 3.5 Photoelectric sensor .................................................................................. 12 3.5.1 IR sensor ............................................................................................. 13 3.6 Flat conveyor Belt ...................................................................................... 14 3.7 Design & Calculation of Flat Conveyor Belt .............................................. 15 3.8 DC Motors ................................................................................................. 25 3.9 DC Pump ................................................................................................... 26 3.10 Worm Gear .............................................................................................. 27 3.11 Rack and Pinion ...................................................................................... 28 Chapter 4 Methodology..................................................................................... 30 4.1 Hardware ................................................................................................... 30 4.2 Electronics ................................................................................................. 30 4.3 Arduino Programming ................................................................................ 30 Chapter 5 Conclusion ....................................................................................... 39 Chapter 6 Recommendations ........................................................................... 40 References ......................................................................................................... 41
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Table of Figures Figure 2-1 (machine designed by Sreenivas and Shankar) ................................. 4 Figure 3-1 (Cup type Brush) ............................................................................... 7 Figure 3-2 (Cylindrical Brush) .............................................................................. 8 Figure 3-3 (Model Designed on PRO E) .............................................................. 8 Figure 3-4 (Ardiuno UNO) ................................................................................. 11 Figure 3-5 (IR Sensor) ....................................................................................... 14 Figure 3-6 (Fabricated Machine FV) .................................................................. 24 Figure 3-7 (Fabricated Machine TV) ................................................................. 24 Figure 3-8 (Fabricated Machine) ........................................................................ 25 Figure 3-9 (DC Motor) ........................................................................................ 26 Figure 3-10 (DC Pump)..................................................................................... 27 Figure 3-11 (worm Gear and Worm Wheel) ....................................................... 28 Figure 3-12 (Rack and Pinion) .......................................................................... 29
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Chapter 1 Introduction
1.1 Overview
As all the persons want to wear a shoe in every place which is clean. This machine help in reducing the difficulty of existing product available in the market at the same time increase the use of this product in offices, institution etc. The Fully automatic shoe polishing machine has been designed considering all the requirement and need of users. It has a sensing device which sense the object which is shoe depending on that it start working. It is portable. The problems which arise in the manual operation have been reduced in this machine. Each and every person thinks that their shoe should be clean and shiny. Taking all these into account we have designed this product which reduces the burden of manual operation at the same time increases the use of modern techniques. This project is to provide an apparatus for shining shoes which overcome the problem encountered in the conventional one. It obtains a desired shoe shining effect greater than a manual one. [1], [2] The Fully automatic shoe polishing machine is used to polish your shoe within a short interval of time which reduces human strength and effort. The selection of shoe nowadays become much difficult all of them want that their shoes should give an attractive look and much better long lasting but forget to follow the steps that needed, therefore reminding all these difficulties we have developed this machine which give your shoes desired look everyday with better shine. Such a places like hospitals, preserved laboratories and highly sensisitive research laboratories like computer labs, instrumentation labs, operational theatre and various production assembly sites in chemical, pharmaceutical industries which are required to be free from dust and dirt which would be carried through the shoe of the concern persons to the work area, unclean shoes causing uncomfortable environment and also sometimes hazardous to the working environment. Every person whether child(student) which goes to school or 1
university or gentleman which goes to office or his working place wants to wear clean and neat shoes. Therefore it is necessary to design such a machine which reduces human effort and saves the time. During early times, there is no concept of shoe polishing machine. Shoe is polished through cloth or rug. Later on when technology is evolved, then shoe polishing machines started to design. All existing shoe polishing machines till now which are required human effort to orient the shoe according to brushes during polishing. [3] Simply put the shoe on conveyor, through beam sensor detects shoe. Then sensor transmits the input to Microcontroller which actuates stepper motor mounted on conveyor driver roller for certain steps according to instructions. As soon as stepper motor completes certain revolution, then shoe reached operation station. Then polishing brushes starts to rotate at certain rpm. After certain time brushes stop to rotate, then stepper motor rotates for certain revolution to put shoe outside according to instructions given to Microcontroller. [4] 1.2 Problem Statement
The main problem to design and fabricate of automatic shoe polishing machine is involvement of human. While polishing shoe manually human involvement is must. There is also shoe polishing machines exist, but there is also human involvement is must to orient the shoe according to brush. It consumes more time to complete the operation. 1.3 Objective Statement
The main objective is to reduce human effort. There are some other objectives such as to minimize operation time and improve the shiny of shoe . 1.4 Working Principle
The proposed design consists of three major parts. One is Conveyor belt that moves the shoe. Second are motors. And the third one is its Electronics assembly which contains Microcontroller, Sensor and Electronic Circuit. The shoe is placed on conveyor belt using a gripper that facilitates shoe to be held firmly. As soon as sensor detects shoe, then sensor transmits a signal to Microcontroller which actuates the conveyor belt. Stepper motor which is mounted on conveyor driver roller completes certain revolution according to instructions which is given 2
to microcontroller. As soon as shoe reach at the position where polishing operation is performed. Then Microcontroller actuates DC motor on which polishing brushes mounted. Side’s brushes and upper brush rotate at higher rpm to polish the shoe effectively. After certain time, brushes stop and then Microcontroller again actuates the stepper motor to put off the shoe from conveyor .
