ETHIOPIAN INSTITUTE OF TECHNOLOGY -MEKELLE, (EIT-M)

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

THESIS IN PARTIAL FULLFILLMENT OF BACHEOLER SCIENCE IN MECHANICAL

ENGINERING

DESIGN AND MODEL OF ASPHALT CLEANER MACHINE

PRAPERED BY ID No SECTION
KASAHUN TOLOSA EIT-M/UR/162351/06 04
JEJEBE HABTAMU EIT-M/UR/162295/06 04
FIROMI JALETA EIT-M/UR/162019/2006 04

ADVISOR. INST. ZEBENAY T.

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 DECLARATION
This is to certify that the thesis prepared by Jejebe Habtamu, kasahun Tolosa and Firomi Jaleta , entitled:
Design and Modeling of Asphalt Cleaner Machine and submitted in partial fulfillment of the requirements
for the degree complies with the regulation of the university and meet the accepted standards with respect
to originality and quality.

Advisor:-_____________________________
Sign:-________

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 ABSTRACT
In this project of asphalt cleaner machine, a mechanism was designed to remove dirt from asphalt. During
conceptual design phase, different concepts were proposed using concept generation methods and the best
concepts were selected. From the selected concepts, the design was developed in accordance with
technical and economic criteria and general arrangement, component shapes and materials were
determined. Moreover, the components and assembly were analyzed by the Catia software. The machine
is compact and manually driven, and capable of reducing the cost of road surface cleaning work. It also
prevents dust from being blown up without spraying water on the road surface during the cleaning process.
At optimum working speed, it absorbs dirt efficiently without damaging the road surface. Moreover, it
applies an absorbing force to the debris effectively.
And this machine is full of mechanical system. In its working process, the coarse debris cleaning
mechanism will clean larger litters first, and then the spur gear mechanism drives the roller brush rotating
at optimum speed, and thus produces negative pressure to direct the fine debris into the container. By
pushing the machine, it moves the coarse and fine debris towards the dirt container. And also the fan is
suck the fine sand or debris from the asphalt at the back of the machine. Therefore, it saves power and
reduces labor force more than manually cleaning using brooms, and reduces cost when compared to
employing street sweepers.

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 ACKNOWLEDGEMENT
First of all, we would like to thank our GOD JESUS for his blessing, love and every day caring. And also
we want to express our deepest gratitude to our advisor Mr. Zebenay who give us unlimited advice,
instructions, and encouragement and for his unwavering support and guidance throughout this Project by
providing an answering to our questions in all phases of our project without being tired.
We are grateful to the staff of the School of Mechanical and Industrial Engineering, EIT-M, who has
provided the most cooperative assistance to our thesis work.

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 TABLE OF CONTENTS

ABSTRACT .................................................................................................................................................................. II
ACKNOWLEDGEMENT............................................................................................................................................... III
TABLE OF CONTENTS .................................................................................................................................................. I
LIST OF FIGURES .......................................................................................................................................................... I
LIST OF TABLES........................................................................................................................................................... II
CHAPTER ONE ............................................................................................................................................................ 1
INTRODUCTION.......................................................................................................................................................... 1
1.1 BACK GROUND ............................................................................................................................................ 1
1.2 PROBLEM STATEMENT AND JUSTIFICATION ...................................................................................... 3
1.3 OBJECTIVE .................................................................................................................................................... 4
General Objective .............................................................................................................................................. 4
Specific Objectives ............................................................................................................................................ 4
1.4 Scope of this Project ........................................................................................................................................ 4
1.5 METHODOLOGY .......................................................................................................................................... 5
1.6 RESULT AND DISCUSSION ........................................................................................................................ 6
1.7 EXPECTED OUT PUT ................................................................................................................................... 9
1.8 SIGNIFICANCE OF THE STUDY ................................................................................................................ 9
CHAPTER TWO ......................................................................................................................................................... 10
LITERATURE REVIEW ................................................................................................................................................ 10
2.1 Literature on road cleaner machine ............................................................................................................... 10
2.1.1 Bicycle asphalt road cleaner ................................................................................................................... 10
2.1.2 Vacuum cleaner machine ........................................................................................................................ 11
2.1.3 Mechanical Broom cleaner .................................................................................................................... 11
2.1.4 Regenerative Air Sweepers ..................................................................................................................... 12
2.1.5 High-Efficiency Sweepers ...................................................................................................................... 13
2.2 Literature on types of debris in Mekelle University ...................................................................................... 13
CHAPTER 3 ............................................................................................................................................................... 18
DESIGN CONCEPTS AND SELECTION ........................................................................................................................ 18
3.1 Concept Generation ....................................................................................................................................... 18
3.3 Overall Product Specification of our design .................................................................................................. 25
3.4 Function Structure ......................................................................................................................................... 25
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 3.4.1 Overall function structure ....................................................................................................................... 25
System Synthesis ............................................................................................................................................. 25
3.5 Power Transmission ....................................................................................................................................... 26
3.6 GENERAL WORKING PRINCIPLE OF THE MACHINE ......................................................................... 28
CHAPTER FOUR ........................................................................................................................................................ 30
DESIGN AND ANALYSIS ............................................................................................................................................ 30
A. FORCE ANALYSIS ON THE MACHINE ................................................................................................. 30
B. DESIGN OF THE WHEEL ......................................................................................................................... 32
C. DESIGN OF SPUR GEAR .......................................................................................................................... 34
D. DESIGN OF WORM AND WORM GEAR ............................................................................................... 38
E. DESIGN OF MAIN SHAFT ....................................................................................................................... 45
F. BALL BEARINGS SELECTION ............................................................................................................... 48
G. SELECTION OF MATERIAL FOR DISC BRUSH ................................................................................... 50
H. SELECTION OF MATERIAL FOR ROLLER BRUSH ............................................................................ 52
I. DESIGN OF WORM GEAR FOR FAN ..................................................................................................... 53
J. DESIGN OF HANDLE ............................................................................................................................... 59
K. UPPER COVER .......................................................................................................................................... 60
L. DESIGN OF KEY ....................................................................................................................................... 60
M. Assembly ................................................................................................................................................. 61
CHAPTER 5 ............................................................................................................................................................ 62
COST ANALYSIS .................................................................................................................................................. 62
CHAPTER 6 ............................................................................................................................................................... 64
CONCLUSION AND RECCOMENDATION................................................................................................................... 64
6.1 CONCLUSION .............................................................................................................................................. 64
6.2 Recommendation ........................................................................................................................................... 65
References ............................................................................................................................................................... 66
Appendix .................................................................................................................................................................. 67

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 LIST OF FIGURES
Figure 1 Asphalt cleaner with broom ........................................................................................................................ 3
Figure 2 Bicycle asphalt road cleaner ...................................................................................................................... 10
Figure 3 Debris like paper, plastics and leaf ............................................................................................................ 14
Figure 4 Debris concrete around new constructions ................................................................................................ 15
Figure 5 Debris leaf from the tree ............................................................................................................................ 15
Figure 6 Debris sand/soil ......................................................................................................................................... 16
Figure 7 Food debris around the cafe ...................................................................................................................... 16
Figure 8 Debris storing mechanism ......................................................................................................................... 17
Figure 9 Concept A .................................................................................................................................................. 18
Figure 10 Concept B with Bajaj .............................................................................................................................. 19
Figure 11 Concept C with blower ............................................................................................................................ 19
Figure 12 Concept D with Fan ................................................................................................................................. 20
Figure 13 Concept E with motor.............................................................................................................................. 20
Figure 14 Concept F with one disc brush ................................................................................................................ 21
Figure 15 Cointainer ................................................................................................................................................ 24
Figure 16 Disc brush with worm gear ..................................................................................................................... 28
Figure 17 Roller brush with spur gear ..................................................................................................................... 29
Figure 18 Fan with worm gear ................................................................................................................................. 29
Figure 19 Force analysis of machine ....................................................................................................................... 30
Figure 20 Front wheel .............................................................................................................................................. 33
Figure 21 Back wheel .............................................................................................................................................. 33
Figure 22 Spur gear ................................................................................................................................................. 34
Figure 23 Type of tooth gear ................................................................................................................................... 36
Figure 24 Worm and worm gear .............................................................................................................................. 39
Figure 25 Parameter of worm gear .......................................................................................................................... 40
Figure 26 Shaft ........................................................................................................................................................ 45
Figure 27 Force analysis of shaft ............................................................................................................................. 46
Figure 28 Bending and shear diagram of shaft ........................................................................................................ 47
Figure 29 Ball Bearing............................................................................................................................................. 48
Figure 30 Disc brush ................................................................................................................................................ 52
Figure 31 roller brush .............................................................................................................................................. 53
Figure 32 Parameter of worm gear .......................................................................................................................... 53
Figure 33 Fan ........................................................................................................................................................... 59
Figure 34 Handle .................................................................................................................................................... 59
Figure 35 Upper cover ............................................................................................................................................. 60
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 LIST OF TABLES
Table 0-1 Table of interpreting customer needs .......................................................................................... 6
Table 0-2 Table of importance need of customer ........................................................................................ 7
Table 0-3 Metrics of target specification ..................................................................................................... 8
Table 0-4 Relative importance of each metric target specification ............................................................. 8
Table 0-5 Concept Screening Matrix......................................................................................................... 22
Table 0-6 Concept Scoring Matrix ............................................................................................................ 23
Table 0-7 Standard tooth system for spur gear .......................................................................................... 36
Table 0-8 Result of spur gear design ......................................................................................................... 38
Table 0-9 Result for Worm and Worm gear .............................................................................................. 42
Table 10 Dynamic and static load on bearing ........................................................................................... 49
Table 11 Result of ball bearing.................................................................................................................. 50
Table 12 Result of worm and worm gear for fan ...................................................................................... 55

