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AT A GLANCE

P: PLANNING BEFORE DOING ANY

WORK.

R: RAW MATERIAL REQUIRED FOR THE

WORK.

O: ORGANIZATION OF WORK.

J: JOINT EFFORTS PUT TOGETHER IN THE WORK.

E: ESTIMATION OF THE MATERIAL REQUIRED IN THE


WORK.

C: COSTING OF WORK.
T: TECHNIQUES USED IN PERFORMING

THE WORK

INDEX
No. Topic Name Page

1. INTRODUCTION

2. CONSTRUCTION

3. WORKING

4. SYSTEM DESIGN

5. PROCESS SHEETS

6. COST ESTIMATION.

7. APPLICATIONS

8. ADVANTAGES.

9. DISADVANTAGES
10. TRIAL & TESTING

11. FUTURE SCOPE

12. CONCLUSION

13. REFERENCE

ACKNOWLEDGEMENT

Ability and Ambition are not enough for success. Many able person fail to

achieve anything worthwhile because he or she has not been properly guided &

directed. Success of any project depends on solely on support, guidance,

encouragement received from the guide and our parent’s well-wishers that include

our staff members and friends. We have been fortunate to have more than one

pillars of strength in our humble effort to make this project successful.

We would like to thank all the people who have helped us complete

this project successfully and without those peoples guidance it would not have

been possible.

We would like to thank our Internal Guide Prof. …….. Who was

really the driving force behind the project. His views and ideas have helped to

bring quality to this project. We would also like to thank all other staff members of

dept. of Electronics & Tele-communication Engineering for their timely help &

guidance.
We would also like to thank to Honorable Prof. …….. (H.O.D. of

Electronics & Tele-communication Department) for his constructive suggestions

and giving us the opportunity to work on this project and present it.

Automatic Car-Washer and dryer is controlled using the electro-


mechanical system as shown. A proto-type model is implemented in our project.
The mechanism includes the lifting of pallel car and moving it in a forward
direction in steps. At intermediate steps the car cleaning water in pure form and
soap water is allowed to fall on the car under wash. Care is taken for not allowing
the water to fall on the assembly. At the end the car lifted is again allowed to come
down and the pallel. Returns back for loading a new car.
The system can be divided in two different sections.
1. Mechanical Assembly.
2. Electrical Control
Let’s illustrate the two sections in details as below….
1) Mechanical Assembly:-
The mechanical assembly consists of two dc motors with gear
assembly with it. This gear assembly reduces the revolutions per minute of the
motor and it increase the torque that is the driving power of the system. As shown
in assembly, first motor is for lifting the car pallet in upward direction i.e. a but and
bolt assembly is used heare. The threaded bolt is bored at its head side and the
motor shaft is inserted inside the fixed properly. The motor is fixed on a base,
which is also movable, but with another motor. If the motor with bolt assembly is
started the bolt rotates in one direction. And being a dc motor if the supply
polarities are interchanged, then the motor and the bolt rotates in opposite
direction.
A bolt which is suitable for nut is used. If the bolt motor assembly
rotates the, nut also rotates in anti-clockwise direction. Since the motor and bolt
assembly is steady, the nut travels in upward direction and downward direction, as
the motor rotates in clockwise and anti-clockwise respectively.
Thus this is the lifting mechanism. After lifting the horizontal travel
of the pallet starts. This movement is done by another dc motor. This dc motor is
also provided with gears, which reduces the speed and increases the power of the
system. A rack and Pinter gear assembly is used here. One horizontal gear is
placed at the bottom of the assembly and the shaft with gear assembly of the motor
is aligned in such a way that. The motor rotates in one direction it travels along the
horizontal gear in horizontal directions. The pallet with the vertical motor
assembly is mounted on this horizontally traveling motor. This assembly also
moves along with the motor. Thus, the motor is operated in steps and thus, the
traveling is also done in steps. In four different steps the four different functions
are done.
Immediate after lifting, the clean water supply is started and then the
trolley movement. i.e. travel starts, and then at another stage, the soap water is
allowed to fall on the car. After the specified time this soap water stops and again
the clean water is allowed to fall on the car. After specified time as above, the
different types of waters different water tanks with electric motor pumps are
provided. These pumps are made on at appropriate time and off at appropriate
time. These tanks are mounted on separate stands along with the assembly. After
passing through different types of cleaning waters, the car is dried in a separate
chamber and then the horizontal motor stops and the vertical lifting motors starts
and rotates in apposite direction than the first movement. The nut assembly with
the car pallet comes down. Then the horizontal traveling motor is on with reversed
supply polarity and the travel starts in apposite direction. The horizontal pallent
moves in back word direction. The pallet comes at its original position, from
where the next car can be loaded for washing purpose.