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Chapter 2 Literature Review
Till the mid of 19th century shoe cleaned or polished manually using a rag, cloth or brush. At that time people used a waxy product to shine or polish shoe. That waxy product was made from natural wax, oil, soda ash and tallow. There was no concept of shoe polishing machine at that time. In January 15, 1974 William A. Beck and River Hills were designed a coin operated shoe polishing machine which contained two brushes, a motor and a coin sensing device. Sensing device used to actuate the motor as soon as sense the coin. As soon as coin put in box where sensing device was mounted, motor started and brushes rotated at higher rpm, then shoe oriented according to polishing brushes. [1] In September 2013, Asst. Professor Sreenivas H T in Department of Mechanical Engineering, VVIT and Shankar Gouda who was Student in Department of Mechanical Engineering, EPCET, Bangalore, Karnataka, India were designed a shoe polishing Machine. It consisted of four brushes mounted on three shafts which were rotated by a motor. Two brushes mounted on sides to left and right side of shoe, one used to clean the sole of shoe and fourth one was mounted on a shaft which used to polish rear and upper part of shoe. In fourth one brush shoe oriented according to brush to polish rear and upper surface of shoe.
In this design shoe polish applied on shoe surface manually during
operation. [5]
Figure 2-1 (machine designed by Sreenivas and Shankar) 4
In April 2015, Chauhan Vipul M., Swami Harsh R. Daiya Pradip R and Chauhan Vishwas S.
were designed a shoe polishing machine under the
supervision of Prof. Rajeshkumar. It consisted on four brushes in which two brushes sliding alongside surfaces of shoe by scotch yoke mechanism. It converts the rotary motion into sliding motion. One brush rotated by a motor which used to clean or polish rear surface of shoe. Fourth one brush is able to moves in up and down direction because it is further attached with flexible joint which give them motion in two directions. It is used to clean or polish front upper periphery of shoe. There is water pump which is used for dispensing of fluid to the surface of the shoe. In April 2016, Animesh Kujur, Digvijay Murmu, Ashok Kumar Law, Amardeep Kumar, Kunal and
Anup Ojha were published a research paper in an
International conference of Engineering and Technology in which they designed a Coin operated shoe polishing machine. It contained two brushes one is for cleaning purpose and other to polish the shoe which both mounted on same shaft rotated by a motor. As soon as metal sensing device detects coin then motor started to move. In this machine shoe is oriented according to brush during polishing operation. [6] In 2016, Amogh A.N., Chirag V.R., Denver Martis, Gagan K.N. (These all are UG scholars, NMAM Institute of Technology, Karkala Taluk, Udupi Dist. Karnataka State, India) designed an Automatic Shoe Polishing Machine under the supervision of Grynal D’Mello ( Asst. Professor, Dept. of Mechanical Engg., NMAMIT, Nitte, Karkala Taluk, Udupi Dist. Karnataka State, India). It consisted of two wax roll, two roller brushes and a carriage on which a gripper mounted to grip the shoe firmly. The shoe is gripped on the carriage using a gripper that facilitates shoes of different sizes to be placed firmly. By pushing the start button on the console will provide input to the microcontroller(Arduino UNO ATMEGA-328) which actuates the lead screw. Thus the carriage (conveyor) starts moving in the forward direction. Simultaneously the wax roll comes in contact with the roller brush and hence a layer of polish is applied to the shoe surface. When the carriage(conveyor) moves to the extreme end in the forward direction and actuates a push button switch, the direction of lead screw will be reversed 5
thus moving the carriage in opposite direction. Simultaneously wax roll gets detached and the roller brush rotates at a higher rpm in the opposite direction performing buffing action in order to provide the necessary shiny effect. [7]
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Chapter 3 Design and Specifications
Model of project designed on Pro E is shown below whose specifications are following Flat conveyor belt:
Length 900mm Width 150mm Micro controller:
Arduino UNO Proximity sensor:
IR sensor Brushes:
Nylon cylindrical brushes Cuptype brush diameter = 100mm Cylindrical brush diameter = 150mm
Figure 3-1 (Cup type Brush)
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Figure 3-2 (Cylindrical Brush)
Figure 3-3 (Model Designed on PRO E)
3.1 Microcontroller
Microcontroller is the integration of a microprocessor with memory and input/output interfaces, and other peripherals such as timers, on a single chip. It
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is an integrated electronic computing and logic device. It uses many functions in order to control machines and automation processes which are following. [8] logic
sequencing
timing
counting
arithmetic
It is basically a single integrated circuit or a small computer. It is a system on chip. It is a small and low-cost computer built for performing specific tasks, such as displaying information in a microwave LED or receiving information from a television’s remote control. Microcontrollers are mainly used in products that
require a degree of control to be exerted by the user. It may contain one or more CPU’s. It also has memory and programmable inputs and outputs phase or
peripherals.