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 CHAPTER ONE

INTRODUCTION

1.1 BACK GROUND

Asphalt road cleaning machine involves the use of specialized equipment to remove litter, loose gravel,
soil, pet waste, vehicle debris and pollutants, dust and industrial debris from road surfaces. Street sweeping
equipment can consist of a truck or truck-like vehicle equipped with multiple brushes, pick-up deflector,
holding bin, water sprayer, vacuum nozzle and filter, or a combination of some or all of these features.
Various types of machines have been designed since many years ago for road cleaning purpose.
In 1876, Jacob Endson have invented certain new and useful improvements in street cleaning machines
which consists improved construction of the frame and stays by which the rotary brush is supported,
improved lifting and holding device for the brush, improvement in the manner of attaching and detaching
the driving wheels to and from the drafting shaft and employment of an adjustable independent dust guard,
which is independent of the rotary brush.
In 1916, M.L Osborne have invented new improvements; movably and adjustably supported casing of
simple and improved construction wherein the rotary brush is mounted, improved adjusting means for the
brush carrying casing and simplify and improve the construction of rotary brush. In 1962, H.I Hanson
have invented improvements in a vehicle propelled over the ground; and having a power driven blower or
pump thereon that pumps air out of a box like body of the vehicle, producing partial vacuum therein; and
the vacuum is communicated to a pick up hose or the like; and causes a stream of air to enter the end of
the hose and pick up the material and carry it into the body; and the material is separated from the air in
the body; and the air, pumped from the body is Discharged by the pump into the atmosphere.
In 1992, Davis have invented a street sweeping machine is incorporated in an industrial vacuum machine.
Extending transversely of the vehicle is a center casing in which a brush is rotated by a hydraulic motor.
A vacuum intake hose is connected to the casing and leads to the vacuum machine. The casing may be
raised and lowered between transport and working positions. On one or both sides of the vehicle are sides
or "curb sweeping" casings, likewise containing a hydraulically driven brush and connected to a vacuum
intake hose. The curb sweeping casing is swivel mounted and spring biased outward to follow the curb on
the street being swept.

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In the main centered casing are hydraulically raised and lowered flaps which improves the vacuum which
can be drawn in the casing. Also provided is a stick breaker which breaks up large pieces of debris so that
they may be drawn into the vacuum duct.
Latter asphalt cleaning machine having a vertical chain driven conveyor apparatus has been developed.
The vertical chain driven conveyor apparatus which is provided with a jointed shaft to compensate for
chain wear over the life of the chains is provided with an automatically adjusting chain tension adjustment
system. It is also provided with locking adjustment mechanism to prevent the chains from losing tension
when the sweeper is turned off. An initialization program is operable to restore chain tension when the
street sweeper is started and prevent sweeping operations until a desired chain tension has been indicated.
The majority of mechanical cleaners are mobile units that use a vacuum system to collect the waste
materials. Generally, the suction action is complemented by one or more rotating brushes for dislodging
residues that adhere to the surface of the road. There is a wide range of mechanical sweepers. They vary
in size from very small units controlled by a pedestrian, to large mechanical cleaner mounted on a
vehicular chassis. The large mechanical cleaner generally are equipped with an auxiliary engine to
generate the vacuum and, in some cases, are fitted with a hose that can be controlled by an operator to
pick up refuse from areas that are difficult to reach (i.e., dry leaves from drainage ditches). The operating
speed of the smallest machines is about 2 to 3 km/hr, that of the largest sweepers is 10 km/hr or greater.
Mechanical cleaner are efficient for the collection of light litter, fine dust, and sand from roadways.
The conditions typically found in economically developing countries limit the role of mechanical cleaner
to that of simply supplementing manual sweeping. Mechanical asphalt cleaners normally are found in the
large metropolitan areas of developing countries. The degree to which mechanical asphalt cleaners are
utilized for a specific application should be based on thorough analyses of advantages and disadvantages,
as well as the costs associated with using them as opposed to using manual sweepers. In addition,
mechanical sweepers have the tendency to be extremely maintenance-intensive units. The internal
mechanisms may be damaged in the process of collecting large objects illegally disposed on the streets.
Consequently, these machines should be supported by well-equipped maintenance facilities

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1.2 PROBLEM STATEMENT AND JUSTIFICATION
There is an urban solid waste management problem facing cities in the developed and developing world.
Then it is important to design a device which is capable of collecting litters or wastes from asphalt road
in safe manner, with minimum cost and time, and that are necessary to the developing nations those unable
to buy mechanical broom cleaners and high-efficiency vacuum-assisted machines. In our country, the
asphalt cleaning process is done manually using brooms, shovels, and handcarts. Hence, it is not efficient
to collect large enough litters within optimum time. It also affects the health of the people, exposing them
to dust and poisonous substances. The cleaning quality using broom is lower than that of cleaning quality
using machines. As a result less cost but easy to drive and to collect solid wastes, with manually driven
machine become essential.

Figure 1 Asphalt cleaner with broom

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1.3 OBJECTIVE
General Objective
The main objective of this project is to design and model asphalt cleaner machine.
Specific Objectives
 To select possible and economical for cleaning mechanism.
 To design and analyze components of the Asphalt cleaner machine
 To make drafting and 3D model with CATIA software.
 To study if the developed machine is suitable for different types of cleaning machines

1.4 Scope of this Project

 The machine is manually driven, and capable of reducing the cost of road surface cleaning work
 The cost analysis is approximate guess
 The customer need is assumed, it’s not actual assessment

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1.5 METHODOLOGY
1.5.1 Data Collection methods
The whole data will be gained through the two perspectives.
Primary Data: - Direct observation, formal and informal interview with different workers and from
written data.
Secondary Data: - Different research works and compactor manufacturing foreign companies from
internet.
1.5.2 Identifying Customer Needs
1.5.3 Concept Generation
1.5.4 Concept Selection
Concept Selection Is an Integral Part of the Product Development Process
 Concept Screening
 Concept Scoring
1.5.5 Product Specifications
1.5.6 Design Analysis
Finally these series of sequential steps to design the Asphalt cleaner machine are followed.
 Understanding the traditional way of cleaning from the road is done by manually using brooms,
shovels, and handcarts
 Gathering and reviewing literatures on the asphalt road cleaning machine
 Product design and development process will be followed while designing
 Selecting feasible and cost-effective mechanism for the asphalt cleaner machine
 Design the components and check their failures and stress
 Selection of material for the components
 Virtual design using CATIA
 Design of the manufacturing procedures and steps

Design definition, Collecting Design

Design need specification and relevant concept
requirement information of generation
design

Material selection
Design model Design Design for design
evaluation analysis analysis
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1.6 RESULT AND DISCUSSION
A. Identifying Customer Needs

Step 1: Gather Raw Data from Customers

To identify customer needs, we started by gathering raw data from the people that are work on the asphalt
cleaner of Mekelle university and Mekelle city. The team used one to one interview method for collecting
data and the interviews were conducted at Mekelle University and Mekelle city office. And we observe
by watching the video of this machine.
Step 2: Interpret Raw Data in Terms of Customer Needs
After getting voice of customers, the data was translated in terms of customer requirements. For
conversion from raw data to interpreted customer needs, we are followed the basic guidelines such as use
of positive phrases, avoiding use of must and should, expressing the needs in terms of product attributes.