2) Electrical Automation:-
The movement of pallets and the water supply is totally
achieved with electrical supply. The details of each block can be explained as
follows.
Our system works on time sharing basis. Initially one timer is
ON which will provide the dc supply to the motor. Within the specified time the
container contacting the car is lifted up. Then this timer is off and next timer starts.
This timer makes the first motor ON which splasher the clean water on the car.
After the time is over this motor is off. The next timer starts and this provides
supply to the horizontally moving pallet. After the specified time it is stopped and
next timer starts which allows the soap water to fall on the car.
Here the washing with soap water is done. Then the time is
over and next timer starts which provide supply to the traveling motor. The car
trolley moves ahead and then stops as the time is over. Then next timer with clean
water again starts and the car is washed with clean water again. Then this timer
stops and the next timer starts which moves, the car in next compartment where car
is dried with the heating elements here the bulbs are used. The car is allowed to
wait here some time and then the motor rotates in opposite direction and the pallet
comes down. The car can be taken out. Now the next timer is ON and the base
trolley travels in opposite direction. All the timers are switching a relay for a
particular time and the motors and the water supplying motor’s are ON for that
period only.

The electrical connection diagram for the same can be given as


below…

Reverse Up
CLK Timer - 1
Generator
Clean water
Timer - 2
Divided
Timer - 10
By
10
Counter Timer - 3 Horizontal
DN Timer - 9 Travel
Timer - 4 Soap water

Timer - 8
Travel
Timer - 5
Heater
Travel Timer - 7 Timer - 6 Clean
Water
230V Dc Power V dc for motors
AC Source V dc for Electronic circuits.

Circuit Explanation:-
The circuit diagram consists of a clock generator. Then divide
by 10 counters & the dc regulated power supply. The power supply is developed
using step down transformer, rectifier, filter and voltage regulators. The detailed
explanation of the power supply is given in a separate chapter.
The clock generator is IC 89c51 in as able mode. When
powered with dc supply, starts oscillating. The time span between two successive
pulses is determined with the help of potentiometer provided on the CKT.
The output pulse is given to divide by 10 decade counter, which
outputs the pulses in sequential manner.
When it receives first pulse, the first output Q0 of the counter is
high and all other outputs are low. The high output switches ON a transistor which
switches on a relay. This relay provides the supply to the motor and the motor
rotates as discussed earier.
When next pulses arrive the 2nd output of the counter goes high
and the logic repeats for all the 10 outputs. The output wave forms of the counter
can be shown as below…

CIRCUIT DIAGRAM OF CAR WASHER AND DRYER

START
CLK 1

CLK 2

CLK 3

CLK 4

CLK 5

CLK 6
CLK 7

CLK 8

CLK 9

CLK 10
As these outputs are on sequentially, the corresponding switching
transistors are also on. The transistors are BC547 npn type, which are switched on
when a positive pulse arrives at its base, and are switched of when the pulse is cut.
This sequential switching of transistor makes the relays connected at its collector
ON. The relay ON/OFF status is shown by the LED indication.
The motors are connected in the NO contacts of the relay.
When a particular relay is ON, the corresponding motor for a particular function is
ON and the it is again off when the time period is over. The dc motors are
provided with AC supply & the motors for water are provided with AC supply.
The wiring diagram for the same is given on next page.
230 V AC +12v
RL 1 RL 2 RL3
NO P NO P NO P
12v dc