These
are
designed
for
many
embedded
applications.
Microcontrollers are used in automatically controlled products and devices like remote controls, office machines, appliances, toys and power tools. Microcontroller is more efficient in size and cost compared to a design that consists of a separate microprocessor, storage, and input/output devices, microcontrollers make such a design economical to digitally control even more devices and processes. Microcontrollers usually contain from several to dozens of general purpose input/output pins. General purpose input/output pins are assigned as either an input or an output state according to software configuration. When these pins are configured to an input state, they are used to read input devices such as sensors or external signals. Configured to the output state, GPIO pins can drive external devices such as LEDs or motors, often indirectly, through external power electronics. So in shoe polishing machine we have to control the sensor and motors with microcontroller. We have to get input f rom the sensor and also give output to the motors. [8]
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3.2 Arduino
There are a lot of microcontrollers like Altera, Atmel, Cypress semiconductor, PLC, Maxim Integrated, Arduino, Fujitsu, Holtek’ Intel etc. But we are using
Arduino in Automatic shoe polishing machine because it is easy to handle arduino in terms of Hardware or Software. It has low cost. It is connected with a computer through serial connection or ports. It can be powered from computer or DC power supply. It can work with both Digital and Analog electronic signals. Sensors and Actuators are Portable. It is user friendly. Its Programming is easy. It is basically open-source electronics platform. That is based on easy-to-use software and hardware. Arduino boards are capable or used to read the input and with the help of input instructions it activate light on a sensor and finger on a button and also convert it into an output. Outputs are in the form of activate a motor and turn on a Light Emitting Diode etc. Arduino Software (IDE) is used to send a set of instructions to the microcontroller on the board. [9]
3.3 Arduino UNO
The Arduino UNO is a microcontroller board based on the ATmega328. It has 14 digital input/output pins ,6 analog inputs, a USB connection, a power jack, a 16 MHz crystal oscillator, an ICSP header, and a reset button. In Automatic shoe polishing machine we have photoelectric sensor input and outputs for motors, so the inputs and outputs are in the limited range that’s why we don’t need any other
type of Arduino like Arduino Mega that has a large number of inputs and outputs. If we look at its technical specifications. It has 5v operating voltage. And input voltage is 7-12v. It has 14 Digital I/O pins and 6 Analog input pins. It has 32KB Flash memory and 16MHZ clock speed. Its length is 68.6mm, width is 53.4mm and weight is 25g. [9], [10]
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Figure 3-4 (Ardiuno UNO)
3.4 Stepper motor
The stepper motor rotates in steps. Each step moves 1.8 degree of 360 degree. Stepper motor consists of multiple coils that are organized in groups called "phases". By energizing each coil in sequence, on each coil energized the stepper motor will rotate one step which means 1.8 degree at a time. Through controller we can move stepper motor for certain steps and control the speed. For this reason, the stepper motors are selected or chose for many precision motion control applications such as process automation and robotics. [11] Positioning: Since steppers move in precise repeatable steps, stepper motor is
used in such applications which are required precise positioning such as 3D printers, CNC, Camera platforms and X, Y Plotters. Some disk drives also use stepper motors to position the read/write head. [12]
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Speed Control: The applications such as process automation and robotics
where we have required precise increment movement, stepper motor provides precise speed control . [12] Low Speed Torque: DC motors have not high torque, but stepper motor have
high torque at low speed. Commonly we have required high torque at precise low speed in robotics in such applications stepper motor is better. [12] Low Efficiency: Unlike DC motors, efficiency of stepper motor is low. Stepper
motor consumes high current when there is no load. It consume less current when it is in working condition . [12] Limited High Speed Torque: As we know that motors have low torque at high
speed and high torque at low speed. Some stepper motors are optimized for better high-speed performance, but they have required to be paired with an appropriate driver to achieve that performance. [12] No Feedback: Servo motors provide feedback but stepper motors do not pr ovide feedback. Although great precision can be achieved running ‘open loop’. Limit switches or ‘home’ detectors are typically required for safety and/or to establish a
reference position. [12] There are three main reasons to select a stepper motor, first we have required a control motion for this, stepper motor is best because it divides a full rotation into a number of equal steps. Most stepper motors move 1.8° per step or has 200 steps for one complete revolution. Second, there is no tuning required while in servo motor, there is tuning required to meet performance criteria for current, velocity, and position in control loop. The most important reason is cost which is usually lower than a servo motor’s because there is no position feedback sensor.