Table 0-1 Table of interpreting customer needs

Question Customer needs Interpreted need

Typical uses I need to easily drive machine Can easily drive by any person.
By small effort.
I need the machine that have The machine have a fan that increase
High cleaning capability. the cleaning capability.

Likes-current tool I like a machine of small The machine is small weight

weight. And we can carry the machine.

Dislike-current tool I don’t like missing spare parts There is spare parts for every
during maintenance. materials.

I don’t like the machine when it The machine have no sound.

makes sound.
Suggested Would be nice if the handle The machine have the adjustable
improvements adjustable. handle and can adjust at every height.

Step 3: Organize the Needs into a Hierarchy

 The machine can easily drive by any person.
 It need less effort
 The handle is adjustable
 The machine have less weight and can carry the machine.
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  And have high cleaning capability
 Maintenance can be easily performed
 This Machines Almost Have No Sound, It doesn’t disturb during functioning
Step 4: Establish relative importance need
Relative importance is a value that is subjectively allocated to customer needs on a scale stars. Ranges
from 1 to 5 stars are selected to rank the customer needs; where 5 stars indicate the least important need.
Whereas 1 star represents the most important need. The importance of needs was taken according to the
voice the customers. The relative importance of needs is shown in the following Table.
Table 0-2 Table of importance need of customer

Need Importance
ACM have adjustable handle *
ACM need less effort **
ACM can easily drive ***
ACM have no sound ***
The machine have small weight and we can ****
carry.
ACM have high cleaning capability *****

Establishing Target Specifications

We were considered the following steps / process to establish the target specifications. The process of
establishing the target specifications contains four steps:
1. Prepare the list of metrics.
2. Collect competitive benchmarking information.
3. Set ideal and marginally acceptable target values.
4. Reflect on the results and the process.
1. Prepare the list of metrics.
A list of matrices for each of the customer needs to establish the relationship between the requirements of
the design (stated from the customer’s point of view) and the product characteristic (in engineering terms).
These matrices are generally referred to as the preliminary specifications which are established after
identifying customer needs and before concept generation. The list of matrices for the ACM and the
relative importance of each metric and the units for the metric are shown below.

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Table 0-3 Metrics of target specification

Metric Needs No.s Metric Important Units

No.
1 28 Light in weight 4 Kg
2 15 Safety 2 Subj.
3 10 Noise 3 Subj.
4 18 Life time 3 Year
5 12 Spare parts 2 Pcs
6 3, 13 Assembly time 3 S
7 30 Cleaning capability 5 Subj.
8 9 Manufacturing cost 3 Eth.birr
9 10 Easily driven 2 Subj.

The relative importance of each metric and the units for the metric.
Table 0-4 Relative importance of each metric target specification
1

9
Cleaning capability

Manufacturing cost
Metrics

Light in weight

Assembly time

Easily driven
Needs
Spare parts
Life time
Safety

Noise

1 Least noise and vibration ■

2 Easily operate ■ ■
3 Helps to save time ■
4 User friendly ■
5 Easily maintain ■
6 Light, decrease weight ■
7 Helps to save human effort ■
8 Works for a long time ■ ■
9 Removable and easily assembled ■

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1.7 EXPECTED OUT PUT
After design of asphalt cleaning machine we would expect with the following output.
 The machine is minimize human effort and number of worker
 The machine would work in suction of the unwanted solid materials from the asphalt road.
 Cleans the asphalt road without dust explosion or air pollution so it is better to health of the workers
and peoples of the city and the city will be very attractive.

1.8 SIGNIFICANCE OF THE STUDY

It also prevents dust from being blown up without spraying water on the road surface during the cleaning
process. At optimum working speed, it absorbs dirt efficiently without damaging the road surface.
Moreover, it applies an absorbing force to the debris effectively. It is easy to operate that means it works
by pushing the machine or human powered. When we compare to other mechanical broom cleaners and
high efficiency vacuum assisted machines it reduces air pollution, easy in maintenance, not expensive, it
has small components.
Manual asphalt road cleaning machine is effective from the asphalt cleaning process is done manually
using brooms, shovels, and handcarts because they affects health of the people and beauty of the city,
manual asphalt road cleaning machine reduces human effort, quantity of workers, saves cost of workers
so economically it is preferable to our country.

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 CHAPTER TWO

LITERATURE REVIEW
Literature review is a written work and evaluative report of information found in the literature related to
manual asphalt road cleaning machine and it helps us in the theoretical and methodological contributions
of the machine.
Our literature review consists two basic things related to machine:
 Literatures about different types of manual asphalt road cleaner machine like bicycle asphalt
road cleaner machine, vacuum assisted cleaner machine, mechanical broom cleaner,
 Literatures about the debris or solid wastes like types of solid wastes, quantity’s and sources
of solid waste.

2.1 Literature on road cleaner machine

2.1.1 Bicycle asphalt road cleaner
In this paper the authors Jialei Cheng and Diniece Peters had identify new strategies to address severe
urban delivery challenges resulting from congested roads and inadequate loading space. One solution with
the potential to achieve benefits for the city, for carriers, and for shippers while making use of the City’s
rapidly growing bicycle infrastructure is freight distribution from an urban micro-consolidation Center
(UMC) via human-powered or electrically-aided freight-tricycle. UMCs have been Successfully
implemented in Paris and London; this study details the results of a comparative Analysis evaluating
economic, infrastructure, and regulatory conditions in the three cities for the purpose of identifying
opportunities and challenges for future implementation in Manhattan.

Figure 2 Bicycle asphalt road cleaner

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2.1.2 Vacuum cleaner machine
Vacuum sweepers may be compared to a household vacuum system. An engine powers a fan, which creates
a vacuum and therefore suction. Typically, there is a suction inlet on one side of the sweeping head, and
the “used” air is constantly exhausted during the sweeping process. These machines employ some type of
broom system to brush debris toward the vacuum opening in the head. These brooms are called windrow
brooms. Vacuum machines usually have gutter brooms, as do most sweepers of all types. Part of the
impetus for the advent of vacuum sweepers was the recognition that the majority of debris, especially the
heavy debris, is collected within 36 inches of the curb line.
Vacuum sweepers are designed to do an effective job of cleaning within this area. Some vacuum sweeper
models are designed to remove only material accumulated within 36 inches (1 meter) of the gutter itself
and employ only gutter brooms to brush debris toward the vacuum opening in the head In areas where
cleaning the entire lane width via air is considered paramount, vacuum sweepers are probably not as
effective as the regenerative air sweeping technology (discussed below). Another disadvantage of vacuum
sweepers is they are expensive from the mechanical broom cleaner and that the windrow broom tends to
fill pavement irregularities with debris that can’t be removed since this windrow area is not being
vacuumed.
Even though vacuum type sweepers typically use water-based dust suppression systems, traditional
vacuum sweepers exhaust a high level of particulates into the atmosphere on a continual basis. While they
seem to do a generally better job than brush sweepers in removing and retaining these small particles, the
level of the emissions of fine particles can still be significant if fugitive dust losses are not controlled.
2.1.3 Mechanical Broom cleaner
Mechanical broom sweeping technology may be likened to cleaning with a broom and a dustpan. For
decades, this was the only type of sweeper available for use by cities, counties, and other agencies. Even
with the advent and continual improvements in the other types of sweepers (to be described later),
mechanical broom sweepers remain as the primary type of machine in use today. Typically, these machines
have a main broom that runs transversely from one side of the sweeper to the other such that the broom
bristles contact the paved surface the full width of the sweeper unit. Collected debris is swept onto some
type of a conveyor for transfer to a containment hopper. Mechanical broom machines are usually outfitted
with gutter brooms. Gutter brooms are relatively small (i.e., typically 36 to 50 inches in width, or 1 to 1.5
meters) and located to the left, right, or both sides of the sweeper. They are primarily used to transfer debris
from the gutter line into the path of the sweeper still tend to create a substantial amount of dust in dry
weather. The use of water during sweeping transforms the accumulated street dirt into a mud-like substance
whose removal becomes more difficult. Recent sweeper pickup performance studies have shown that the

