FABRICATION OF DUAL SIDE WATER

PUMPING SYSTEM WITH MOBILE

PHONE CHARGER
PROJECT REPORT 2014-2015
Submitted by
(Team name)

COLLEGE LOGO

Guided by:

Submitted in partial fulfillment of the

requirement for the
Award of Diploma in
----------------------------------------By the State Board of Technical Education
Government of

Tamilnadu, Chennai.
DEPARTMENT:
COLLEGE NAME:
PLACE:

COLLEGE NAME
PLACE
DEPARTMENT
PROJECT REPORT-2014-2015

This Report is certified to be the Bonafide work

done by
Selvan/Selvi ---------------- Reg.No. ------------ Of VI
Semester class of this college.

Guide

Head of the

Department
Submitted for the Practical Examinations of the
board of Examinations,State Board of Technical
Education,Chennai,
TamilNadu.On -------------- (date) held at the
------------ (college name),Coimbatore

Internal

Examiner

External Examiner

DEDICATED TO OUR BELOVED

PARENTS

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At this pleasing movement of having successfully

completed our project, we wish to convey our sincere thanks
and gratitude to the management of our college and our
beloved chairman------------------------.who provided all the
facilities to us.

We would like to express our sincere thanks to our

principal ------------------for forwarding us to do our project and
offering adequate duration in completing our project.

We are also grateful to the Head of Department

prof.,

for

her/him

constructive

suggestions

&encouragement during our project.

With deep sense of gratitude, we extend our earnest

&sincere thanks to our guide --------------------, Department of

Mechanical for her/him kind guidance and encouragement

during this project we also express our indebt thanks to our
TEACHING staff of MECHANICAL ENGINEERING DEPARTMENT,
---------- (college Name).

FABRICATION OF DUAL SIDE

WATER PUMPING SYSTEM WITH
MOBILE PHONE CHARGER

CONTENTS

CONTENTS

CHAPTER NO

TITLE

SYNOPSIS
LIST OF FIGURES
1
2
3
3.1
3.2

Introduction

3.3
3.4
3.5
3.6
3.7
4
4.1
4.2
5
6
7
8
9
10

Pneumatic cylinder
Cam
Non-return valve
Tube
Chain drive
Design and drawing
Machine components
Overall diagram
Working principle
Merits & demerits
Applications
List of materials
Cost Estimation
Conclusion
BIBLIOGRAPHY
PHOTOGRAPHY

Literature review
Description of equipments
Dynamo
Pedal

LIST OF FIGURES

LIST OF FIGURES

Figure
Number
1

Title
Overall diagram

SYNOPSIS

SYNOPSIS

The pedal type water pumping and mobile phone charger

system machine is a new innovative concept is mainly used to save
power. In this concept we have designed a fabrication of pedal type
water pumping system. Here we are using the mechanical energy for
pumping the water without using any other electrical energy or any
other fuel based energies and also generates the electrical power
from the dynamo by the rotation of the cam plate.

CHAPTER I
INTRODUCTION

CHAPTER I
INTRODUCTION

This invention relates to water distribution systems, and more

particularly, to water distribution systems powered by human power.
Needed in a developing country is a manually operated pump
which can be easily operated by a person for relatively long periods
of time and which lifts significant volumes of water with as little effort
as possible. Because of the high usage requirements, and because
the pump must operate as a practical device far from cities having
maintenance facilities and personnel, the pump must be both reliable
and easily repaired.
Energy is the ability to do work. While energy surrounds us in
all aspects of life, the ability to harness it and use it for constructive
ends as economically as possible is the challenge before mankind.
Alternative energy refers to energy sources which are not based on
the burning of fossil fuels or the splitting of atoms. The renewed
interest in this field of study comes from the undesirable effects of

pollution (as witnessed today) both from burning fossil fuels and from
nuclear waste byproducts. Fortunately there are many means of
harnessing energy which have less damaging impacts on our
environment.
The alternatives are,
Solar
Wind Power
Geothermal
Tides
Hydroelectric

