PEDAL OPERATED WATER PUMPING SYSTEM

SYNOPSIS

Water plays an important role in the material, social and cultural life of man kind. 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 under ground water is available.

INTRODUCTION

The aim of the project is Pedal operated water pumping system. Radial plunger Pedal operated reciprocating water pumping system are reciprocating pump in which the piston is provided for the pumping action. The piston is reciprocated with the help of a pneumatic cylinder, pedal with chain sprocket mechanism and Cam mechanism.

pump is a !echanical device which converts mechanical energy into hydraulic energy. This pump is classified into two types"

i. ii.

Positive #isplacement and $on%Positive #isplacement pump

&n positive displacement pump is the one, in which the li'uid is transferred positively from one stage to another stage by the to and fro motion of the plunger or piston of the pump.

&n non%positive displacement pump the li'uid is transferred by the centrifugal force. This force is cause due to the rotary movement of an impeller. &n this, our project, pedal operated reciprocating water pump is of positive displacement pump. The salient features of a pedal operated reciprocating water pump have been retained in our project model and this has been achieved with great care.

#ue to high precision work involved in producing pedal operated reciprocating water pump besides higher cost these pumps are not widely manufactured by most of the industries. The very name itself indicates that it works with the help of a piston. This piston is reciprocated with the help of a solenoid valve and electronic timing control unit.

LITERATURE SURVEY

PNEUMATICS

The word (pneuma) comes from *reek and means breather wind. The word pneumatics is the study of air movement and its phenomena is derived from the word pneuma. Today pneumatics is mainly understood to means the application of air as a working medium in industry especially the driving and controlling of machines and e'uipment.

Pneumatics has for some considerable time between used for carrying out the simplest mechanical tasks in more recent times has played a more important role in the development of pneumatic technology for automation.

Pneumatic systems operate on a supply of compressed air which must be made available in sufficient 'uantity and at a pressure to suit the capacity of the system. When the pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the 'uestion of compressed air supply.

The key part of any facility for supply of compressed air is by means using reciprocating compressor. compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure.

Compressor capacity is the actual 'uantity of air compressed and delivered and the volume e+pressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature.

The compressibility of the air was first investigated by Robert ,oyle in -./0 and that found that the product of pressure and volume of a particular 'uantity of gas.

The usual written as

P1 2 C

3or4 P515 2 P010

&n this e'uation the pressure is the absolute pressured which for free is about -6.7 Psi and is of courage capable of maintaining a column of mercury, nearly 89 inches high in an ordinary barometer. used system now a days. ny gas can be used in pneumatic system but air is the mostly

SELECTION OF PNEUMATICS

!echani:ation is broadly defined as the replacement of manual effort by mechanical power. Pneumatic is an attractive medium for low cost mechani:ation particularly for se'uential 3or4 repetitive operations. !any factories and plants already have a compressed air system, which is capable of providing the power 3or4 energy re'uirements and the control system 3although e'ually pneumatic control systems may be economic and can be advantageously applied to other forms of power4.

The main advantage of an all pneumatic system are usually economic and simplicity the latter reducing maintenance to a low level. &t can also have out standing advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made available. &n sufficient 'uantity and at a pressure to suit the capacity of the system. When pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the 'uestion of compressed air supply.

The key part of any facility for supply of compressed air is by means using reciprocating compressor. compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure.

Compressor capacity is the actual 'uantity of air compressed and delivered and the volume e+pressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature. Clean condition of the suction air is one of the factors, which decides the life of a compressor. Warm and moist suction air will result in increased precipitation of condense from the compressed air. Compressor may be classified in two general types.

-. Positive displacement compressor. 0. Turbo compressor

Positive displacement compressors are most fre'uently employed for compressed air plant and have proved highly successful and supply air for pneumatic control application.

The types of positive compressor -. Reciprocating type compressor 0. Rotary type compressor

Turbo compressors are employed where large capacity of air re'uired at low discharge pressures. They cannot attain pressure necessary for pneumatic control application unless built in multistage designs and are seldom encountered in pneumatic service.