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mechanical sweeper model tested with the use of water increased the remaining mass of material by 124%
when compared to the same sweeper operated without the use of water (Sutherland 2009b).
In recent times, it has been recognized that modern air sweepers (discussed below) have many advantages
over mechanical broom sweepers for general road sweeping usage. One reason is that most mechanical
sweepers only give the illusion of leaving a clean pavement surface. Although large debris is removed by
mechanical broom sweepers, most are ineffective at removing small particles on the order of 60 microns
and smaller. Studies have even shown that, from an environmental standpoint, some mechanical broom
sweepers may actually have a negative effect on the amount of storm water runoff pollution (Pitt 1979).
This is because the action of the broom tends to break larger particles down into smaller ones, creating
more small-micron particles than there were to start with. And, whenever debris pickup is via an elevator
rather than involving any type of air/suction action, a large amount of these small particles are left on the
pavement’s surface.
Broom sweepers remain the standard for sweeping extremely heavy or packed- down material, and for
sweeping deicing sand in cold-climate regions. However, most mechanical sweepers are a poor choice for
sweeping programs designed to improve water and air quality. It must be noted that this discussion relates
to the great majority of broom sweepers in use throughout the country. The author does know of one broom
sweeper that has been engineered to provide greater pickup efficiencies for smaller-micron particles. The
characteristics of this specific model have dramatically increased the pickup performance expected of most
mechanical machines and will be described later in the High-Efficiency Sweeper section.
2.1.4 Regenerative Air Sweepers
Generally speaking, regenerative air systems are more environmentally friendly than are vacuum or
mechanical broom sweepers. There are several factors that contribute to this. Regenerative air sweepers
employ a closed-loop “cyclonic effect” to clean. They are similar to vacuum sweepers in that there is a
similar vacuum inlet located on one side of the sweeping head. Unlike vacuum machines, however,
regenerative air sweepers constantly recirculate (regenerate) their air supply internally. To accomplish this,
the recirculating air is blasted into the sweeping head on the side opposite the pickup, or inlet, tube.
Essentially, the air “blasts” down onto the pavement on one side of the head, travels across the width of
the head (gathering debris with it as it goes), and then travels up the pickup hose on the other side with the
debris. Manufacturers design their sweeping heads so as to swirl the air, so it will retain the collected debris
within the airstream as it moves from the blast to the intake side of the head.

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2.1.5 High-Efficiency Sweepers
This is a relatively new technology that employs various fugitive dust loss controls and includes a variety
of different types of machines such as vacuum, regenerative air, and one known mechanical broom
machine, for example, to efficiently remove accumulated wastes and associated organic material. The key
to the current definition of a high-efficiency sweeper is that these machines not only remove a high level
of accumulated material of all sizes (but especially small-micron material less than 60 microns), but also
are designed to control fugitive dust losses. This means they are designed to exhaust no visible fugitive
dust, and most are designed to sweep without water. Not having to deal with water is a huge plus in terms
of time savings and fuel savings, because water is heavy and adds to the machine’s weight that has to be
transported.
The term high efficiency sweeper was first coined by the author in 1997 to describe a brand-new vacuum
sweeping technology that employed a sophisticated filtration system for dust containment in combination
with the use of both main and gutter brooms (Sutherland and Jelen 1997). This high-efficiency vacuum
sweeper (which is no longer in production) was developed by Enviro Whirl Technologies of Centralia, IL,
in 1995 and later acquired by Schwarze Industries of Huntsville, AL, in 1999. The EV-series machines
that Schwarze built and marketed based on the original Enviro Whirl design employed a unique self-
cleaning filtration system that can filter “dust” and exhaust only PM less than 2.5 microns. Fugitive dust
control was not available at that time by any other sweeper in the nation. And because the EV-series fan
operated only in filtered air with no debris or dust coming in contact with the blades, the manufacturer
could provide a lifetime guarantee for the fan, which was unheard of at the time.

2.2 Literature on types of debris in Mekelle University

Debris type and characteristics

Solid wastes could be defined as non-liquid and nongaseous products of human activities, regarded as
being useless. It could take the forms of refuse, garbage and sludge. Information on the nature of debris
on roads, its composition, physical and chemical characteristics and the quantities generated are basic
needs for the design of appropriate cleaning device.

Types of solid wastes in Mekelle University

 Paper
 Plastics
 Leaf from the tree
 Metals
 Sand around building
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  Food wastes
 Textiles
 Ashes
 Concrete around new construction sites
 Dirt
 Steel and wood around new construction
 Wood

Figure 3 Debris like paper, plastics and leaf

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 Figure 4 Debris concrete around new constructions

Figure 5 Debris leaf from the tree

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 Figure 6 Debris sand/soil

Figure 7 Food debris around the cafe

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They store the debris by this way for a long time.

Figure 8 Debris storing mechanism

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 CHAPTER 3

DESIGN CONCEPTS AND SELECTION

The conceptual design phase included primarily the determination of the general layout and design of
the road cleaning mechanism.
3.1 Concept Generation
Concept A
The source of power for this machine is direct human power applied on the handle. Worm gear pairs were
selected to transmit the front wheels rotational motion to the vertical axis rotation of the disc brushes. Spur
gears were selected to transfer back wheels rotational motion for horizontal axis rotation of roller brush.
Full mechanical system.

Figure 9 concept A

Concept B

In these concept there is two idea

Idea 1
The source of power for this machine is direct from the Bajaj (three wheel) motor or from the rotation of
the Bajaj wheel i.e. the worm gear rotates by the rotation of the front wheel of the Bajaj and the spur gear
also rotates by the rotation of the back wheel of Bajaj.
Idea 2
Attaching the concept 1 machine to the Bajaj, by increasing the size of that machine.

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 Figure 10 Concept B with Bajaj

Concept C

The compressor or fan used to clean very fine sand or to dislodge debris from the asphalt. When the fan
or compressor rotate it blow the fine sand and dislodge debris from the asphalt to the container.

Figure 11 Concept C with blower

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Concept D

In this concept it suck the fine sand or debris from the asphalt that not clean by the roller brush and disc
brush. So it have high efficiency. Creating vacuum on the back of the container to suck the fine sands.

Figure 12 Concept D with Fan

Concept E

In this concept the machine operate by motor. The roller brush and the disc brush rotate by the rotation of
the motor that attached on the above of the machine. Motor instead of spur and worm gear to rotate disc
brush and roller brush.

Figure 13 Concept E with motor

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Concept F

The same with the concept one but this mechanism have only one disc brush to collect the debris to the
roller brush.

Figure 14 Concept F with one disc brush

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3.2 Concept Selection

Table 01 Concept Screening Matrix

Selection criteria Concept-A Concept- Concept - Concept- Concept- Concept-

(reference) B C D E F
Cost 0 - - - + +
Weight 0 - - - - +
Easy 0 + - + + +
manufacturing
Dust blowing up 0 0 - + 0 -
Power 0 + 0 0 0 0
consumption
Space utilization 0 - 0 0 0 0
Design complexity 0 - - 0 - 0
Quick operation 0 + 0 0 0 0
High efficient 0 0 + + 0 -
Require skilled 0 - 0 0 0 0
man power
less maintenance 0 - + + + 0
Sum of + 0 3 2 4 3 3
Sum of 0 11 2 4 5 6 6
Sum of - 0 6 5 2 2 2
Sum of (+ and -) 0 -3 -3 2 1 1
Rank 3 3 1 2 2
All the above design concepts have their own advantages and disadvantages. After this screening four
concept (concept A, concept D, concept E and Concept F) are selected. From this concept by rating we
select one concept.

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Table 02 Concept Scoring Matrix

Selection Concept A Concept D Concept E Concept F

criteria (ref)
Weigh ratin Weighte ratin Weighte Ratin Weighte ratin Weighte
t g d g d g d g d
scored scored scored scored
Cost 10% 3 0.3 3 0.3 2 0.2 3 0.3
Weight 5% 3 0.15 3 0.15 3 0.15 3 0.15
Ease 5% 3 0.15 3 0.15 3 0.15 3 0.15
manufacture
Dust 10% 4 0.4 4 0.4 3 0.3 2 0.2
blowing up
Power 15% 3 0.45 3 0.45 3 0.45 2 0.3
consumptio
n
Space 5% 2 0.1 2 0.1 2 0.1 3 0.15
utilization
Design 5% 3 0.15 2 0.1 2 0.1 3 0.15
complexity
High 35% 3 1.05 5 1.75 4 1.4 3 1.05
cleaning
capability
Require 5% 2 0.1 2 0.1 2 0.1 2 0.1
skilled man
power
Less 5% 3 0.15 3 0.15 3 0.15 3 0.15
maintenance
Total 3.0 3.65 3.1 2.7
Score
Rank 3 1 2 4

Therefore, to select the best concept we made concept screening matrix and we select concept D.

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Store debris in dirt container: We want to design the medium size container that a single person can
unload the container easily.