ELECTRICITY GENERATION
Electricity generation is the process of generating electric power from
other sources of primary energy. The fundamental principles of
electricity generation were discovered during the 1820s and early
1830s by the British scientist Michael Faraday. His basic method is
still used today: electricity is generated by the movement of a loop of
wire, or disc of copper between the poles of a magnet.[1] For electric
utilities, it is the first process in the delivery of electricity to
consumers. The other processes, electricity transmission, distribution,

and

electrical

power

storage

and

recovery

using pumped-

storage methods are normally carried out by the electric power

industry. Electricity is most often generated at a power station by
electromechanical generators, primarily driven by heat engines fueled
by chemical combustion ornuclear fission but also by other means
such as the kinetic energy of flowing water and wind. Other energy
sources include solar photovoltaics and geothermal power.

CHAPTER II
LITERATURE REVIEW

CHAPTER II
LITERATURE REVIEW
The history of positive displacement reciprocating pumps goes
back as far as 275 BC in Ancient Rome. In the sixteenth century,
great lift and force pumps, driven by water wheels became the
principle method for pumping water to be piped in Europe.
As late as 1987, the World Bank estimated that, throughout the
world, 1.8 billion people would need improved water supplies, and
that wells equipped with handpumps would be an appropriate choice
to meet the needs of this number of people. Most of the reciprocating
handpumps commonly used in developing countries have their
origins in designs developed during the late 19th and early 20th
Centuries in the United States and in Europe. In the United States,
about 42 million handpumps were made until 1920, when electric
pumps began to replace them. While the basic design of the
reciprocating handpump has not changed much in this century, its
typical use has changed greatly. In the early part of this century, in
the United States and Europe, the big market for pumps was for small
backyard pumps used for ten to thirty minutes per day by individual

families or farmers. In a developing country today, a single pump may

have to supply more than 500 villagers and may be in continuous
operation for ten or more hours per day.
A pump connected with a typical well is driven by pressing the
end of a lever downward and by either pulling it upward, or permitting
it to return upward due to the weight of the well. The work of lifting the
water occurs as the lever is pressed downward. The simplest type of
reciprocating pump is the suction pump, which draws water from
shallow wells by creating a partial vacuum in a suction pipe. All of the
moving parts, including a plunger moved by the lever and a suction
check valve, are located above ground; only the suction pipe extends
downward into the well. As the lever is pushed downward, the plunger
is moved upward, lifting the water above it to be discharged through a
spout, and pulling water below it upward through an open suction
check valve. As the lever is moved upward, the plunger is moved
downward, through the water below it, creating a pressure which
opens a valve in the plunger while closing the suction check valve.
Two disadvantages of this type of pump are first, it must be primed
with water before it can be used and, second, the suction principle,

depending on atmospheric pressure to lift water, limits the usefulness

of the device to wells having depths less than about seven meters.
A number of pump configurations have been built to overcome
various of these disadvantages in the way driving forces are applied.
For example, a treadle type foot pedal drive, together with a pair of
flywheels, has been applied to a double piston pump, Model SB-115,
produced by the Water Conservancy Bureau of Shandong Province,
China. The Climax pump, manufactured by Wildon Engineering of
Worcestor, United Kingdom, and the Volanta pump, manufactured by
Jensen Venneboer BV, The Netherlands, are both pumps in which a
reciprocating motion is developed using a connecting rod driven by a
rotating crank mounted on a shaft along with a flywheel. An eccentric
rod extends from the flywheel for use as a hand crank. The Climax
pump also uses a counterweight to balance the lifting force applied
through the crank.
The usage of traditional power generation method such as
burning of coal, wood, diesel (generators) etc is continuously
depleting our natural resources such as fossil fuels, which is the
demand for

power has exceed the supply due to the rising

population. In addition to this the traditional methods cause pollution,

encourage deforestation (cutting of trees) the consequences are

global warming, power shortage like we are facing in Tamilnadu.

CHAPTER III
DESCRIPTION OF EQUIPMENTS

CHAPTER III
DESCRIPTION OF EQUIPMENTS

3.1. DYNAMO
Dynamo is an electrical generator. This dynamo produces direct
current with the use of a commutator.dynamo were the first generator
capable of the power industries.The dynamo uses rotating coils of
wire and magnetic fields to convert mechanical rotation into a pulsing
direct electric current. A dynamo machine consists of a stationary
structure, called the stator, which provides a constant magnetic field,
and a set of rotating windings called the armature which turn within
that field. On small machines the constant magnetic field may be
provided by one or more permanent magnets; larger machines have
the constant magnetic field provided by one or more electromagnets,
which are usually called field coils.