RECIPROCATING COMPRESSORS ,uilt for either stationary 3or4 portable service the reciprocating compressor is by far the most common type. Reciprocating compressors lap be had is si:es from the smallest capacities to deliver more than ;99 m<=min. &n single stage compressor, the air pressure may be of / bar machines discharge of pressure is up to -; bars. #ischarge pressure in the range of 0;9 bars can be obtained with high pressure reciprocating compressors that of three > four stages.

?ingle stage and -099 stage models are particularly suitable for pneumatic applications , with preference going to the two stage design as soon as the discharge pressure e+ceeds / bar , because it in capable of matching the performance of single stage machine at lower costs per driving powers in the range .

COMPONENTS AND DESCRIPTION

Pneumatic cylinder

n air cylinder is an operative device in which the state input energy of compressed air i.e. pneumatic power is converted in to mechanical output power, by reducing the pressure of the air to that of the atmosphere.

Single acting cylinder

?ingle acting cylinder is only capable of performing an operating medium in only one direction. ?ingle acting cylinders e'uipped with one inlet for the operating air pressure, can be production in several fundamentally different designs.

?ingle cylinders develop power in one direction only. Therefore no heavy control e'uipment should be attached to them, which re'uires to be moved on the piston return stoke single action cylinder re'uires only about half the air volume consumed by a double acting for one operating cycle.

Do !le acting cylinder"#

double acting cylinder is employed in control systems with the full pneumatic cushioning and it is essential when the cylinder itself is re'uired to retard heavy messes. This can only be done at the end positions of the piston stock. &n all intermediate position a separate e+ternally mounted cushioning derive most be provided with the damping feature.

The normal escape of air is out off by a cushioning piston before the end of the stock is re'uired. s a result the sit in the cushioning chamber is again compressed since it

cannot escape but slowly according to the setting made on reverses. The air freely enters the cylinder and the piston stokes in the other direction at full force and velocity.

$%$%&% Part" o' Pne (atic Cylinder

Pi"ton The piston is a cylindrical member of certain length which reciprocates inside the cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter and it is fitted to the top of the piston rod. &t is one of the important part which converts the pressure energy into mechanical power.

The piston is e'uipped with a ring suitably proportioned and it is relatively soft rubber which is capable of providing good sealing with low friction at the operating pressure. The purpose of piston is to provide means of conveying the pressure of air inside the cylinder to the piston of the oil cylinder.

*enerally piston is made up of luminium alloy%light and medium work.

,rass or bron:e or C&%@eavy duty.

The piston is double acting type. The piston moves forward when the high% pressure air is turned from the right side of cylinder. The piston moves backward when high pressure acts on the piston from the left side of the cylinder. The piston should be as strong and rigid as possible.

The efficiency and economy of the machine primarily depends on the working of the piston. &t must operate in the cylinder with a minimum of friction and should be able to withstand the high compressor force developed in the cylinder and also the shock load during operation.

The piston should posses the following 'ualities. a. The movement of the piston not creates much noise. b. &t should be frictionless. c. &t should withstand high pressure.

Pi"ton Rod

The piston rod is circular in cross section. &t connects piston with piston of other cylinder. The piston rod is made of mild steel ground and polished. high finish is

essential on the outer rod surface to minimi:e wear on the rod seals. The piston rod is connected to the piston by mechanical fastening. The piston and the piston rod can be separated if necessary.

Ane end of the piston rod is connected to the bottom of the piston. The other end of the piston rod is connected to the other piston rod by means of coupling. The piston transmits the working force to the oil cylinder through the piston rod. The piston rod is designed to withstand the high compressive force. &t should avoid bending and withstand shock loads caused by the cutting force. The piston moves inside the rod seal fi+ed in the bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air from the bottom of the cylinder while the rod reciprocates through it.

Cylinder Co)er Plate"

The cylinder should be enclosed to get the applied pressure from the compressor and act on the pinion. The cylinder is thus closed by the cover plates on both the ends such that there is no leakage of air. n inlet port is provided on the top cover plate and

an outlet ports on the bottom cover plate. There is also a hole drilled for the movement of the piston.