DC MOTOR AC MOTOR DC MOTOR

230V AC +12V
RL 4 RL 5

NO P
NO P

AC MOTOR DC MOTOR
230V AC +12V +12V DC
RL 8 RL 7 RL 6
NO P NO P NO P

HEATING LAMP DC MOTOR DC MOTOR

+12VDC 230V AC
RL 9 RL10
NO P NO P

DC MOTOR AC MOTOR

WIRING DETAILS

Component List:-
Component Value
1) IC-I- 89c51
2) Resistor-
R1 470 K
R2 2K2
R3=R4=R5=R6=R7=R8=R9=R10=R11=R12= 4.7 K
R13=R14=R15=R16=R17=R18=R19=R20=R21=R22=R2=2K2
3) Diode:-
D1 = D2 to D20 = IN4007
4) Capacitor:-
C1 = 10 µf/ 25v
C2 = 0.01 µf
5) Relay:-
RL1 to RL10
6) LED:-
LD1 to LD10
7) Transistor:-
T1 to T10 = BC 157
.
AUTOMATIC CAR WASHING SYSTEM
BLOCK DIAGRAM.

TRANSMISSSIO
N SPROCKETS DRIVE MOTOR CONTROL
& GEARS WITH DRIVE PANEL
SPROCATE

SIMPLEX BELT PLAT FORM CAR CARRYING


CHAIN FLAT

PUMP
ON 1
M1
SPRAYING

CAR CLEAN WATER DELAY


AT STATION 15 SEC.
S1

PUMP
ON 2

SOAP WATER
STATION

PUMP
ON 1 CLEAN WATER
STATION

DRYING STATION
Cooling fan Air station
WITH COOLING OUT
CHAMBER
MICROCONTROLLER :-

The AT89C51 is a low-power, high-performance CMOS 8-bit microcomputer with

4K bytes of Flash programmable and erasable read only memory (PEROM). The

device is manufactured using Atmel’s high-density nonvolatile memory technology

and is compatible with the industry-standard MCS-51 instruction set and pinout.

The on-chip Flash allows the program memory to be reprogrammed in-system or

by a conventional nonvolatile memory programmer. By combining a versatile 8-bit

CPU with Flash on a monolithic chip, the Atmel AT89C51 is a powerful

microcomputer which provides a highly-flexible and cost-effective solution to

many embedded control applications.

Features :-

• Compatible with MCS-51™ Products

• 4K Bytes of In-System Reprogrammable Flash Memory


• Endurance: 1,000 Write/Erase Cycles

• Fully Static Operation: 0 Hz to 24 MHz

• Three-level Program Memory Lock

• 128 x 8-bit Internal RAM

• 32 Programmable I/O Lines

• Two 16-bit Timer/Counters

• Six Interrupt Sources

• Programmable Serial Channel


• Low-power Idle and Power-down Modes

Pin Description:-

VCC:-

Supply voltage.

GND:- Ground.

Port 0:-

Port 0 is an 8-bit open-drain bi-directional I/O port. As an output port, each pin can

sink eight TTL inputs. When 1s are written to port 0 pins, the pins can be used as
high impedance inputs.Port 0 may also be configured to be the multiplexed

loworder address/data bus during accesses to external program and data memory.

In this mode P0 has internal pullups.Port 0 also receives the code bytes during

Flash programming, and outputs the code bytes during program verification.

External pullups are required during program verification.

Port 1:-

Port 1 is an 8-bit bi-directional I/O port with internal pull ups. The Port 1 output

buffers can sink/source four TTL inputs.When 1s are written to Port 1 pins they are

pulled high by the internal pullups and can be used as inputs. As inputs,

Port 1 pins that are externally being pulled low will source current (IIL) because of

the internal pullups. Port 1 also receives the low-order address bytes during

Flash programming and verification.

Port 2:-

Port 2 is an 8-bit bi-directional I/O port with internal pull ups. The Port 2 output

buffers can sink/source four TTL inputs.When 1s are written to Port 2 pins they are

pulled high by the internal pullups and can be used as inputs. As inputsPort 2 pins

that are externally being pulled low will source current (IIL) because of the internal

pullups. Port 2 emits the high-order address byte during fetchesfrom external

program memory and during accesses to external data memory that use 16-bit

addresses (MOVX @ DPTR). In this application, it uses strong internal pullups


when emitting 1s. During accesses to external data memory that use 8-bit addresses

(MOVX @ RI), Port 2 emits the contents of the P2 Special Function Register.