The commutator was needed to produce direct current. When a

loop of wire rotates in a magnetic field, the potential induced in it
reverses with each half turn, generating an alternating current.
However, in the early days of electric experimentation, alternating
current generally had no known use. The few uses for electricity, such
as electroplating, used direct current provided by messy liquid
batteries. Dynamos were invented as a replacement for batteries.
The commutator is a set of contacts mounted on the machine's shaft,
which reverses the connection of the windings to the external circuit
when the potential reverses, so instead of alternating current, a
pulsing direct current is produced.

speed = 1000 rpm

Volts = 12 v
Watts = 18 w
If the dynamo rotates at 1000 rpm it will produce 6- 8 v

3.2 PEDAL
A pedal is the part of an equipment in this project that the
human pushes with his or her foot to propel the bicycle. It provides
the connection between the cyclist's foot or shoe and the crank
allowing the leg to turn the bottom bracket axle. Pedals usually
consist of a spindle that threads into the end of the crank and a body,
on which the foot rests or is attached, that is free to rotate on
bearings with respect to the spindle.

3.3 PNEUMATIC CYLINDER:

All the strange names and terms around pneumatics have

evolved through about 100 years of their use in manufacturing.
Double acting, four way, quick connect are all terms that were
invented to describe (as best as could be) the difference between the
parts. Don't let the names discourage you. They're just names. I've
used quite colorful terms myself when working with pneumatics, most
of which i won't use here...
The first thing to remember is: Pneumatics are easy... really! Its all
the different names and parts that seem to be overwhelming. But
enough about that... on to the fun stuff.
Note:
This isn't the place to discuss every different kind of part that's
available - it would take hundreds of pages. But what I'd like to cover
is the basic things for a haunter to keep in mind when 'playing' with
pneumatics.

AIR CYLINDERS:

There are only two main kinds of air cylinders: Double acting,
and single acting. They come in all variations, shapes and sizes. Both
kinds are useful for haunt work. Double acting cylinders are useful
when you need to push in both directions, and single acting cylinders
are useful when only a push in one direction is needed. And,
sometimes 'in a pinch', you can adapt a double to act as a single, and
a single to act as a double.
Air cylinders are measured by three main values: "pressure rating",
the "bore", and "stroke"
This is the maximum pressure the air cylinder
Pressure
can safely handle.
Bore

The interior diameter of the cylinder.

Stroke

The range of movement of the air cylinder's rod.

There are lots of calculations to accurately figure the power of a

cylinder, but most haunt pop-up applications can be handled by air
cylinders in the range of 3/4" to 1-1/2" bore, and 3" to 8" stroke.
Power measurements primarily take into account the air
pressure (the higher the pressure, the more power); and the bore (the
larger the bore - the more power). The power ratings are usually only
quoted at maximum pressure. So if a cylinder produces180 pounds of

'push', it will only deliver that at the maximum pressure (usually 250
psi for commerical cylinders).

Haunters should work their props to work and much, much

lower pressures. A good goal is not to exceed 60-70psi for working
props. Going much higher causes more stress on the prop and all
parts in the air system, and make your compressor run more often.
Even at lower pressures, air cylinders can still move very fast and
deliver quite a lot push, so always be very careful around pneumatics!
Double Acting means the air cylinder rod is 'pushed' out, and
'pushed' in.

A typical double acting air cylinder

Every double acting air cylinder has these basic parts. A

cylinder to hold everything together, a 'plunger' that the air pushes
against, two connections to get the air in and out, and a rod that goes
in and out. That's it. Here's a simple animation to illustrate the
motion...
As air is sent into the left connection (pressure is shown in
yellow), it pushes against the plunger and the rod goes out. At the
same time, air is released out of the right connection. To reverse the
motion, air is sent into the right connection, pushing against the
plunger on the other side and the rod is forced back in.
The trick to the double acting cylinder is that you have to let air
OUT of the other side! This is an important feature of the double
acting cylinder, and an advantage that gives you great control over
the motion of the rod (but, more on that later!).
TIP: the most useful double acting cylinder I've found is one
with 1/4" connections, 6"-8" stroke, 1" bore, and end clevis mounts.
Of course, most any cylinder can be adapted for haunt use!