The cylinder cover plate protects the cylinder from dust and other particle and maintains the same pressure that is taken from the compressor. The flange has to hold the piston in both of its e+treme positions. The piston hits the top plat during the return stroke and hits the bottom plate during end of forward stroke. ?o the cover plates must be strong enough to withstand the load.

Cylinder Mo nting Plate"#

&t is attached to the cylinder cover plates and also to the carriage with the help of (B) bends and bolts.

SPRAC*ET AND C+AIN DRIVE MEC+ANISM#, This is a cycle chain sprocket. The chain sprocket is coupled with another generator shaft. The chain converts rotational power to pulling power, or pulling power to rotational power, by engaging with the sprocket. The sprocket looks like a gear but differs in three important waysC -. ?prockets have many engaging teeth" gears usually have only one or two. 0. The teeth of a gear touch and slip against each other" there is basically no slippage in a sprocket. 8. The shape of the teeth is different in gears and sprockets.

Digure Types of ?prockets

+OUSE AND FITINGS#

&t is provided for the passage of compressed air from the compressor outlet to the operating valve.

Two separate pipes also connect the operating valve with the working cylinder pressure drop through and air line depends on the flow rate, pipe diameter, pipe length and pipe geometry. &t can be determined directly for straight pipes of any given length. small chaining bore si:e can have marked effect on pressure drop, where as even doubling the pipe length, will only result in doubling the pressure drop.

Pressure drop through bends and fittings can only be determined by empirical tests, since it is specific to the internal geometry involved. Rigid pipes however are less manipulated through remain form of bends with arrangements increase and variable air have to flow and the flow itself may be of fluctuating or pulsating nature. &n this case it is thus normally based on practical recommendation.

SEALS#

?eal is an important component of a pneumatic system and is used to prevent the air leakage through the joint.

This project passes the static seal which are used to prevent the leakage through the stationary surface.

!aterial of the seal is Teflon tape. Teflon has the following properties

Withstand the system pressure and temperature without any damage. Resist the wear and abrasion. Recover from deformation. Resists the adverse effects such as deterioration and shrinking caused by the system air.

?eals are devices for closing gaps to prevent leakage or make pressure joints and also to prevent the entry of air and dirt from outside into the system. The material of seal must be compatible with the fluid medium. &t is a circular ring made of synthetic rubber. &t is used for providing tight sealing between the piston and the cylinder wall. &t prevents air leakage from the top and bottom of the cylinder.

?eals for air cylinder and valves are not normally called upon to seal pressure higher than about 0 bars. ?ince the fluid to be seated is a gas, 3in our case air4 rubbing speeds tends to be high and the seal the seal may have to be operated under dry conditions with minimal lubrication. NON,RETURN VALVE#,

T+EORY OF OPERATION The non%return valve is employed in all those circuits where the fluid must flow in one way only, avoiding the flow in the opposite direction.

TO O-TAIN PERFECT SEALING

&. !ake sure that all tubes are perfectly clean and that there are no impurities in the system where the fluid will flow. .% Remove protective caps only when ready to assemble, making sure that in the assembly phase no impurities enter the system.

TEC+NICAL C+ARACTERISTICS &. The non%return valve assures a perfect tightness of the circuit, provided that the indicated nominal working pressures are kept as recalled in this catalogue. .% The particular profile of its inner elements assures the correct flow with a minimum pressure drop.

/% The valve is a compact, particularly sturdy element" the seal is obtained by a plain seat metal to metal plug with an electrometric seal gasket assuring tightness at low working pressures. $% basic body allows to interchange different types of non return valves applying from

time to time the different engaged stud ends as chosen by the customer allowing an easy logistic of the stock. 0% The valve may be used for convoying mineral oils, fuels, compressed air or gases. 1% The nominal working temperature is between E09F and G-09F Celsius degrees for carbon steel, and between E/9F and G099F Celsius degrees for stainless steel. The limit may change according to the type of gasket used.

COMPONENT TESTING 1alves are checked for leakages at low pressure and at high pressure 3nominal working pressures plus 88H4.

SAFETY FACTORS ?afety factor is 0.;C- at static load with temperature within range. FINIS+ TREATMENT ll valves are treated with a chemical polishing with steel spheres which eliminate all o+ides and burrs due to the machining phase, without altering or damaging the product. ll valves are plugged to avoid internal damages.