In servo motor there is position feedback sensor which require more wiring. [12]
3.5 Photoelectric sensor
Photoelectric sensor is a type of sensor which uses infrared light to detect the object. It detects the object in three different sensing modes which are following
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Retro-reflective mode
Diffused Mode
Thru-beam mode
In Retro-reflective mode, both receiver and transmitter are enclosed in a single housing, transmitter transmits a beam and receiver receives reflected beam which is reflected when target is present in path of beam with different characteristics as emitted from transmitter. One additional component which is used in this mode is reflector. It is different from other mode due to its unique property, because it allows longer sensing ranges than diffused mode due to the increased efficiency of the reflector compared with the reflectivity of most targets. [13] In Diffused Mode, the transmitter and receiver are in the same housing. Light beam which is emitted from the transmitter strikes the target which ref lects light at arbitrary angles. Some beam is diffused in target and remaining reflected light beam returns to the receiver, and then target is detected. [13] In Thru-beam mode, this mode uses two separate housings, for the transmitter and receiver. One of them is mounted on either side and other is mounted on side of target. when light beam emitted from the transmitter is not reached at the receiver due to target, the output on the receiver is activated. It is the most efficient of the three modes, due to the longest possible sensing ranges. [13] Through beam sensing made applications are Stack heights, Conveyors package detection, Parts counting and Part presence etc. [13]
3.5.1 IR sensor
There are many reasons for using IR sensor but main two reasons for choosing IR sensor which are following Cost
The most important question which is asked by anyone about project is cost. We select such a sensor which is cost effective. Therefore we selected IR sensor whose cost is 150 rupees. 13
Availability
Second important thing during selecting any component is its availability in market easily. Therefore we selected IR sensor which is easily available in market.
Figure 3-5 (IR Sensor)
3.6 Flat conveyor Belt
There are two main reasons to select a flat conveyor belt than other conveyor belts which are following Cost The main reasons to select flat conveyor belt is the cost. Because it’s complete
assembly consists of two rollers, belt and a motor to actuate the conveyor. Power
The second main reason is that flat conveyor belt is required less power to convey the items as compared to other conveyors.
