Animal Driven Gear Box and Pumpweb.iitd.ac.in/~saha/public_html-old/iitd08sep11vkvijay.pdf4. ISKCON...
Transcript of Animal Driven Gear Box and Pumpweb.iitd.ac.in/~saha/public_html-old/iitd08sep11vkvijay.pdf4. ISKCON...
Animal Driven Gear Box and
Pump
Prof. S.K. Saha (Prof. V.K. Vijay and Dr. S.V. Modak)
Naren Gupta Chair Professor
Dept. of Mech. Eng.
IIT Delhi
Sept.08,’11@RDL722: rural Energy Systems (Prof. V.K. Vijay)
Existing ADGB (Panchal Pumps, Kanpur)
with Water Pump
Water discharge (from 30 feet deep): 7,000-10,000 litre/hr.
Outline
Animal power
Gear box
CAD of Gear Box
Design checking
MS-Excel program
MuDRA
Conclusions
3
Introduction
India is a predominantly an agricultural country,
where about 70% of population lives in rural areas
and depends on the agriculture.
They use animal for farming purposes.
The animal power can be used for other purposes,
e.g., water pumping, chaff cutting, for atta-chakki,
electricity generation, etc.
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Objective
To study each component of Animal Driven Gear Box
(ADGB) in detail and prepare its specifications.
Evaluation of the existing technology by Panchal
Pumps, Kanpur, and standardization of the same.
To study the factors affecting on the efficiency and
improve them as much as possible.
Fabrication and field trials of the standardized design.
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Gearbox & Pump Sold/Installed: 32SN Customer Name City / State Contacted:
Remarks
1. Bioved Research & Communication
CenterAllahabad / Uttar
Pradesh
2. Dr. Punjabrao Deshmukh Krishi
VidyapeetAkola / Maharashtra
3. Mahant Bharatpuri Banda / Uttar Pradesh
4. ISKCON (Goverdhan Krishi Farm) Thane / Maharashtra
5. Bhartiya Govanshrakshan
Savardhan ParishadThane / Maharashtra
6. Shri Santosh Singh Bhadauriya Kanpur / Uttar Pradesh
7. Shri Vivek Chaturvedi Kanpur / Uttar Pradesh
8. Office Of The Project Director,
ATMA
Jamshedpur /
Jharkhand
1 set working
for 1 year
9. Shri Surendra Sharma C/o. -
Gayatri ParivarNoida / Uttar Pradesh Not used
10. Aghor Guru Sewa Peeth Aghor
FoundationVaranasi / Uttar
Pradesh
3 sets working
for 1 year
Co
nta
cte
d o
n
12
/08
/20
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Inside of the Gear box
Output pulley
Pair 3
(helical)
Pair 2 (spur) Pair 1 (spur)
Lever holder
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CAD Modeling of ADGB (Animation)
Gearbox
Lever Holder
V-Pulley
Base Plate
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Analysis of the Gear BoxComponents
1. Gear pairs
2. Shafts
2. Bearings Specification of the existing gear box
Input power 2 hp (~1.5 kw)
Overall gear ratio 1:63
Input velocity 2 rpm
Module of gear pair 1 (spur gear) 6 mm
Face width of gear pair 1 35 mm
Module of gear pair 2 (spur gear) 7 mm
Face width of gear pair 2 70 mm
Module of gear pair 3 (helical gear) 2.5 mm
Face width of gear pair 3 35 mm
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Gear
Properties of the gear pair: Material
Face width
Module
Bending stressSurface fatigue stress
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Factor of Safety (FOS) for Gear Pairs
Pair and
type
Gear or pinion Material FOS in
bending
FOS in
surface
fatigue
Pair 1:
Spur
Gear CI FG-210-Gr 1.29 1.22
Pinion EN-8= AISI 1040 1.25 1.36
Pair 2:
Spur
Gear EN-24= AISI 4340 1.99 1.87
Pinion EN-24= AISI 4340 1.5 1.87
Pair 3:
Helical
Gear EN-24= AISI 4340 6.87 5.16
Pinion EN-24= AISI 4340 5.37 5.16
FOS >> 1 means large size,
high cost, less efficiency
Reduction of FOS for Gear Pair 3
FOS for
different
materials
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FOS for
different
face widths
FOS for
different
modules
Suggestion on Gear Pair 3
To change the type of gear pair 3
From helical gear to spur gear
If the type of gear pair is not changed
Change the face-width of gear pair from 35 mm to 15 mm
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Checking of Shafts
Standard equations
1/ Nf2 = (σa / σe)
2+( 1.73*τm / σy)2
σa = kf*(32*Ma / π*d3) MPa
τm= kfs*(16*Tm / π*d3) MPa
kf = 1+q*(kt-1)
kfs = 1+q*(kts-1)
Free body diagram of shaft 1
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FOS of each shaft
Shaft Material FOS
Cattle drive gear shaft AISI 4340 1.28
Drive gear shaft AISI 4340 1.08
Idler gear shaft AISI 4340 1.52
Driven gear shaft AISI 4340 1.23
FOS > 1 means that the shafts
are safe. No change is required.