SINGLE ACTING CYLINDER

Single Acting means the air cylinder rod is ONLY pushed in a

single direction, either out or in. There is only one connection for air,
and a little hole in the other end to let air in and out. A spring is used
to push the rod in the opposite direction after air pressure is removed.

Single Acting Air Cylinder, with the rod normally out without pressure

Single Acting Air Cylinder, with the rod normally in without pressure
As air is pushed into the connection, the plunger begins to
move and compress the spring. Exhaust air exits out the exhaust hole
on the other end. When air is released, it exits out the connection,
and air is sucked into the exhaust hole as the spring pushes the
plunger back to its resting position. Basically, the spring is 'push'
needed to return the plunger and rod back to their starting position.

When selecting a cylinder for an application, remember that a double

acting cylinder pushes in both directions, while a single acting
cylinder only pushes in one direction.
MOUNTING
There are about as many ways to mount an air cylinder as there are
different types of air cylinders. Again, this is because of all the uses.
My personal favorite is the clevis mount. (see photo below) Clevis
mounts give the greatest amount of movement, flexibility, and ease of
mounting over other mounts.

DESIGN CALCULATION FOR PNEUMATIC CYLINDER

(32 x100)
Mini pressure applied in the cylinder (p)

: 2x10 5N/m2

Diameter of the cylinder (D)

: 32 mm

Stroke length

: 100 mm

Area of cylinder (A)

: (3.14/4*(D 2)
: (.785x.0322)
: 8.0384 x 10-4m2

Force exerted in the piston (F)

: Pressures applied X area

Of cylinder
Force

: (2 x 105 n /m2) (8.0384 x 10-4m2)

: 160.68 N

For lifting one kg weight, the force required is given by,

Force = m x a
= 1 x9.81
= 9.81 N
And the pressure required for one pneumatic cylinder to lift I kg is
given by,
Pressure, P =Force/ Area
= 9.81 N/8.0384 x 10-4 m2
=12203.92 N/m2
=12203.92 pa
Pressure

=0.1220392

bar

Maximum load in the cylinder = Pressure*area

= 160.68 N

Total load in the cylinder = m x a

= 160.68 x9.81
= 1576.27 kg

3.4 CAM
A cam is a projecting part of a rotating wheel or shaft that
strikes a lever at one or more points on its circular path. The cam can
be a simple tooth, as is used to deliver pulses of power to a steam
hammer, for example, or an eccentric disc or other shape that
produces a smooth reciprocating (back and forth) motion in the
follower which is a lever making contact with the cam.
The reason the cam acts as a lever is because the hole is not
directly in the centre, therefore moving the cam rather than just
spinning. On the other hand, some cams are made with a hole
exactly in the centre and their sides act as cams to move the levers
touching them to move up and down or to go back and forth.

3.5 NON-RETURN VALVE:

A check valve, clack valve, non-return valve or one-way valve
is a mechanical device, a valve, which normally allows fluid (liquid or
gas) to flow through it in only one direction.
Check valves are two-port valves, meaning they have two
openings in the body, one for fluid to enter and the other for fluid to
leave. There are various types of check valves used in a wide variety
of applications. Check valves are often part of common household
items. Although they are available in a wide range of sizes and costs,
check valves generally are very small, simple, and/or cheap. Check
valves work automatically and most are not controlled by a person or
any external control; accordingly, most do not have any valve handle
or stem. The bodies (external shells) of most check valves are made
of plastic or metal.
An important concept in check valves is the cracking pressure
which is the minimum upstream pressure at which the valve will

operate. Typically the check valve is designed for and can therefore
be specified for a specific cracking pressure.