Port 2 also receives the high-order address bits and some control signals during

Flash programming and verification.

Port 3:-

Port 3 is an 8-bit bi-directional I/O port with internal pullups. The Port 3 output

buffers can sink/source four TTL inputs. When 1s are written to Port 3 pins they

are pulled high by the internal pullups and can be used as inputs. As inputs,

Port 3 pins that are externally being pulled low will source current (IIL) because of

the pullups. Port 3 also serves the functions of various special features of the

AT89C51 as listed below: Port 3 also receives some control signals for Flash

programming and verification.

RST:-

Reset input. A high on this pin for two machine cycles while the oscillator is

running resets the device.

ALE/PROG:-

Address Latch Enable output pulse for latching the low byte of the address during

accesses to external memory. This pin is also the program pulse input (PROG)
during Flash programming. In normal operation ALE is emitted at a constant rate

of 1/6 the oscillator frequency, and may be used for external timing

or clocking purposes. Note, however, that one ALE pulse is skipped during each

access to external Data Memory. If desired, ALE operation can be disabled by

setting bit 0 of SFR location 8EH. With the bit set, ALE is active only during

a MOVX or MOVC instruction. Otherwise, the pin is weakly pulled high. Setting

the ALE-disable bit has no effect if the microcontroller is in external execution

mode.

PSEN:-

Program Store Enable is the read strobe to external program memory. When the

AT89C51 is executing code from external program memory, PSEN is activated

twice each machine cycle, except that two PSEN activations are skipped during

each access to external data memory.

EA/VPP:-

External Access Enable. EA must be strapped to GND in order to enable the device

to fetch code from external program memory locations starting at 0000H up to

FFFFH. Note, however, that if lock bit 1 is programmed, EA will be

internally latched on reset. EA should be strapped to VCC for internal program

executions. This pin also receives the 12-volt programming enable voltage

(VPP) during Flash programming, for parts that require 12-volt VPP.
XTAL1:-

Input to the inverting oscillator amplifier and input to the internal clock operating

circuit.

XTAL2:-

Output from the inverting oscillator amplifies


Relay Driver Block :–

This block is responsible for driving the relay which is in turn responsible for ON

or OFF operation of a particular device.

Power Supply Block: –

This project works on the +5V regulated power supply. Here +5V is generated by

using 78XX series regulators. The +5V DC is supplied to the rest of the circuitry.

BELOW IS LOGIC OF THE PROJECT...

 M0 for driving the car moving platform.

 The position sensor S1 is for sensing the car at station no. 1.

 M1 pump motor M1, for spraying the clean water.

 Sensor S2 is for sensing car at station no.2.

 Pump motor M2. Is for spraying the soap water at station no. 2.

 Sensor S3 is for sensing the car at station no. 3.

 Pump motor M3 is for spraying the fresh water at station no. 3.

 Sensor S4 is for sensing the car at station no.4.

 Cooling fan is for drying the car at station no.4.


The total control will be achieved by making the used of 89C51

MICROCONTROLLER.

CONTROLS:

1) Time setting timer on delay type. Model 800A – 3 Nos.

2) Pump controllers only ON / OFF – using sensors Detection.

3) Fan controller.

4) Moving platform – Dc motor control.

5)

Technical Specifications:-

1) Supply – 230V AC.

2) Logic – Analog and digital based.

3) Microcontroller – condenser micro controller.

4) Motor- dc

5) Relay – 12V dc.


POWER SUPPLY

Power supply is the first and the most important part of our project.For our project

we require +5v regulated power supply with maximum current rating 500 mA Following

basic building blocks are required to generated power supply.

3 Terminal
Step Down Rectifier Filter Vtg.
Transformerr Regulator
230vac Reg.o/p

STEP DOWN TRANSFORMER :

Step down transformer is the first part or regulated power supply . To

step down the mains 230V A.C. we require step down transformer. Following

are the main characteristic of electronic transformer.


I) Power transformer are usually designed to operate from source of low

impedance at a single freq.

II) It is required to construct with sufficient insulation of necessary

dielectric strength.