Checking of Bearing Life
Equivalent load on the Bearings - P = X*V*Fr + Y*Fa
Life of the Bearing - L = (C / P) 3 X 106 revolutions
Bearing type Desired life
(revolutions)
Calculated life
( revolutions)
Taper roller bearing
SKF-300356
1.7*106 4.2*1010
Ball bearing SKF 6215 1.7*106 4.56*108
Ball bearing large SKF 6310 5.9*106 2*109
Ball bearing small SKF 6306 1.05*108 2.3*109
Life of the different bearings
Calculated life of bearings > desired life (based on
for 8 hrs/day for 10 yrs.). No change is required.
Additional Suggestions Provide a wheeled support under the wooden beam to reduce
the load on the bullocks.
A test facility be created at IIT Delhi to compare the gear boxes
for standard tests.
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• Company (Panchal Pumps) has taken most of the
suggestions (i.e., all spur gears, and less face-width
for gear pair 3).
• The water flow rates only require 0.8 kW power
input (not 1.5 kW) the company reduced diameters
of gears Gear box is much lighter.
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Lever Holder
Wheel Arrangement
BullockWooden Lever
Water Pump
Gear Box
Water Discharge
Design checks can be done very quickly using MS-Excel
programs developed by us. Anybody can check design.
Test of Standardized ADGB Water Pump
(For Sprinklers)
August 11, 2011
MS-Excel Program
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Set-up for Evaluation of ADGB
(at IIT Delhi)
Gearbox
Digital Ammeter
Speed Sensor
Digital
Counter
Alternator12V -Battery
Chain Sprocket
Cover
Support frame DC Motor-Gear Assembly
(To Simulates bullocks motion)
Noise Testing
Point Indicates
(Noise level
measured in that
area of the gear box)
1 2 3 4 5 6 7 8 9 10
Noise level in
db (decibel)
73.5 75.45 74.25 75.35 74.85 74.5 75.15 73.65 74.25 72.5
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Vibration Testing
(a) Voltage (b) Frequency
Point Indicates (Vibration
level measured in that area
of the gear box)
1 3 5 7 9
Vibration level in
mV (milivolts)112 102 372 128 232
Vibration frequency in
MHz (Mega hertz)22.73 5.00 20.83 92.59 4.46
a. Oscilloscope , b. Accelerometer, c. Charge Amplifier
Publications
[1] Gupta, R.K., Singh, S., Jain, A., Sharma, M., Saha, S.K., 2010,
“Computer aided analysis of animal driven gear box,” Proc. of
10thNat. Conf. on Industrial Problems on Machines and
Mechanisms (IPRoMM), MNIT, Jaipur, Dec. 17-18, pp. 35-38.
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Future Applications
Major applications other than pumps are:
Chaff cutting
Thrasher
Wheat-grinding (Atta chakki)
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MuDRA: Multibody Dynamics for
Rural Problems
MuDRA: Multibody Dynamics for Rural Applications
! LET’S TAKE LEAD AT LEAST IN THESE AREAS !
US Entry in this field (see next slide)
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Conclusions
All components of animal-driven gear box were checked for
safety
Design suggestions were made for reduction of weight and to
increase efficiency
CAD modeling was done in Autodesk Inventor to study the
designs
MS-Excel programs were written for easy/quick design checks
Standardized gear box was tested in Kanpur.
Contact has been made with ICAR, Patna for further field testing
and certification to be able to recommend for subsidy (presentcost is around ₹1.25 lakhs)
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Acknowledgements
1. Mr. Rajkumar Gupta
2. Mr. Mangal Sharma
3. Students
• Mr. Amit Jain
• Mr. Sanjay Singh
• Mr. Joyti Bahuguna
• Mr. Mayank Agrawal, Applied Mechanics
• Mr. Vinayak, Applied Mechanics