3.6 TUBE:
A hose is a hollow tube designed to carry fluids or air from one
location to another. Hoses are also sometimes called tube or pipes
(the word pipe usually refers to a rigid tube, whereas a hose is
usually a flexible one), or more generally tubing. The shape of a hose
is usually cylindrical (having a circular cross section).
Hose design is based on a combination of application and
performance. Common factors are Size, Pressure Rating, Weight,
Length, Straight hose or Coilhose and Chemical Compatabiltiy.
Hoses are made from one or a combination of many different
materials. Applications mostly use nylon, polyurethane, polyethylene,
PVC, or synthetic or natural rubbers, based on the environment and
pressure rating needed. In recent years, hoses can also be
manufactured from special grades of polyethylene (LDPE and

especially LLDPE). Other hose materials include PTFE (Teflon),

stainless steel and other metals.

3.7 CHAIN DRIVE

Chain drive is a way of transmitting mechanical power from one
place to another. It is often used to convey power to the wheels of a
vehicle, particularly bicycles and motorcycles. It is also used in a wide
variety of machines besides vehicles. The power is conveyed by a
roller chain, known as the drive chain, passing over a sprocket gear,

with the teeth of the gear meshing with the holes in the links of the
chain. The gear is turned, and this pulls the chain putting mechanical
force.

DESIGN PROCEDURE
Chain drive design is done by following this procedure and referring to the
DESIGN DATA
1. Calculate the drive ratio R (velocity ratio) given the input RPM and
output RPM.
Drive ratio=N1/N2 = T2/T1
VELOCITY RATIO = N1/N2
So,
N1/N2 = T1/T2
N1= 30

N2= ?
T1= 44
T2 = 18
N1/N2 = T1/T2
30/N2 = 44/18
N2 = (30) / (44/18)
N2 = (30)/2.44
N2 = 12.30 RPM

Velocity ratio = N1/N2

= 30/12.30
Velocity ratio =2.44
2. Determine the number of teeth of the sprockets.
Minimum number of teeth on the sprocket = 18
3. Number of teeth on the larger sprocket
Number of teeth on the larger sprocket = 44
4. Determine the design power by using the service factor, such that
Design power = Rated power x Service factor(Ks)

= 0.25 x Service factor (Ks)

= 0.25 x ( (Load factor(K1) x (Lubrication factor (K2) x
Rating factor (K3)
= 0.25 x (1.5 x 2.44 x 1.25)
Design power = 1.143kW
5. Choose the type of chain, number of strands for the design power and
RPM of the smaller sprocket
Types of chain = simple roller chain (06B)
Power rating (in kW) = 0.25
Speed of smaller sprocket or pinion (RPM) = 30
6. Note down the parameters of the chain, such as pitch, roller diameter,
minimum width of roller.
ISO chain number = 06B
Pitch (mm) = 9.525
Roller diameter (mm) = 6.535
Minimum width (mm) = 5.72

Braking load (simple type roller chain) in kN = 8.9

7. Find the velocity.
Velocity, v = ( D N)/60
(3.140.006530)/60
0.0102 m/s
8. Find the pitch circle diameter and pitch line velocity of the smaller
sprocket
Pitch circle diameter (D) = p / (sin (180/T))
= 9.525 /(sin (180/18))
= 9.525 / (sin (7.5))
= 9.525/0.173648
Pitch circle diameter (D) in mm = 54.852

CHAPTER IV
DESIGN AND DRAWING

CHAPTER IV
DESIGN AND DRAWING

4.1 MACHINE COMPONENTS:

The fabrication of dual side water pumping system with mobile
charger consists of the following components to full fill the
requirements of complete operation of the machine.
1. DYNAMO
2. PNEUMATIC CYLINDER
3. PEDAL
4. CAM
5. CHAIN DRIVE
6. NON RETURN VALVE
7. TANK