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3.7 Design & Calculation of Flat Conveyor Belt [14]
Belt width (B) – 130 mm Length between centers (L) – 750mm Pulley diameter (D) – 76mm [15], [16] Belt speed (V) – 2.5 m/s [15], [16] Mass of Shoe (m) – 0.5Kg Effective pull (Te) is given by Te= m · µ · g Coefficient of friction = µ = 0.35 Putting values in given equation Then Te = 1.71675N Belt Tension From Euler’s law of friction drive, considering no slip between belt and pulley T 1 T 2
e
(3.1)
Where T 1 Belt tension at tight side T2
Belt tension at slack side
Wrap angle in radian radian
Coefficient of
T1
T1
T2
friction between belt and pulley 0.35
T e
3.2
T 2 1.71675
15
Putting value of wrap angle and coefficient of friction T 1
e
0.35*3.14
T 2 T1
T 2 *3.0011
Putting value of T 1 in above equation Then T2
0.8579N
2.5746N
T1
P A
Absorbed Power which is required to derive pulley after taking loss into account
P A
PDP
(RW
RB )V
(3.3)
Where R B is Pulley bearing resistance for drive pulley RW is
RW
wrapping resistance between belt and pulley, generally calculated from formula
9 B[140 0.01
T AV B
]
t D
(3.4)
Where B = Belt width t = Belt thickness = 2mm D = Pulley diameter T AV
T1
T 2
2
(3.5)
Putting values in above relation, then RW = 4.3145N RB is negligible. [14]
Putting values in absorbed power formula, then P A = 15.0782W 16
1hp = 746watt P A = 0.0202hp We have to calculate motor output power. As we know that motor power is P M
P A
(3.6)
Where P A
Absorbed power
Overall efficiency
0.90
Putting values in above relation to find motor power PM = 0.0224hp The rpm of drive roller is calculated by using the formula,
V
* D * N
N
60 60*V
(3.7)
* D
Where V
Belt speed
N Output rpm D pulley diameter putting values in above relation to output rpm (N) N
628rpm
As we know that the torque is calculated by using the following formula P A
2* * N * T
T
60 P A *60
(3.8)
2* * N Putting values to calculate Torque T 0.2282 Nm
T 1 = Carrying side belt tension 17
T1 = 2.5746N T 2 = Return side belt tension T2 = 0.8579N W = weight of the drive pulley W = 2.5kg = 2.5*9.81 = 24.525N Resolving horizontal and vertical components
FH = 2.5746 + 0.8579 FH = 3.4325N FV = 24.525N
Horizontal loading
Point load acting at C, RCH = FH /2 = 1.7162 N Point load acting at D, RDH = FH /2 = 1.7162 N
Taking moment at point A, as we know that
M
AH
0
(3.9)
(RCH x 0.015) + (RDH x (0.015+ 0.130)) – (RBH x 0.160) = 0 18
(1.7162 x 0.015) + (1.7162 x 0.145) – (RBH x 0.160) = 0 RBH = 12.2625 N
Similarly, we can calculate R AH R AH =12.2625 N Horizontal moments
Taking the moment at point C, M CH = RCH x .015 = 1.7162 x 0.015 M CH = 0.0257N-m Taking moment at point D, M DH = RDH x 0.35 = 1.7162 x 0.015 M DH = 0.0257N-m Vertical loading
By considering the vertical loads Point load acting at C, RCV = FV/2 = 12.2625N Point load acting at D, RDV = FV/2 = 12.2625N
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Taking moment at point A,
As we know that,
M
AV
0
(3.10)
(R CV x 0.015) +(R DV x (0.015+0.130)) –(R BV x0.160) = 0 (5.886 x 0.015) + (5.886 x 0.145) – (R BV x 0.160) = 0 R BV = 5.886N Similarly, we can also calculate R AV R AV = 5.886N Vertical moments
Taking moment at C, MCV = RCV x 0.015 MCV = 5.886 x 0.015 MCV = 0.0882N-m Taking moment at D, MDV = RDV x 0.015 MDV = 5.886 x 0.015 MDV = 0.0882N-m
Resultant moment at C is given by Resultant moment at C ( M CV ) 2 (M CH ) 2
Putting values Resultant moment at C = 0.1839Nm 20
(3.11)
Resultant moment at D ( M DV ) 2 ( M DH )2
(3.12)
Putting values Resultant moment at D = 0.1839Nm Shaft subjected to combined bending and twisting moment: [17]
When shaft is subjected to combined twisting moment and bending moment, in such condition there are two theories exist which are following
Maximum shear stress or Guest’s theory which deals with ductile material
such as mild steel.
