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
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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: 32

SN 1. 2. 3. 4. 5. 6. 7. 8. Customer Name City / State Contacted: Remarks Bioved Research & Communication Allahabad / Uttar Center Pradesh Dr. Punjabrao Deshmukh Krishi Akola / Maharashtra Vidyapeet Mahant Bharatpuri Banda / Uttar Pradesh ISKCON (Goverdhan Krishi Farm) Thane / Maharashtra Bhartiya Govanshrakshan Thane / Maharashtra Savardhan Parishad Shri Santosh Singh Bhadauriya Kanpur / Uttar Pradesh Kanpur / Uttar Pradesh Jamshedpur / 1 set working Jharkhand for 1 year Noida / Uttar Pradesh Not used Varanasi / Uttar Pradesh 3 sets working for 1 year

Shri Vivek Chaturvedi Office Of The Project Director, ATMA 9. Shri Surendra Sharma C/o. Gayatri Parivar 10. Aghor Guru Sewa Peeth Aghor Foundation

Contacted on 12/08/2011

Inside of the Gear box

Lever holder

Output pulley

Pair 2 (spur)

Pair 1 (spur)

Pair 3 (helical)

CAD Modeling of ADGB (Animation)

Lever Holder

Gearbox

V-Pulley

Base Plate

Analysis of the Gear Box

Components

1. Gear pairs 2. Shafts 2. Bearings

Specification of the existing gear box

Input power 2 hp (~1.5 kw)

Overall gear ratio

Input velocity Module of gear pair 1 (spur gear) Face width of gear pair 1 Module of gear pair 2 (spur gear) Face width of gear pair 2 Module of gear pair 3 (helical gear)

1:63
2 rpm 6 mm 35 mm 7 mm 70 mm 2.5 mm

Face width of gear pair 3

9

35 mm

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 Gear or pinion type Material FOS in FOS in bending surface fatigue 1.29 1.25 1.99 1.22 1.36 1.87

Pair 1: Spur Pair 2: Spur Pair 3:

Gear Pinion Gear

CI FG-210-Gr EN-8= AISI 1040 EN-24= AISI 4340

Pinion
Gear Pinion

EN-24= AISI 4340

EN-24= AISI 4340 EN-24= AISI 4340

1.5
6.87 5.37

1.87
5.16 5.16

Helical

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

Free body diagram of shaft 1

1/ Nf 2 = (a / e)2+( 1.73*m / y)2

a = kf*(32*Ma / *d3) MPa

m= kfs*(16*Tm / *d3) MPa kf = 1+q*(kt-1)
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k = 1+q*(k -1)

FOS of each shaft

Shaft Cattle drive gear shaft Drive gear shaft Idler gear shaft Driven gear shaft Material AISI 4340 AISI 4340 AISI 4340 AISI 4340 FOS 1.28 1.08 1.52 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

Life of the different bearings

Bearing type Desired life (revolutions) 1.7*106 Calculated life ( revolutions) 4.2*1010

Taper roller bearing SKF-300356 Ball bearing SKF 6215 Ball bearing large SKF 6310 Ball bearing small SKF 6306

1.7*106 5.9*106 1.05*108

4.56*108 2*109 2.3*109

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.

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. 18

Test of Standardized ADGB Water Pump (For Sprinklers)

Lever Holder Wooden Lever Bullock

Gear Box

Water Discharge

Water Pump

Wheel Arrangement

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Design checks can be done very quickly using MS-Excel programs developed by us. Anybody can check design.

MS-Excel Program

20 August 11, 2011

Set-up for Evaluation of ADGB (at IIT Delhi)

Chain Sprocket 12V -Battery Alternator Gearbox

Cover

Digital Ammeter

Digital Counter Speed Sensor Support frame DC Motor-Gear Assembly (To Simulates bullocks motion)

Noise Testing

Point Indicates (Noise level measured in that area of the gear box) Noise level in db (decibel)
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10

73.5

75.45 74.25 75.35 74.85 74.5 75.15 73.65

74.25 72.5

Vibration Testing
a. Oscilloscope , b. Accelerometer, c. Charge Amplifier

(a) Voltage

(b) Frequency

Point Indicates (Vibration level measured in that area of the gear box) Vibration level in mV (milivolts) Vibration frequency in MHz (Mega hertz)

1
112 22.73

3
102 5.00

5
372 20.83

7
128 92.59

9
232 4.46

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

! LETS 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 (present cost 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

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Thank You
saha@mech.iitd.ac.in http://web.iitd.ac.in/~saha

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