Figure 2 COINTAINER

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 3.3 Overall Product Specification of our design
Based on the above machine requirements specification of the product specifies as follow:
Sweeping width: 1200 mm
𝐤𝐠
Density of debris = 297𝐦𝟑

Mass of the machine maximum: 28kg with debris in the container

Maximum sweeping capacity: 2400 square meter per hour
Human average speed=1.1m/s
Human average power=110watt
Container capacity: 0.12 m3

3.4 Function Structure

To simplify the design process and to get plenty of alternative concepts, it important to establish function
structures.
3.4.1 Overall function structure
The overall function shows the problem in general with inputs and output relationships. Here the inputs
are material (debris on roads), energy (human power) and fan motor whereas the outputs are material
(debris on dirt container) and energy (kinetic energy).

Human power Debris on container

Overall function
Debris on street
Kinetic energy

Fan

System Synthesis
To fulfill the overall function, it is then necessary to generate overall solutions by combining the working
principles into a working structure. The basis of such a combination is the established function structure,
which reflects logically and physically possible or useful associations of the sub functions .The disturbing,
gathering, lifting and moving sub functions are fulfilled by same function carrier as shown in the selected
design concepts. To satisfy the overall function, the working principles of the various sub functions have
been combined and this combination results in the working structure of a solution. It is through this
25 | P a g e
combination of working principles that the solution principle for fulfilling the overall task can be
recognized. The working structure derived from the function structure thus represents how the solution will
work at the fundamental principle level. The designs which are necessary to build the system are shown in
figure below as working structure.

Manual driven asphalt

cleaner machine

Brush Handle Gear system Dirt Fan (sucker) Wheel

assembly container assembly

Worm gear

Disc brush Roller brush Worm gear Spur gear Front wheel Back wheel

Figure 4-8 Schematic diagram of working structures

3.5 Power Transmission

Power transmission is the movement of energy from its place of generation to a location where it is applied
to performing useful work. The source of power for this machine is direct human power applied on the
handle. When the average human force is applied on the handle, it directly pushes the wheels of the machine
hence it moves forward. The power can be transmitted to the required point using mechanical components
such as shaft, and gears. Among these, worm gear pairs were selected to transmit the front wheels rotational
motion to the vertical axis rotation of the disc brushes whereas spur gears are selected to transfer back
wheels rotational motion for horizontal axis rotation of roller brush.
Manual asphalt cleaner machine comprises two worm gear mechanisms and two spur gear mechanisms.
The worm gear is connected to the front wheel to change the direction of rotation of wheel to the disc brush.
Hence the rotation of the front wheel gives angular motion of the disc brush through worm gear which
enables it to dislodge and collect debris from street to roller brush. The forward motion of the disc brush
with respect to the ground is gained from the translational motion of the wheels.
The spur gear mechanisms enable the roller brush to gather fine debris towards dirt container. The spur
gears are mounted on shaft that connects the two back wheels while the pinion gears are mounted under
frame that supports the dirt container. The roller brush is engaged in the pinion gears. The sizes of

26 | P a g e
 Wheels and gears have great influence on the cleaning efficiency of both the roller and disc brushes.
Therefore, the kinematic relations have been established. Worm gear is rigidly mounted on the front wheel
and connected to disc brush holder using shaft. The disc brush is attached on the disc holder. The disc
brush holder rotates freely on the disc brush holder frame which is rigidly mounted on the front enclosure
and frame and it is adjusted by pulling or pushing the adjuster bar. On the other hand the spur gear is
mounted on back wheel and engaged with pinion gear. The roller brush is connected to both left and right
sides pinion gears so it can get rotation and torque. Shaft balances the rotation of both back wheels. When
the machine moves forward the two disc brushes rotate inward about perpendicular axis to the guider plate
and the roller brush rotate towards dirt container in horizontal axis.
Obviously, this motion transmission from wheels to brushes is not a direct drive, therefore, the relations
between the linear velocity of the machine and the angular velocities of wheels as well as the angular
velocity of the gears and brushes have to be established.

Rotation of Motion of
disc brush coarse debris

Translational
Debris in dirt
Human power rotational motion
container
of wheels

Rolling of Motion of
roller brush fine debris

Worm gear Fan Suck the fine Debris in

debris container

Figure 4-9 Overall power transmission

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3.6 GENERAL WORKING PRINCIPLE OF THE MACHINE
Here in this design all the cleaning process is done by the force applied by the machine operator. The process
is started from the man who droves the machine. As he/she pulls the handle the force make the wheel to
rotate (both the front & the rear wheels). After this there is three stage to collect the debris,.
1ST STAGE
In the first stage the disc brush collect and dislodge debris that attached to the asphalt. And deliver debris
to the roller brush.

Wheel
Shaft rotation Gear rotation Worm rotation
rotation

Shaft with Disc brush Both cleaning and delivering dirties to

worm rotation rotation the roller brush operation is done

Figure 3 Disc brush with worm gear

2ND STAGE
In this stage the roller brush store or deliver debris in to the container the debris that collected by the disc
brush.

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 Wheel
Shaft rotation Spur gear rotation Pinion Gear rotation
rotation

Roller brush Both cleaning & delivering dirties to the container operation is
rotation done.

Figure 4 Roller brush with spur gear

3rd STAGE
At the last stage there is a fan that suck a very fine sands at the back of the machine.

Wheel rotation Shaft rotation Gear rotation Worm rotation

Shaft with
Fan rotation Sucking of fine dust, sand … is done
worm rotation

Figure 5 Fan with worm gear

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 CHAPTER FOUR

DESIGN AND ANALYSIS

A. FORCE ANALYSIS ON THE MACHINE

Figure 19 Force analysis of machine

work done = W = Fx ∗ d And also the work done=power*time

W=P∗t
d
P = Fx ∗ t average human power P =110watt
d
V= V average speed of human = 1.1m/s
t
P = Fx ∗ V
P 110watt
Fx = = = 100N
V 1.1m
s
θ is taken to be 300 to drive the machine easily
F = Fx/cos θ
100
F= = 115.47N
cos30
 Fy = Fx tan30 = 100 ∗ tan30 = 57.73N
To get the normal force that support two wheel
ΣFy = 0
F1 + F2 − Fy − W = 0
ΣMA = 0
1 Fxc
( ) (−Wa − Fya) + F2(a + b) + =0
2 2
From this two equation
Wa + Fya Fxc
− 2
F2 = 2
a+b
W + Fy
F1 = − F2
2
W is weight of the machine plus debris in the container plus fan which is equal to 280N.
a=b=0.15m
c=0.3
Then F1 = 134.45N and F2 = 34.4N
The static friction forces can be obtained using Newton’s law of motion:
ΣFx = ma = 0
Fx − (Ff1 + Ff2) = 0
Fx − (μF1 + μF2 ) = 0 μ1 = μ2 = μ
Fx = μ(F1 + F2 ) = 0
1 (Fy+W)b+Fxc 1 (Fy+W)a−Fxc
Fx = μ(2 [ ] + 2[ ])
a+b a+b
μ
Fx = (F + W)
2 y
μ
To move the machine 2 (Fy + W) < Fx

The static coefficient of friction of nylon on asphalt is 0.4 and substituting the values in
0.4
(57.73 + 280) = 67.546N < 100N
2
Torque produced by the rotation of wheels is computed as follows:
From front wheel
1 1
Tfw = Ffw ∗ r Ffw = 4 Fx = 4 ∗ 100 = 25N

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 = 25 ∗ 0.061 = 1.525Nm
Back wheel
Tbw = Fbw ∗ R
= 25 ∗ 0.115 = 2.875Nm

B. DESIGN OF THE WHEEL

The wheels have two purposes: 1) to support and move the machine 2) The front wheels serve as
a source of rotational motion for the worm and worm gears while the back wheels for the spur
gears. Therefore, the wheels should have flat surface in the side that the gears to be joined. The
gears are joined to the wheels by using bolts and nuts, rivets, adhesives or can be manufactured as
integral part of the wheels. The sizes of the wheels are determined based on the average angular
speed of disc brush for front wheels whereas roller brush speeds for back wheels. Hence the linear
speeds of the wheels are given as human average working speed which is 1.1m/s.
Material selection for the wheel
 Rubber
Reason for selection
 Good strength
 Ease of fabrication
 Good corrosion, wear and abrasion resistance
 They have the ability to reduce weight and noise
V
ωfw =
R
V
ωbw =
r
ωfw And ωbw was determined based on the recommended angular speed of brushes for effective
cleaning and from gear design section we get ωfw = ωw = 18rad/s and ωbw = ωg =
9.5rad/s. The radius of front wheel and back wheel will be-

32 | P a g e
 1.1
Rfw = = 61mm
18

Figure 20 Front wheel

1.1
Rbw = = 115mm
9.5

Figure 21 Back wheel

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There are standard wheels available in market with different sizes and loading capacities. Thus,
the selected wheels should have the following features:
• Ergonomic: extraordinarily easy to push
• Wheel dampens shock and vibration thus reducing noise.
• High impact strength: resists fracture from repeated shock loads.
• Higher resilience: wheel returns to original shape without deforming when deflected by loads or
rapidly applied stresses.
• Longer life: shows minimal wear in extended use-resists abrasion, water and many hazardous
chemicals.
• Chemical resistance

C. DESIGN OF SPUR GEAR

Teeth is parallel to axis of rotation and transmit power from one shaft to another parallel shaft.
 It transmits exact velocity ratio.
 It may be used to transmit large power.
 It may be used for small center distances of shafts.
 It has high efficiency.
 It has reliable service.
 It has compact layout.