Maximum normal stress or Rankine’s theory which deals with brittle
material such as cost iron. We have selected mild steel which is ductile material. According to Guest’s theory Max
b
1
b
2 32 M
2
4 2
(3.13) (3.14)
3
d
16T
(3.15)
3
d
Putting equations (3.14) and (3.15) in equation (3.13). Then we get
Max
16
M 2 T 2
3
d
or 3
d
16
* Max
M 2 T 2
The exp ression M 2 T 2 is called Equivalent Twisting Moment and is written in equation form as Te
M 2 T 2
(3.16)
3
T e
d
16 where
d
(3.17)
Max
diameter of shaft
21
Now according to maximum normal stress Theory, we know that
1
b
1
2
4 2
(3.18) 2 2 putting values of b and in equation (3.18), then
b max
b
we get 1 32 M
b max
32
2
d3
b max d 3
The term
1
2
1 32 M 16T 4 3 3 2 d d 1
2
2
M M 2 T 2
M M 2 T 2 is called Equivalent
2 Bending Moment. It i s written in equation form as M e
1 2
M M 2 T 2
(3.19)
Based on Equivalent torque
We know T= 0.2282 Nm M = MCR = MDR = 0.1839N-m Equivalent Torque T Eq
( M * Kb )2 (T * K t )2
Where K b (bending service factor) = 1.5 [8] K t (torque service factor) = 1.25 [8] Putting values Teq = 0.3987 Nm
22
(3.20)
16
Allowable Shear stress ( S )
d
3
* d 3
* T Eq
(3.21)
16* T Eq
S
*
putting values to calculate shaft diameter Shaft diameter 8.2289mm Based on Equivalent moment
Equivalent moment is calculated by formula M Eq
M Eq
1 2 1
[( M * K b ) T Eq ]
(3.22)
[( M * K b ) (M * K b ) 2 (T * K t ) 2
(3.23)
2 Putting values
M Eq
0.2176 Nm 32
Allowable Bending Stress ( b )
d
3
3
* d
* M Eq
32* M Eq b
*
putting values Shaft diameter
d
6.9096 mm
We have selected the diameter of shaft which is 12mm .
23
(3.24)
Figure 3-6 (Fabricated Machine FV)
Figure 3-7 (Fabricated Machine TV)
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Figure 3-8 (Fabricated Machine)
3.8 DC Motors
In this project, we have used three DC motors to rotate nylon brushes at high Rpm. The specifications of Dc motors are many but our concern is its rpm which is 2300. [14]
25
Figure 3-9 (DC Motor)
3.9 DC Pump
We have required a pump to spray liquid polish on shoe during polishing operation. Therefore we have selected a DC pump of 12 volts to spray liquid polish during polishing operation.
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Figure 3-10 (DC Pump)
3.10 Worm Gear
We have worm gear mechanism because we have required to meet our design. We have required low speed and high torque. The main purpose of worm gear is to reduce speed and increase torque. Worm gear is self locking. Rotation is given through worm or worm gear and load is mounted on worm wheel. Worm wheel cannot rotate due to load. [18]
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Figure 3-11 (worm Gear and Worm Wheel)
3.11 Rack and Pinion
Rack and pinion mechanism converts rotatory motion into linear or translatory motion. We have to grip the shoe for polishing operation, here we have used the rack and pinion mechanism for gripping the shoe.
28
Figure 3-12 (Rack and Pinion)
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Chapter 4 Methodology
The project is basically consist of three parts which are following Hardware
Electronics
Arduino programming
4.1 Hardware
It consists of flat conveyor belt, worm gear, Rack and pinion mechanism and cylindrical brushes mounted on dc motors. Flat conveyor belt is used to transfer or convey shoe from initial point to operation section. Worm gear is used lock one motion while cylindrical brush like pendulum motion moving in forward direction it locks backward motion. Rack and pinion mechanism is used to grip the shoe while it reached in operation section and ungrip after completing polishing operation. 4.2 Electronics
Second part of project is electronics which consists of circuit board, wires and power supply. Dc motors and stepper motors are connected to Arduino through drivers because high current and voltage required actuating these motors. We cannot give high current and voltage directly. Therefore we required drivers to actuate these motors. 4.3 Arduino Programming