III) Transformer rating are expressed in volt-amp. The volt-amp of each

secondary winding or windings is added for the total secondary VA.

To this are added the load losses.

IV) Temperature rise of a transformer is decided on two well known

factors i.e. losses on transformer and heat dissipating or cooling

facility provided unit.

RECTIFIER UNIT:

Rectifier unit is a ckt. Which converts A.C. into pulsating D.C.

Generally semi-conducting diode is used as rectifying element due to

its property of conducting current in one direction only Generally

there are two types of rectifier.

1. Half wave rectifier

2. Full wave rectifier.


In half wave rectifier only half cycle of mains A.C. rectified so its

efficiency is very poor. So we use full wave bridge type rectifier, in

which four diodes are used. In each half cycle, two diodes conduct at

a time and we get maximum efficiency at o/p.

Following are the main advantages and is advantages of a full-wave

bridge type rectifier ckt.

ADVANTAGES :

1. The need of center tapped transformer is eliminated.

2. The o/p is twice that of center tap circuit for the same secondary

voltage.

3. The PIV rating of diode is half of the center taps circuit.

DISADVANTAGES :

1. It requires four diodes.


2. As during each half cycle of A.C. input, two diodes are

conducting therefore voltage drop in internal resistance of

rectifying unit will be twice as compared to center tap circuit

Filter circuit :

Generally a rectifier is required to produce pure D.C. supply for using at

various places in the electronic circuit, However, the o/p of rectifier has pulsating

character i.e. if such a D.C. is applied to electronic circuit it will produce a hum

i.e. it will contain A.C. and D.C. components. The A.C. components are

undesirable and must be kept away from the load. To do so a filter circuit is used

which removes (or filter out) the A.C. components reaching the load. Obviously a

filter circuit is installed between rectifier and voltage regulator. In our project we

use capacitor filter because of his low cost, small size and litile weight and good

characteristic. Capacitors are connected in parallel to the rectifier o/p because it

passes A.C. but does not pass D.C. at all.

DESIGN PART:-
1) Car moving plat form design.

2) Belt selection.

3) Platform moving motor selection.

4) Platform width, length & height design.

5) Bearing selection depends on shafts sizes.

6) Shaft design.

7) Control part presetting & cycle time study.

8) Electrical wirings.

9)Moving platform speed design & selection etc.

4.3 DESIGN OF BEARING :-

Irrespective of the type of bearing the common requirement of spindle

support can be specified as

1) Guiding accuracy
2) Ability to perform satisfactory under varying condition of spindle

operation .

3) High stiffness

4) Minimum beading of this can lead to spindle deformation

5) Vibration stability which governed by the damping.

Here we have proposed to used ball bearing. It is not most commonly

used. Type of bearing with deep groves. This type of bearing have a high radial

load capacity and moderate thrust load capacity. The distinguishing features of

antifriction bearing as compared to the other are

1) Low friction movement and heat generation

2) Low starting registance

3) High load capacity.

4) Easy maintenance and less composition of lubrication

Ball bearing are less prone to heating and therefore permits larger

rotational speed they are also cheaper than other and less sensitive to small

alignment error. The structure of selected ball bearing .

Design of bearing on the basis of load capacity


W = Load on the journal = 58.860 N

( Maximum overall shaft weight)

d = Diameter of Journal = 15mm

1 = length of bearing =10 mm

Bearing pressure = w/ 1 x d

= 58.860 / 15 x 10

= 0.3924 N/mm3

P max = 1.5 mpa

P max > w/ 1x d

Since the bearing pressure is less than maximum bearing pressure given

fort the transmission shaft in heavy categories.

Hence the design is safe and selected bearing are safe in design and use.

Design of bearing on the basis of friction

W = load = 58.860 N

Ra = Normal Reaction

F = frictional force

f = angle between R ( resultant of F and Rn) & Rn.

M = Co – efficient of friction between the journal and


Bearing = 0.03

T = frictional torque

R = radius of shaft 30mm

Bh = diameter of shaft 15mm

N = speed of shaft = 400 rpm

W = angular velocity of shaft = 2p x400 / 60

= 130.33 rad /sec.