Figure 22 Spur gear

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The objective of design of the spur gear set is to transmit motion from back wheels to the roller
brush with high velocity ratio. Therefore, it is kept the number of teeth of the gears as low as
possible to minimize weight and cost while still fulfilling the design objectives. The input
parameters which are necessary to determine the size of gear are discussed in this section.
Material for spur gear
Gears are commonly made of cast iron, steel, bronze, phenolic resins, acetal, nylon or other
plastics. The selection of material depends on the type of loading and speed of operation, wear life,
reliability and application. Cast iron is the least expensive. ASTM / AGMA grade 20 is widely
used. Grades 30, 40, 50, 60 are progressively stronger and more expensive. CI gears have greater
surface fatigue strength than bending fatigue strength. Better damping properties enable them to
run quietly than steel. Nodular cast iron gears have higher bending strength together with good
surface durability. These gears are now a days used in automobile cam shafts. A good combination
is often a steel pinion mated against cast iron gear. Steel finds many applications since it combines
both high strength and low cost. Plain carbon and alloy steel usage is quite common.
Through hardened plain carbon steel with 0.35 - 0.6% C are used when gears need hardness more
than 250 to 350 Bhn. These gears need grinding to overcome heat treatment distortion. When
compactness, high impact strength and durability are needed as in automotive and mobile
applications, alloy steels are used. These gears are surface or case-hardened by flame hardening,
induction hardening, nitriding or case carburizing processes. Steels such as En 353, En36, En24,
17CrNiMo6 widely used for gears. Bronzes are used when corrosion resistance, low friction and
wear under high sliding velocity is needed as in worm-gear applications. AGMA recommends Tin
bronzes containing small % of Ni, Pb or Zn. The hardness may range from 70 to
85Bhn.Nonmetallic gears made of phenolic resin, acetal, nylon and other plastics are used for light
load lubrication free quiet operation at reasonable cost. Mating gear in many such applications is
made with steel. In order to accommodate high thermal expansion, plastic gears must have higher
backlash and undergo stringent prototype testing.
So for our design plastic (nylon) gear is good because of
 relative low cost
 resistance to corrosion
 reduction in weight (about 15% the weight of steel)
 low inertia

35 | P a g e
  self-lubrication capacity
 potential for noise reduction
 color coding capability for fast, error-free assembly,
Table 0-1 Standard tooth system for spur gear

200 full depth involute gear-for high load-carrying capacity.

Figure 23 Type of tooth gear

200 full depth involute gear-for high load-carrying capacity.

Teeth of pinion and gear
2Aw
Tp = Aw=1, G=5 and 200 pressure angle
1 1
G[√1+ ( +2)sin2 φ)−1
G G

36 | P a g e
 1
Tp = 2 ∗ = 15.74 = 16
1 1
5√1 + ( + 2) sin2 20 − 1
5 5
Tg = 5 ∗ 16 = 80
Module=m=2mm
Pitch circle diameter of gear and the pinion
Dg = mTg = 2 ∗ 80 = 160mm
Dp = mTp = 2 ∗ 16 = 32mm
From the wheel the angular speed of the back wheel=ωbw = 9.5rad/sec
60 60
Ng = ωbw ∗ = 9.5 ∗ = 90.7RPM
2π 2π
Np = 5 ∗ 90.7 = 453.5RPM

Power transmitting capacity of plastic spur gears:

The characteristics of gears made of plastic materials are so different from those of metal gears
that they should be considered in a class by themselves. Because of the low modulus of elasticity,
most of the effects of small errors in tooth form and spacing are absorbed at the tooth surfaces by
the elastic deformation, and have but little effect on the strength of the gears.
The allowable tangential force (Wta) kilogram force (Kgf) at the pitch circle of nylon spur gear can
be obtained from the Lewis formula.
Wta = m ∗ y ∗ b ∗ σb ∗ f
Where
Wta=allowable tangential force
m=module=2
y=tooth profile factor at pitch point=0.296(for 200 full depth gear)
b=face width 9m<b<14m
b=10m=10*2=20mm
ϭb =1.25Kg/mm2 for unlubricated
f=1 for unlubricated
Wta = 2 ∗ 0.296 ∗ 20 ∗ 1.25 ∗ 1 = 14.8Kg = 14.8 ∗ 9.81 = 145.188N
Tangential force on spur gear (Wt)
2000∗T
Wt = Where T is the torque on the back wheel Tbw=2.875Nm
Dg

37 | P a g e
 2000 ∗ 2.875
Wt = = 35.93N
0.16
Radial force on the spur gear
Fr = Wt tan φ = 35.93 ∗ tan 20 = 13.07N
allowable tangential force
Factor of safety =
tangential force on spur gear
145.188
FS = = 4.04 > 1 … … … so its safe.
35.93
Torque output on the pinion
Tg 2.875
To/p = = = 0.575Nm
VR 5
Table 03 Result of spur gear design

No Specification (symbol) Formula Gear dimension Pinion

dimension
1 Module (m) 2mm 2mm
2 Pressure angle(φ) 200 200
3 Number of teeth(T) 80 16
4 Diameter of pitch circle(D) D=T*m 160mm 32mm
5 Addendum (a) 1m 2m 2mm
6 Dedendum(b) 1.25m 2.5mm 2.5mm
7 Input torque(Ti/p) Equal to Tbw 2.875Nm
8 Output torque(To/p) Tg 0.575Nm
To/p =
VR
9 Tangential force(Wt) 2000∗T 35.93N 35.93N
Wt = Dg

D. DESIGN OF WORM AND WORM GEAR

The worm gears are widely used for transmitting power at high velocity ratios between non-
intersecting shafts that are generally, but not necessarily, at right angles. It can give velocity ratios
as high as 300: 1 or more in a single step in a minimum of space, but it has a lower efficiency. The
worm is generally made of steel while the worm gear is made of bronze or cast iron for light
service.

38 | P a g e
 Figure 24 Worm and worm gear

Types of Worm Gears

1. Straight face worm gear- is like a helical gear in which the straight teeth are cut with a form
cutter. Since it has only point contact with the worm thread, therefore it is used for light service.
2. Hobbed straight face worm gear - is also used for light service but its teeth are cut with a hob,
after which the outer surface is turned.
3. Concave face worm gear- is the accepted standard form and is used for all heavy service and
general industrial uses. The teeth of this gear are cut with a hob of the same pitch diameter as the
mating worm to increase the contact area.
Straight face worm gear selected because the machine operate on the light load.
The objective of design of the worm and worm gear set is to transmit motion from front wheels to
the disc brushes with low velocity ratio.
By considering space, material and center distance between gears, the following gear parameters
were selected.
The worm is generally made of steel while the worm gear is made of bronze or cast iron for light
service. (From book of machine design (gupta))
Material selection for worm gear
Worm –steel
Worm gear-phosphorus bronze

39 | P a g e
 Figure 25 Parameter of worm gear

By considering
 Space
 Material
 Center distance between gears
Let
Module=m=2.5mm
Velocity ratio (VR) =6
From the table 31.2(a text book of machine design (gupta)) for velocity ratio of 10 the number of
start or n is equal to 6 (sextuple).