We programmed arduino according to our desired sequence. As soon as shoe is put on conveyor, IR proximity sensor detects the shoe then sensor sends a signal to ardiuno to actuate stepper motor for certain steps (revolution) according to given instructions. The shoe is reached operation section where polishing of shoe is done according to given instructions. Then ardiuno actuates second stepper motor for certain steps to grip shoe. Polishing process starts and during polishing 30
ardiuno actuates pump for 2 seconds to spray liquid polish. After finishing of shoe, ardiuno actuates the stepper motor for certain steps according to given instructions to ungrip the shoe. Then Arduino actuates the conveyor belt stepper motor to unload the finished or polished shoe. The Program uploaded in the arduino is given bellow [12], [13] int s1_1=2; int s1_2=3; int s1_3=4; int s1_4=5; int s2_1=6; int s2_2=7; int s2_3=8; int s2_4=9; int s3_1=10; int s3_2=11; int s3_3=12; int s3_4=13; int b1=A5; int b2=A4; int b3=A3; void stepper1 (int a); void stepper2_up (int a); void stepper3_up (int a); void stepper2_down (int a); 31
void stepper3_down (int a); void wait (void); void setup ( ) { pinMode(s1_1,OUTPUT); pinMode(s1_2,OUTPUT); pinMode(s1_3,OUTPUT); pinMode(s1_4,OUTPUT); pinMode(s2_1,OUTPUT); pinMode(s2_2,OUTPUT); pinMode(s2_3,OUTPUT); pinMode(s2_4,OUTPUT); pinMode(s3_1,OUTPUT); pinMode(s3_2,OUTPUT); pinMode(s3_3,OUTPUT); pinMode(s3_4,OUTPUT); pinMode(b1,OUTPUT); pinMode(b2,OUTPUT); pinMode(b3,OUTPUT); digitalWrite(s1_1,LOW); digitalWrite(s1_2,LOW); digitalWrite(s1_3,LOW); digitalWrite(s1_4,LOW); digitalWrite(s2_1,LOW); 32
digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW); digitalWrite(s2_4,LOW); digitalWrite(s3_1,LOW); digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW); digitalWrite(s3_4,LOW); digitalWrite(b1,LOW); digitalWrite(b2,LOW); digitalWrite(b3,LOW); } void loop() { int s1=analogRead(A0); if(s1<512){ digitalWrite(b1,LOW);digitalWrite(b2,LOW); stepper1(80); digitalWrite(b1,HIGH);digitalWrite(b2,HIGH);stepper1(80); delay(500); stepper3_down(100); delay(500); stepper2_down(700); delay(500); stepper2_up(700); delay(500); 33
digitalWrite(b3,HIGH);delay(4000);digitalWrite(b3,LOW); stepper2_down(700); delay(500); stepper2_up(700); delay(500); stepper3_up(100); delay(1000); digitalWrite(b1,LOW);digitalWrite(b2,LOW); stepper1(200); delay(500); } } void wait(void) {delay(3);} void stepper1(int a) {int b; for (b=0;b<=a;b++) { digitalWrite(s1_1,HIGH);digitalWrite(s1_2,LOW); digitalWrite(s1_3,LOW);digitalWrite(s1_4,LOW); wait( ); digitalWrite(s1_1,LOW);digitalWrite(s1_2,HIGH); digitalWrite(s1_3,LOW);digitalWrite(s1_4,LOW); 34
wait( ); digitalWrite(s1_1,LOW);digitalWrite(s1_2,LOW); digitalWrite(s1_3,HIGH);digitalWrite(s1_4,LOW); wait( ); digitalWrite(s1_1,LOW);digitalWrite(s1_2,LOW); digitalWrite(s1_3,LOW);digitalWrite(s1_4,HIGH); wait( ); } digitalWrite(s1_1,LOW);digitalWrite(s1_2,LOW); digitalWrite(s1_3,LOW);digitalWrite(s1_4,LOW); wait( ); } void stepper2_up(int a) {int b; for (b=0;b<=a;b++) { digitalWrite(s2_1,HIGH);digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW);digitalWrite(s2_4,LOW); wait(); digitalWrite(s2_1,LOW);digitalWrite(s2_2,HIGH); digitalWrite(s2_3,LOW);digitalWrite(s2_4,LOW); wait(); digitalWrite(s2_1,LOW);digitalWrite(s2_2,LOW); 35
digitalWrite(s2_3,HIGH);digitalWrite(s2_4,LOW); wait(); digitalWrite(s2_1,LOW);digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW);digitalWrite(s2_4,HIGH); wait(); } digitalWrite(s2_1,LOW);digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW);digitalWrite(s2_4,LOW); wait(); } void stepper3_down(int a) {int b; for (b=0;b<=a;b++) { digitalWrite(s3_1,HIGH);digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW);digitalWrite(s3_4,LOW); wait(); digitalWrite(s3_1,LOW);digitalWrite(s3_2,HIGH); digitalWrite(s3_3,LOW);digitalWrite(s3_4,LOW); wait(); digitalWrite(s3_1,LOW);digitalWrite(s3_2,LOW); digitalWrite(s3_3,HIGH);digitalWrite(s3_4,LOW); wait(); 36