Therefore,

torque transmitted Ts = 0.03 x 58.860 x 0.0375 =0.066 N –m

and power transmitted,

p = T x w =0.066 x130.33 = 8.601W

Heat generation and dissipation in bearing:-

Heat generated Hg = m . W.V

m = 0.03

W= 58.860 N

V = DN /60

= 0.075 x 400 /60

V = 0.5m/s
Therefore , Hg = 0.03 x 58.860 x 0.5

= 0.889W

Heat deposited

Hd = kA ( tb –ta + 18 ) 2]

Where ;

K = 2.5 W /m2 0c for Normal ventilation

Ta = ambient temperature = 270 c

Tb = Housing temperature

To find Tb,

T oil = 2( tb + ta )+ ta

T oil = 800c ( Assumed)

Therefore , tb = 2.5 x 7.5 x 2.5 x 10 4 (53.5 – 27 +18)2

= 9.28

Bm at c = 0

For rotating shaft selecting,

Kb = 1.7 & kt =1.5

__________________

Tmax = (16 x103 / p xd3) V ( Kb xm ) 2+ ( Kt +T)2


__________________

= (16 x 103 / p xd3) V( 1.7 x 20 .68 )2 +(1.5 x110.185)2

= 1930638.2 /d3

Selecting material SAE 1050

Syt = 1200 N/mm2

Tmax = 0.3 x1200

= 36 N/mm

d =5mm

taking factor of factory =3

d = 5 x3 =15mm

d =15 mm.

4.7 PROPOSED DESIGN COMPONENT FOR BELT

Assumption for the Prototype :-

1) Power transmitted is 5kw

2) Motor is running at 400rpm.

3) Mechanism is running at 150 rpm.


Torque transmitted ,

T = ( p x 60 ) (2 x N)

Load factor K = 1.5

= (5x 103x 60x 1.5) / ( 2 x150)

= 154.5N –m

T = 154.5x 103N-mm

DESIGN OF BELT :-

400 rpm 150 rpm

For power rated to 1.5 to 15B is the Designession

For B W =17 mm

t = 11mm

D min = 91mm

D1 /D2 =N2/N1

D2 = 91 x400 /150

D2 =242mm

Fc = kc ( Vp/5)2

VP = D1 N1
= 0.003 x 91 x 400

= 109.2 m /min

= 109 m/min.

Kc = 4.34

4.34 (10.17/5)2

Fc = 17.986 N

Fw =w 2 = 17 2 =289N

q =p –( D2 - D 1)/ 1000

= P – (200-91)/1000

= 2.93 rad

Consider a =38, m =0.3

Power /belt = {( Fc-Fc) (emq/sin(a/2)-1)/ emp/sin(a/2}Vp

= {(289- 17.89) (e 0.3x 2.93/sin ( 19) -1)/ e 0.3x 2.93/sin (19)}

10.17

Power /belt = 2.774 Kw

No. of belt =pd / power /belt

Pd = 5 x1.10

=5.5Kw

There fore , No. of belts = 5.5/2.774= 1.98


No. of belts =2
MATERIAL USED:-

Sr no Part name quantity Material used


1 Belt 1 Rubber
2 Dc motor 1
3 Sheet metal tank 3 Ms
4 Nozzles 3 plastic
5 Dc fan 1 plastic
6 Pipe 1 Plastic
7 Power transformer 1
Machine used during the competition of Entire project:-

1. Cutting Machine : For cutting the angles


2. Welding Machine : For welding the angles together
3. Grinder : For finishing the welded joints
4. Drilling Machines : For drilling purpose
Operation sheet

1) Component Foundation frame

Sr no operation machine Tool used description


1 Cutting Hacksaw Blade Cutting the frame
angles in given length
2 Welding Arc welding By hand To make frame in
given size
3 Finishing Hand grinder Abrasive To avoid sharp
wheel corners
4 painting By hand Paint & brush For good aesthetic
look

2) Component sheet metal tank

Sr no operation machine Tool used description


1 Cutting Hacksaw Blade Cutting the frame
angles in given length
2 Welding Arc welding By hand To make frame in
given size
3 Finishing Hand grinder Abrasive To avoid sharp
wheel corners
4 painting By hand Paint & brush For good aesthetic
look
3) Component base tray