So n=Tw=4

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From VR and n can calculate worm gear teeth
Tg
VR =
n
Tg = VR ∗ n = 4 ∗ 6 = 24
Then the rotation or speed of worm is
Nw
VR =
Ng
Where
Ng = Nfw = 172RPM
Nw = 6 ∗ 172 = 1032RPM
From the module and worm gear teeth can calculate pitch diameter of worm gear.
Dg = mTg = 2.5 ∗ 24 = 60mm
Pitch circle (Pc) =axial pitch (Pa) =πm=π*2.5mm=7.85mm
From the axial pitch and n can calculate lead.
L = Pa ∗ n = 7.85 ∗ 4 = 31.4mm
Pitch diameter of the worm
Dw = 3 ∗ Pa = 3 ∗ 7.85 = 23.55mm
Then can calculate lead angle
L 31.4mm
tan λ = = = 0.424
πDw π ∗ 23.55mm
λ = 230
From the table 31.1 (a text book of machine design (gupta) for the lead angle of 16 ≤ λ ≤ 25 the
recommended angle is 200 pressure angle.

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Table 04 Result for Worm and Worm gear

No Particular Formula Worm Worm gear

1 Pressure angle(ȹ) 200 200
2 Module(m) 2.5mm 2.5mm
3 Number of teeth(T) 4 (Quadruple) 24
4 Addendum(a) a=0.286Pc 2.245 -

5 Hub diameter 1.726Pc+25mm 38.54mm -

6 Face length(Lw) Pc(4.5+0.02Tw) 35.971mm -
7 Maximum bore shaft Pc+13.5mm 21.35mm
8 Outside diameter of worm Dg+0.8903Pc 67mm
gear
9 Face width(b) 2.15Pc+5mm 21.8775mm
10 Throat diameter(Dt) Dg+0.572Pc - 64.5mm
11 Depth of tooth (h) 0.623 pc 4.89mm
12 Lead (L) L=Pa*n 31.4mm
13 Lead angle (𝛌) 𝐦. 𝐧 230
𝐭𝐚𝐧 𝛌 =
𝐃𝐰
14 Pitch circle diameter (D) 23.55mm 60mm

Checking for tangential load

T
Wt = 2 ∗
Dg
T torque of worm gear that is equal to torque of front wheel. Tfw = T = 1.525Nm
1.525
Wt = 2 ∗ = 50.83N
0.06
Peripheral velocity
π ∗ Dg ∗ Ng π ∗ 0.06 ∗ 172
v= = = 0.54m/sec
60 60
Velocity factor
6 6
Cv = = = 0.92
6 + v 6 + 0.54

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And tooth form factor for 20° involute teeth
0.912 0.912
y = 0.154 − = 0.154 − = 0.116
Tg 24
Allowable static stress for phosphor bronze, σo = 84 MPa or N/mm2.
We know that the designed tangential load,
Wt = σ0 ∗ Cv ∗ b ∗ π ∗ m ∗ y
Wt = 84 ∗ 0.92 ∗ 21.87 ∗ π ∗ 2.5 ∗ 0.116
Wt = 1539.8N
This is more than the tangential load acting on the gear (i.e. 50.87 N), therefore the design is safe
from the standpoint of tangential load.
Checking dynamic load
Wt
WD =
Cv
1539.8
WD = = 1673.69N
0.92

This is more than Wt = 50.8N, therefore the design is safe from the standpoint of dynamic load.
Design of worm shaft
Torque of gear (Tgear ) =1.525Nm
Tgear
Torque of worm (Tworm ) = VR∗η

VR=6
tan λ
η=
tan(λ + ϕ)
Rubbing velocity
π ∗ Nw Dw π ∗ 1032 ∗ 0.02355
Vr = = = 82.94m/min
cos λ cos 23
Coefficient of friction
0.0275
μ= = 0.0091
Vr 0.25
Angle of friction
ϕ = tan−1 0.0091 = 0.522
Then the efficiency
tan 23
η= = 0.97 = 97%
tan(23 + 0.522)
43 | P a g e
Then torque worm is
1.525
Tworm = = 0.262Nm
6 ∗ 0.97
Tangential force on the worm
2 ∗ Tworm 2 ∗ 0.262
Wt = = = 22.25N
Dw 0.02355
Wt = 22.25N
Axial force on the worm gear
2 ∗ Tgear 2 ∗ 1.525
WA = = = 50.87N
Dg 0.06
Radial force on the worm
WR = WA tan ϕ = 50.87 ∗ tan 20
WR = 18.5N
Bending momentum due to axial force
DW 50.87 ∗ 0.02355
= WA ∗ = = 0.299Nm
3 4
Bending momentum due to radial force
WR ∗Dg 18.5∗0.06
= = = 0.277Nm
3 4

Total bending moment vertical plane

M1 = 0.299 + 0.277 = 0.576Nm
Bending moment due to tangential force (WT) in the horizontal plane,
WT ∗ Dg 22.25 ∗ 0.06
M2 = = = 0.334Nm
3 3
Resultant bending moment on the worm shaft,

Mworm = √M12 + M22 = √0.5762 + 0.3342 = 0.665Nm

Equivalent twisting moment on the worm shaft,

2
Tew = √Tworm 2
+ Mworm

= √0.2622 + 0.6652 = 0.714Nm

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From this we can get diameter of worm shaft
τ = 50N/mm2
π ∗ τ ∗ d3w
Tew =
16
dw =4.2mm but let take 10mm
Let us now check the maximum shear stress induced.
We know that the actual shear stress,
16Tew 16 ∗ 714
τ= = = 3.636MPa
πd3w π ∗ 103
And direct compressive stress on the shaft due to the axial force,
WA 50.87
σc = π = π = 0.647MPa
(4) ∗ d2w (4) ∗ 102

Maximum shear stress,

1 2 1
τmax = √σc + 4τ2 = √0.6472 + 4 ∗ 3.6362 = 7.3MPa
2 2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the design of
Worm shaft is satisfactory.

E. DESIGN OF MAIN SHAFT

A shaft is the component of a mechanical device that transmits rotational motion and power. In
this section there are two shafts, the one is to transmit motion from back wheels to spur gears and
the other one is to transmit motion from pinion gears to the roller brush bristles which are attached
on its surface in a row of clusters.

Figure 26 Shaft

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 Figure 27 Force analysis of shaft

Force analysis
ΣFy = 0
R b + R c + R d + R b = F + 2Fr
Where
R a = R b = F2 = 34.4N
W 280
F= = = 140N
2 2
W weight of machine
2 ∗ 34.4 + R c + R d = 140 + 2 ∗ 27.53
Rc = Rd
2 ∗ R c = 195.06 − 68.8
R c = 63.13N = R d
The shear force and bending moment

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 Figure 28 Bending and shear diagram of shaft

Mmax = 26.21Nm
Now we can calculate diameter of the shaft
16 2FS
d3 = √M 2 + T 2 ∗
π Sy
Sy = yield strenght of material = 60MPa
Let factor of safety FS=2 (light load)
M=26.21Nm
T=2.875Nm

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 16 2∗2
d3 = √26.212 + 2.8752 ∗
π 60
d=20.76mm
Select the shaft size to be used form the nearest size in the range of preferred metric sizes [20]
(1,1.2,1.6,2,2.5,3,4,5,6,8,10,12,16,20,25,30,35,40,45,50,55,60,65,70,75,80,90,100 mm.) The
nearest shaft size selected is 20 mm.

F. BALL BEARINGS SELECTION

Ball bearings are used primarily to support rotating shafts in mechanical equipment.

Figure 29 Ball Bearing

Rating life of ball bearing

Rating life is defined as the life of a group of apparently identical ball bearings, in number of
revolutions or hours, rotating at a given speed, so that 90% of the bearings will complete or exceed
before any indication of failure occur.
The magnitude of the rating life L in millions of revolutions and 𝐋𝐡 in hours, for a radial ball
bearing application is given by the formula:
C 3
L=( )
p
106 C 3
Lh = ( )
60n P
Where C: dynamic basic load rating (N)
P: equivalent radial load (N)
n: revolution per minute (rpm)

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Equivalent radial load
Pe = XPr + YPa
Y=0 there is no axial load
X radial factor
Pr = radial load
Pe = equivalent radial load
Table 05 Dynamic and static load on bearing