4.2 DRAWING FOR FABRICATION OF DUAL SIDE

WATER PUMPING SYSTEM WITH MOBILE PHONE
CHARGER

CHAPTER V
WORKING PRINCIPLE

CHAPTER V
WORKING PRINCIPLE
In this concept we have design the gym based system is the
simple mechanism for water pumping and generate the electrical
power with the help of pedaling operation. It system also consists of
one more advantage, the pedaling operation just acts like an exercise
to the human being. Here the pedaling arrangement is coupled with
the cam. So whenever we operate the chain drive to pedal its rotated
the cam mechanism which makes the pedaling operation easier to
pump the water. The output from the pedaling system is coupled with
the pneumatic cylinder. Here we are converting the rotary motion in to
the linear motion for pumping the water. The pressure pushes the
piston for the stroke. At the end of the stroke pressure reaches the
rear end of the cylinder block. The pressure remains the same but the
area is less due to the presence of the piston rod. This exerts greater
pressure on the piston pushing it at a faster rate thus enabling faster
return stroke. The outlet of the cylinder is connected with the tank on
one side and the same to discharge the water with help of a T joint.
When the piston of the cylinder actuates it sucks the water in the tank

due to the vacuum produced in the cylinder. Here the dynamo is

coupled with the cam plate; the dynamos output power is used to
charge the mobile phone.

CHAPTER VI
MERITS & DEMERIT

CHAPTER VI
MERITS & DEMERIT

MERITS
Power is not required
Low maintains
Cost is less compared to other pumping devices

DEMERIT
It does not operate through long time.

CHAPTER VII
APPLICATIONS

CHAPTER VII
APPLICATIONS

It is used in gym and home uses.

CHAPTER VIII
LIST OF MATERIALS

CHAPTER VIII
LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are
discussed below.
1.PROPERTIES
The material selected must posses the necessary properties for
the proposed application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand
environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials
decisively affect their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific

gravity, electrical conductivity, magnetic purposes etc.
The various Mechanical properties Concerned are strength in tensile,
Compressive shear, bending, torsional and buckling load, fatigue
resistance, impact resistance, eleastic limit, endurance limit, and
modulus of elasticity, hardness, wear resistance and sliding
properties.
The various properties concerned from the manufacturing point
of view are,
Cast ability
Weld ability
Surface properties
Shrinkage
Deep drawing etc.
2. MANUFACTURING CASE
Sometimes the demand for lowest possible manufacturing cost or
surface qualities obtainable by the application of suitable coating
substances may demand the use of special materials.

3. QUALITY REQUIRED
This generally affects the manufacturing process and ultimately
the material. For example, it would never be desirable to go casting of
a less number of components which can be fabricated much more
economically by welding or hand forging the steel.
4. AVAILABILITY OF MATERIAL
Some materials may be scarce or in short supply, it then
becomes obligatory for the designer to use some other material which
though may not be a perfect substitute for the material designed. The
delivery of materials and the delivery date of product should also be
kept in mind.
5. SPACE CONSIDERATION
Sometimes high strength materials have to be selected because the
forces involved are high and space limitations are there.
6. COST
As in any other problem, in selection of material the cost of
material plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and nonmaintenance of the designed part are involved in the selection of
proper materials.

CHAPTER IX
COST ESTIMATION

CHAPTER IX
COST ESTIMATION
1.MATERIAL COST
2. LABOUR COST
Lathe, drilling, welding, drilling, power hacksaw, gas cutting cost

3. OVERGHEAD CHARGES
The overhead charges are arrived by manufacturing cost
Manufacturing Cost

=Material Cost + Labour Cost

=
=

Overhead Charges

=20%of the manufacturing cost

=

4.TOTAL COST
Total cost = Material Cost +Labour Cost +Overhead Charges
=

=
Total cost for this project =

CHAPTER X
CONCLUSION

CHAPTER X
CONCLUSION

This project is made with pre planning, that it provides flexibility

in operation.
The comparative gain that can be accomplished is the
utilization of pedal. This innovation has made the more desirable
This project FABRICATION OF DUAL SIDE WATER PUMPING
SYSTEM WITH MOBILE PHONE CHARGER is designed with the
hope that it is very much economical and help full to many peoples
on their needs.
This project helped us to know the periodic steps in completing
a project work. Thus we have completed the project successfully.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. Design data book

-P.S.G.Tech.

2. Pneumatic handbook

-R.H.warrning

3. Machine tool design handbook Central machine tool Institute,

Bangalore.

4. Strength of Materials

-R.S.Kurmi

5. Manufaturing Technology -M.Haslehurst.

6.Design of machine elements- R.s.Kurumi

PHOTOGRAPHY