digitalWrite(s3_1,LOW);digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW);digitalWrite(s3_4,HIGH); wait(); } digitalWrite(s3_1,LOW);digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW);digitalWrite(s3_4,LOW); wait(); } void stepper2_down(int a) {int b; for (b=0;b<=a;b++) { digitalWrite(s2_1,LOW);digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW);digitalWrite(s2_4,HIGH); wait( ); digitalWrite(s2_1,LOW);digitalWrite(s2_2,LOW); digitalWrite(s2_3,HIGH);digitalWrite(s2_4,LOW); wait( ); digitalWrite(s2_1,LOW);digitalWrite(s2_2,HIGH); digitalWrite(s2_3,LOW);digitalWrite(s2_4,LOW); wait( ); digitalWrite(s2_1,HIGH);digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW);digitalWrite(s2_4,LOW); 37
wait( ); } digitalWrite(s2_1,LOW);digitalWrite(s2_2,LOW); digitalWrite(s2_3,LOW);digitalWrite(s2_4,LOW); wait( ); } void stepper3_up(int a) {int b; for (b=0;b<=a;b++) { digitalWrite(s3_1,LOW);digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW);digitalWrite(s3_4,HIGH); wait ( ); digitalWrite(s3_1,LOW);digitalWrite(s3_2,LOW); digitalWrite(s3_3,HIGH);digitalWrite(s3_4,LOW); wait ( ); digitalWrite(s3_1,LOW);digitalWrite(s3_2,HIGH); digitalWrite(s3_3,LOW);digitalWrite(s3_4,LOW); wait ( ); digitalWrite(s3_1,HIGH);digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW);digitalWrite(s3_4,LOW; wait ( ); } digitalWrite(s3_1,LOW);digitalWrite(s3_2,LOW); digitalWrite(s3_3,LOW);digitalWrite(s3_4,LOW); wait ( ); } 38
Chapter 5 Conclusion
In this project report we conclude that this project can be further enhanced by doing some modifications as discussed in recommendations. The main objective to design an automatic shoe polishing is save the time by reducing human effort. We have succeeded to design such a project but our design is restricted for standard shoes. The machine polishes the pair of shoe in just a short interval of 100 seconds. We are succeeded to design an automatic shoe polishing machine in which there is zero human effort.
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Chapter 6 Recommendations
We suggest that design a flexible automatic shoe polishing machine which can polish shoe any kind whether black or brown or any size. For such design, we have to design to operation section, one for brown shoe and other for black shoe. We have to design a flexible gripping system which can grip any size of shoe and also design a color detection system which can shoe color whether black or brown. But our project designed for standard black shoe and liquid polish used. We suggest designing such a machine, put shoe on machine whether black or brown or standard or small sizes, then polished shoe according to shoe color properly come out from machine. There is no concern whether shoe black or brown, but machine is concerned to polish the shoe.
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References
[1] Williams, B. E. (1999). U.S. Patent No. 5,991,967 . Washington, DC: U.S. Patent and Trademark Office. [2] Chen, H. J. (1995). U.S. Patent No. 5,418,996 . Washington, DC: U.S. Patent and Trademark Office. [3] Ferrari, L. (2005). U.S. Patent No. 6,912,752 . Washington, DC: U.S. Patent and Trademark Office. [4] Bleth, J. J. (1999). U.S. Patent No. 5,964,959. Washington, DC: U.S. Patent and Trademark Office. [5] Sreenivas H T, Shankar Gouda (2013). Design of Shoe Sole Cleaning with Polishing Machine. International Journal of Innovative Research in Science, Engineering and Technology, ISSN: 2319-8753. [6] Animesh Kujur, Amardeep Kumar, Digvijay Murmu, Ashok Kumar Law, Kunal & Anup Ojha (2016). Coin operated shoe polishing machine. International Research Journal of Engineering and Technology (IRJET), e-ISSN: 2395 -0056. [7] Amogh A.N, Chirag V.R, Denver Martis, Gagan K.N & Grynal D'Mello. Design and Fabrication of Automatic Shoe Polishing Machine. National Conference on Advances in Mechanical Engineering Science (NCAMES-2016). [8] Davies, J. H. (2008). MSP430 microcontroller basics. Elsevier. [9] Noble, J. (2009). Programming Interactivity: A Designer's Guide to Processing, Arduino, and Openframeworks. " O'Reilly Media, Inc.".
[10] Arduino, S. A. (2015). Arduino. Arduino LLC . [11] Chevailler, S. (2006). Comparative study and selection criteria of linear motors (Doctoral dissertation, ÉCOLE POLYTECHNIQUE FÉDÉRALE DE
LAUSANNE).
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