DESIGN OF E2UIPMENT AND DRA3ING

Pne (atic co(4onent" and it" "4eci'ication
The pneumatic cutting and Diling machine consists of the following components to full fill the re'uirements of complete operation of the machine.

-. #ouble acting pneumatic cylinder 0. Connectors 8. @oses

&% Do !le acting 4ne (atic cylinder Tec5nical Data ?troke length Piston rod Kuantity ?eals Lnd cones Piston !edia C C C C C C C Cylinder stoker length -/9 mm 2 9.-/ m -I mm 2 -I + -9J< m 0 $itride 3,una%$4 Llastomer Cast iron L$ E I ir

Temperature

9%I9 M C

Pressure Range

I $=mN

.% Connector" Tec5nical data !a+ working pressure Temperature Dluid media !aterial C C C C -9 + -9 $=mN 9%-99 M C ir ,rass

/% +o"e" Tec5nical date !a+ pressure Auter diameter &nner diameter C C C -9 + -9 $=mN / mm 2 / + -9 J <m 8.; mm 2 8.; + -9 J <m

DESIGN CALCULATION PNEUMATIC CYLINDER#

De"ign o' Pi"ton rod#

Boad due to air Pressure. #iameter of the Piston 3d4 Pressure acting 3p4 !aterial used for rod Oield stress 3y4 ssuming factor of safety 2 2 2 2 2 69 mm / kgf=cm C 6; 8/ kgf=mm 0

Dorce acting on the rod 3P4 2 2 2 P #esign ?tress3y4 2 2 2 2 d 2

Pressure + rea p + 3d = 64 / + P3 + 6 ) = 6 Q 78.8/ Rgf y = D9 ? 8/ = 0 2 I Rgf=mm

P = 3 d = 6 4 6 p = S y T

2 2

6 + 7;.8/ = P + -IQ ;.88 2 0.8 mm

 !inimum diameter re'uired for the load We assume diameter of the rod

2 2

0.8 mm -; mm

DISTRI-UTION C+AM-ER# De"ign o' cylinder t5ic6ne""#

!aterial used ssuming internal diameter of the cylinder Ultimate tensile stress Working ?tress 2 2

2 2

Cast iron 7; mm 2 0;99 gf=mm

0;9 $=mm

Ultimate tensile stress = factor of safety

ssuming factor of safety Working stress 3 ft 4 ccording to (B !L? LKU T&A$)

2 2

6 0;99 = 6 2 /0; Rgf=cm

!inimum thickness of cylinder 3 t 4

ri P 3ft G p4 = 3ft E p 4 %- Q

Where, ri ft 2 2 inner radius of cylinder in cm. Working stress 3Rgf=cm4

Working pressure in Rgf=cm

 ?ubstituting values we get, t t 2 2 8.7; P 3/0; G /4 = 3 /0; E /4 %-Q 9.98/ cm 2 9.8/ mm

We assume thickness of cylinder &nner diameter of barrel Auter diameter of barrel

2 2 2 2

7.; mm 7; mm 7; G 0t 7; G 3 0 + 7.; 4 2 .9 mm

De"ign o' Pi"ton rod# Dia(eter o' Pi"ton Rod# Dorce of piston Rod 3P4 2 2 2 Pressure + area 2 / + 3 = 64 + 37.;4 0/; Rgf p + /4 3d4

lso, force on piston rod 3P4 P 0;/ 2 2

3=64 3dp4 + ft

3V=64 + 3dp4 + /0; 3V=64 + 3dp4 + /0;

dp

2 2

0;/ + 36=V4 + 3-=/0;4 9.;0 -.I7 cm 2 -I.7 mm

dp

,y standardi:ing dp

09 mm

Lengt5 o' 4i"ton rod# pproach stroke Bength of threads L+tra length due to front cover L+tra length of accommodate head Total length of the piston rod 2 2 2 2 2 2 ,y standardi:ing, length of the piston rod 2 ;9 mm 0 + 09 2 -0 mm 09 mm ;9 G 69 G -0 G 09 -0.0 cm -09 mm 69mm

3OR*ING PRINCIPLE

&nitially starting with cycle pedaling operation is manually. The sprocket is coupled to another sprocket with the help of chain drive. The second sprocket shaft is coupled to the Cam plate with the help of Lnd bearings. The Cam plate is coupled to the pneumatic cylinder with the help of Cam shaft

The 0 outlet ports are connected to an actuator 3Cylinder4.