Sr no operation machine Tool used description


1 Cutting Hacksaw Blade Cutting the frame
angles in given length
2 Welding Arc welding By hand To make frame in
given size
3 Finishing Hand grinder Abrasive To avoid sharp
wheel corners
4 painting By hand Paint & brush For good aesthetic
look

4) Component pallet

Sr no operation machine Tool used description


1 Cutting Hacksaw Blade Cutting the frame
angles in given length
2 Welding Arc welding By hand To make frame in
given size
3 Finishing Hand grinder Abrasive To avoid sharp
wheel corners
4 painting By hand Paint & brush For good aesthetic
look

5) Component nozzle assy

Sr no operation machine Tool used description


1 Cutting Hacksaw Blade Cutting the frame
angles in given length
2 Finishing Hand grinder Abrasive To avoid sharp
wheel corners
3 painting By hand Paint & brush For good aesthetic
look
6) Component shaft

Sr no operation machine Tool used description


1 Cutting Hacksaw Blade Cutting the frame
angles in given length
2 Welding Arc welding By hand To make frame in
given size
3 Finishing Hand grinder Abrasive To avoid sharp
wheel corners
4 painting By hand Paint & brush For good aesthetic
look

Cost Estimation of the Project:-


The project, car washing &drying system is implemented with a
proper cost to performance ratio. Being a development proto, many repetitions are
their, which can not be avoided. Also, each spare of the project is to be done in 01
quantity, so the costing is more.

Later if the regular production will be started, the costing will be less. The price

details for our development are given as below

Cost Estimation:-
Sr Name of part Material Material Machine total
no cost(raw) cost(bought) &assly.
cost
1 Foundation frame 150 0 200 350

2 Bush bearing 100*4 0 150 550

3 Metal shaft 100*2 0 150 350

4 Rubber belt 00 25 25

5 Dc motor with 00 2000 350 2350


gear head

6 Plat form tray 80 0 150 430

7 Sheet metal tank 200*3 0 150 750

8 Electric motor 250*3 50 800

9 Spray nozzle 0 100*3 50 350

10 Dc fan 0 60 20 80

11 Pipe plastic 10 10

12 Power 0 250 0 250


transformer

13 Power card 300 25 325

14 miscellaneous 0 800 0 800

TOTAL 7420
APPLICATIONS

1) In car manufacturing companies. - After assembly of car.

2) In service stations.

3) Car replacing and maintaining stations

4) Car body building industry

ADVANTAGES

1) The whole system is automatic so no manpower required.

2) If we use special car washing pressure pumps no compressor will required.

3) Can be use in domestic service stations, as there is no compressor & no. loud

noise.

4) Very less maintenance.

5) Comparatively cost of system is less.

6) No. more space required.

7) No. environmental pollution.

LIMITATIONS

1) ELECTRIC POWER WILL REQUIRED TO RUN THE SYSTEM.


TRIAL & TESTING

To complete any project ,one has to go through many difficulty .during

completion of this project we also have faced many problem beginning the project

has been complicated in two different phase say electrical and mechanical one

problem faced in electrical part are different and Problem encountered in

mechanical part are different during pcb testing many point were short and many

track were cut through proper chalking problem we over come the ics required for

our project not available n local market

Mechanical trouble shoot also difficult initially motor capacity was not

melting the assembly requiring motor with higher torque and capacity was taken

the gear assembly was very difficult the horizontal gear with sufficient lent was

not available so number of gear connected together to form long length gear the

working is very difficult after major exercise the result were achieved.

Before soldering in components:

 Check that component agree with the parts list (value and power of resistors,

value and voltage rating of capacitor, etc.) if in any doubt double check the

polarized components (diodes, capacitor, rectifiers etc)


 If there is a significant time elapse between circuit, take the trouble to read

the article; the information is often given in a very condensed from. Try to

get most important point out of the description of the operation of the circuit,

even if you don’t understand exactly what is supposed to happen.

 If there is any doubt that some component may not be exact equivalent,

check that they are compatible.

 Only use good quality IC sockets.