The pneumatic

activates is a double acting, single rod cylinder. The cylinder output is coupled to further purpose. The piston end has a water horning effect to prevent sudden thrust at e+treme ends. The end of the cylinder two $on return valve is connected for both of the side. Ane $on return valve for suction side and another one non return valve are for delivery side.

The pedaling operation done by manually with the help of man and this power is transferred to the Cam mechanism. This Cam and cam shaft is used to activate the pneumatic cylinder. The pneumatic cylinder forward stroke is suction the water and return stroke will deliver the water.

FA-RICATION
COMPONENTS#
Piston ctuating rod

,ase Plate ,ush Dle+ible hoses Cylinder block

Pi"ton#

The piston is fitted in the cylinder block and reciprocates inside. When the solenoid valve supplies the air in the front end of the piston, the piston is pushed forward. This moves the hacksaw and the cutting stroke takes place. Then the solenoid valve supplies air to the rear end of the piston. The pressure is same but the contact area is less due to the presence of the piston rod and pushes the piston at a greater pressure thus resulting in a fast return stroke. The material for the piston is luminum.

Act ating Rod#

The actuating rod is fitted inside the bush. &t is connected at one end to the piston rod and at the other end it is connected to the hacksaw frame. &t reciprocates inside the bush. The material for the actuating rod is mild steel.

-a"e Plate#

ll the components of the machine are mounted on the base plate. &t withstands the vibrations encountered during machining. &t is mounted on the bench.

Fle7i!le +o"e#

The fle+ible hoses connect the solenoid valve and the cylinder block. @oses are made of in layer of elastomer 3or4 synthetic rubber and braided fabric which takes up the higher pressure. &f the hose is subjected to rubbing, it should be enclosed in a protective sleeve.

Cylinder !loc6#

The cylinder block has two opening for admitting air inside the block for achieving the reciprocation motion of the piston. The material for cylinder block is luminium.

- "5#
&t is cylindrical in shape with a central hole. &t supports the actuating rod. The actuating rod reciprocates in the bore at the bush. The material for the bush is mild steel.

APPLICATIONS

?ince the Pedal operated reciprocating water Pump is more efficient it is used for pumping the water or oil mostly. #omestic pplications &ndustrial pplications &t is widely applicable in industrial practices. &t is used, -. &n hydraulic lifts and Wacks 0. &n hydraulic press 8. &n load transfer applications 6. &n hydraulic puller ;. &n service centers /. &n mechanical clamping applications 7. &n deep drawing, shearing etc I. &n machine shops for actuating various machines .. &n wheel mechanism of an aero crafts

nd it is used in all places wherever positive displacement is re'uired. There it has a wide range of application in all fields.

NEED FOR AUTOMATION

$owadays almost all the manufacturing process is being atomi:ed in order to deliver the products at a faster rate. The manufacturing operation is being atomi:ed for the following reasons.

To achieve mass production To reduce man power To increase the efficiency of the plant To reduce the work load To reduce the production cost To reduce the production time To reduce the material handling To reduce the fatigue of workers To achieve good product 'uality Bess !aintenance

ADVANTAGES AND LIMITATIONS

ADVANTAGES#

Lven if all the other pumps are similar in use the Pedal operated reciprocating water pump is more advantageous than the other pumps.

-. This is of compact in si:e 0. Bess !aintenance is enough 8. The oil or water pumped is of higher pressure 6. Kuite running and smooth operation is achieved. ;. @igher efficiency /. Dull efficient positive displacement pump 7. Lffective working principle I. &t does not have any Prime mover, like electric motor related to the unit. .. s the air is freely available, we can utili:e the air to pumping the water and hence it is economical. -9. Bess !aintenance

LIMITATIONS
&t is costlier than the other types of pump because of compressor unit. Bess efficiency when compressed to other device. Beakage of air affects the working of the unit.