 Check the continuity of the tracks on the PCB (and through plated holes

with double sided boards) with a resistance meter or continuity tester.

 Make sure that all drilling, filling and other ‘heavy’ work is done before

mounting any components.

 If possible keep any heat sinks well isolated from other components.

 Make a wiring diagram if the layout involves lots of wires spread out in all

directions.

 Check that the connectors used are compatible and that they are mounted the

right way round.

 Do not reuse wire unless it is of good quality. Cut off the ends and strip it a

new.
After mounting the component:

 Inspect all soldered joints by eye or using a magnifying glass and check

them with a continuity tester. Make sure there are no dry joints and no tracks

are short circuited by poor soldering.

 Ensure that the positions of all the component agree with the mounting

diagram

 Check that any links needed are present and that they are in the right

positions to give the desired configuration.

 Check all ICs in their sockets (see that there are no pins bent under any ICs,

no near ICs are interchanged etc.)

 Check all the polarized components (diodes, capacitor etc) are fitted

correctly.

 Check the wiring (watch for off cuts of components leads) at the same time

ensure that there are no short-circuits between potentiometer, switches, etc.

and there immediate surrounding (other components or the case). Do the

same with mounting hardware such as spacers, nuts and bolts etc.
 Ensure that the supply transformer is located as closely as possible to the

circuits (this could have a significant improvement in the case of critical

signal level).

 Check that the connections to the earth are there and that they are of good

contact.

 Make sure the circuit is working correctly before spending any time putting

it into a case.

And if it breaks down:

 Recheck everything suggested so far.

 Re-read the article carefully and carefully anything about which you are

doubtful.

 Check the supply voltage or voltages carefully and make sure that they reach

the appropriate components especially pins of the ICs (test the pins of ICs

and not the soldered joints).

 Check currents (generally they are stated on the circuit diagram or in the

text). Don’t be too quick to suspect the ICs of overheating.

 If possible check the operation of the circuit in the separate stages as a

general rule follow the course of the signal.


 While checking voltages, currents, frequencies or testing the circuits with an

oscilloscope work systematically and take notes.

And don’t forget to switch the power on and check the fuses.
Problems Encountered during completion:-
To complete any project, one ha to go through many
difficulties. During the completion of this project, we also have faced many
problems. Being the project has been completed in two different phases say
electrical one and the mechanical one. The problem encountered in mechanical
part is different. During PCB Testing, many points were sport and many tracks
were cut. Through proper checking the problems we over-come. Also, the ICS
required for our project were not available in the local market.
Hence, we searched for them in Pune and Bombay. During
trouble shooting also, many problems were occurred. After a large exerciser these
problem were solved. Now, our electrical part is completely ready.
Mechanical troubleshoot is also very difficult. Initially the
motor capacity was not meeting the assembly’s requirement. The motor with
higher torque and capacity was taken. The gear assembly was very difficult.
The horizontal gear with a sufficient length was not available so
the number of gears was connected together to from a long length gear. The
working is very difficult. After a major exercise the results were achieved.

Future Scope:-
Even though our project is completed successfully, it has many
limitations. Further development can be done to a large extent. Some of the points
in development area can be mentioned as below…
1. Now the existing system works on electrical mechanism, which results in
major electrical power loss. This loss can be minimized using the
hydraulic cylinders and hydraulic jack lifting system operated
automatically.
2. The existing system is based on time sharing system. The time specified
may not be appropriate for a particular car. Hence, some system which
will allow the proper type for a particular operation may be made
possible.
3. The system may be made through computerized numerical control or
PLC control or PC based control.
4. Also we can implement a counter which will be allowing the number of
cars washed to be counted.
Instead of dc motors dc drive systems can be used for the purpose
moving the horizontal as well as up down moving pallet.
CONCLUSION :-

After completion of the project auto car washer and dryer ,we can come to

conclusion than such automation system are quite beneficial ,and saving time of

operation and also man power reduced ,improving the economy of the system the

future such type of system will have more demanded.


REFERENCES

1. The 8051 microcontroller by Kenneth Ayala


2. The 8051 microcontroller and embedded system by M. A. Mazidi
3. www.atmel. Com
4. www. Alldatasheets.com