Principal dimensions Basic load ratings Fatigue Speed ratings Mass Designation

load unit
d D B Dynamic Static Pu(KN) Reference Limiting m(Kg) =SKF Explorer

(mm) (mm) (mm) C(KN) Co(KN) Speed speed bearing

N(R/min) N(R/min)
12 21 5 1.43 0.67 0.028 70000 43000 0.0063 61801
12 21 5 1.43 0.67 0.028 70000 36000 0.0063 61801-2Z
12 24 6 2.25 0.98 0.043 67000 40000 0.011 61901
12 32 10 7.28 3.1 0.132 50000 26000 0.037 6201-2RSL
20 32 7 4.03 2.32 0.104 45000 28000 0.018 61804
20 37 9 6.37 3.65 0.156 43000 26000 0.038 61904
20 42 8 7.28 4.05 0.173 38000 24000 0.05 16004*
From this table we get dynamic and static load on bearing
C = 4.03KN
Co = 2.32KN
Pr = 63.13N
Rating life in millions revolutions and hours
106 4030 3
Lh = ( ) = 48174.14 ∗ 103
60 ∗ 90 63.13
From the Table 27.1. Principal dimensions for radial ball bearings.(a text book of machine
design(gupta))

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Table 07 Result of ball bearing

Bearing No.204 Dimension

Bore 20mm
Outside diameter 47mm
Width 14mm

G. SELECTION OF MATERIAL FOR DISC BRUSH

Brushes have to be very specialized in order to meet all of the unique requirements of the road
cleaning purpose. They are shaped and sized for cleaning of coarse and fine debris. Proper bristle
selection is also extremely important. Longer bristles offer greater flexibility when compared to
the same material in a shorter trim. The key to efficiency is maximum bristle tip contact to surface
and the proper type of bristle for the surface to be cleaned. Proper selection is extremely important
for making the cleaning process as easy and efficient as possible.
Material for brush
Material for brush into basically three types:

a. Synthetic = Man made plastics

b. Natural = Hair, bristle or vegetable fiber
c. Wire = Strands of metallic filament

Synthetic brush material

 Nylon
 Polypropylene
 Polyester
 Teflon
 Abrasive impregnated

Natural brush material

 Horse hair
 Bristle

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  Soft hair

Wire brush materials

 Stainless steel
 Steel wire
 Brass wire
 Phosphor bronze
 Nickel silver
 Beryllium copper

From this we select one from synthetic and one from wire brush material by punching flat wire
(steel) and polypropylene to get more efficiency of cleaning and enables better performance.

Polypropylene Sweeps

 For wet or dry sweeping of fine dust or coarse debris

 Will not absorb moisture; resistant to most chemicals, acids and oils
 Durable synthetic sweep can be washed to extend performance life
 Cleaning medium-soiled areas
 lower cost than nylon
 Has excellent stiffness when wet and is inert to most solvents, oils, acids or chemicals and
is fungus resistant.

Carbon steel Wire

 Cleaning heavily-soiled areas, street sweeping after the winter season

 To dislodge the debris that attached to the asphalt.
 Strength and durability
 Very aggressive.

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 

Figure 30 Disc brush

H. SELECTION OF MATERIAL FOR ROLLER BRUSH

The roller brush is used to lift the debris from asphalt to the container and used to clean fine debris
or fine sands from the asphalt. But the main purpose of roller brush is to lift the debris in to
container. For this we select polypropylene. Because of, first the disc brush dislodge and clean the
debris from the asphalt then the roller brush lift and clean the debris in to the container. So the
polypropylene can lift the dislodged debris in to container.
Polypropylene (PP)
 Very durable.
 Good abrasion resistance and shear/break strength.
 Resistant to solvents, acids, oils, fungus and bacteria growth.
 Can be used wet or dry.
 Best in medium to heavy floor sweeps and scrub brushes.

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 Figure 31 roller brush

I. DESIGN OF WORM GEAR FOR FAN

Material selection for worm gear
Worm –steel
Worm gear-phosphorus bronze

Figure 32 Parameter of worm gear

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By considering
 Space
 Material
 Center distance between gears
Let
Module=m=2.5mm
Velocity ratio (VR) =24 to get high speed in the rotation of fan
From the table 31.2(a text book of machine design (gupta)) for velocity ratio of 20 the number of
start or n is equal to 2 (double).

So n=Tw=2
From VR and n can calculate worm gear teeth
Tg
VR =
n
Tg = VR ∗ n = 24 ∗ 2 = 48
Then the rotation or speed of worm is
Nw
VR =
Ng
Where
Ng = Nbw = 91RPM
Nw = 24 ∗ 91 = 2184RPM
From the module and worm gear teeth can calculate pitch diameter of worm gear.
Dg = mTg = 2.5 ∗ 48 = 120mm
Pitch circle (Pc) =axial pitch (Pa) =πm=π*2.5mm=7.85mm
From the axial pitch and n can calculate lead.
L = Pa ∗ n = 7.85 ∗ 2 = 15.708mm
Pitch diameter of the worm
Dw = 3 ∗ Pa = 3 ∗ 7.85 = 23.55mm

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Then can calculate lead angle
L 15.708mm
tan λ = = = 0.2123
πDw π ∗ 23.55mm
λ = 11.980
From the table 31.1 (a text book of machine design (gupta)) for the lead angle of 0 ≤ λ ≤ 16 the
recommended angle is 141/2 pressure angle.

Table 07 Result of worm and worm gear for fan

No Particular Formula Worm Worm gear

1 Pressure angle(ȹ) 𝟏𝟒𝟏/𝟐 𝟏𝟒𝟏/𝟐
2 Module(m) 2.5mm 2.5mm
3 Number of teeth(T) Double (2) 48
4 Addendum(a) a=0.318Pc 2.497 -

5 Hub diameter 1.66Pc+25mm 38.03mm -

6 Face length(Lw) Pc(4.5+0.02Tw) 35.796mm -
7 Maximum bore shaft Pc+13.5mm 21.35mm
8 Outside diameter of worm Dg+1.0135Pc 128mm
gear
9 Face width(b) 2.38Pc+6.5mm 25.19mm
10 Throat diameter(Dt) Dg+0.636Pc - 125mm
11 Depth of tooth (h) 0.686 pc 5.38mm
12 Lead (L) L=Pa*n 15.708mm
13 Lead angle (𝛌) m. n 11.980
tan λ =
Dw
14 Pitch circle diameter (D) 23.55mm 120mm

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Checking for tangential load
T
Wt = 2 ∗
Dg
T torque of worm gear that is equal to torque of front wheel. Tbw = T = 2.875Nm
2.875
Wt = 2 ∗ = 76.67N
0.075
Peripheral velocity
π ∗ Dg ∗ Ng π ∗ 0.075 ∗ 91
v= = = 0.357m/sec
60 60
Velocity factor
6 6
Cv = = = 0.943
6 + v 6 + 0.357
And tooth form factor for 141/2 pressure angle involute teeth
0.684 0.684
y = 0.124 − = 0.124 − = 0.1012
Tg 30
Allowable static stress for phosphor bronze, σo = 84 MPa or N/mm2.
We know that the designed tangential load,
Wt = σ0 ∗ Cv ∗ b ∗ π ∗ m ∗ y
Wt = 84 ∗ 0.943 ∗ 25.192 ∗ π ∗ 2.5 ∗ 0.1012
Wt = 1586.1N
This is more than the tangential load acting on the gear (i.e. 76.67 N), therefore the design is safe
from the standpoint of tangential load.
Checking dynamic load
Wt
WD =
Cv
1586.1
WD = = 1681.9N
0.943

This is more than Wt = 76.67 N, therefore the design is safe from the standpoint of dynamic
load.
Design of worm shaft
Torque of gear (Tgear ) =2.875Nm
Tgear
Torque of worm (Tworm ) = VR∗η

VR=15

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 tan λ
η=
tan(λ + ϕ)

Rubbing velocity
π ∗ Nw Dw π ∗ 1365 ∗ 0.02355
Vr = = = 103.23m/min
cos λ cos 11.98
Coefficient of friction
0.0275
μ= = 0.00863
Vr 0.25
Angle of friction
ϕ = tan−1 0.00863 = 0.494
Then the efficiency
tan 11.98
η= = 0.95 = 95%
tan(11.98 + 0.494)
Then torque worm is
2.875
Tworm = = 0.201Nm
15 ∗ 0.95
Tangential force on the worm
2 ∗ Tworm 2 ∗ 0.201
Wt = = = 17.07N
Dw 0.02355
Wt = 17.07N
Axial force on the worm gear
2 ∗ Tgear 2 ∗ 2.875
WA = = = 76.67N
Dg 0.075
Radial force on the worm
WR = WA tan ϕ = 76.67 ∗ tan 20
WR = 27.9N
Bending momentum due to axial force
DW 76.67 ∗ 0.02355
= WA ∗ = = 0.9027Nm
3 2
Bending momentum due to radial force
WR ∗Dg 27.9∗0.075
= = = 1.046m
3 2

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Total bending moment vertical plane
M1 = 0.9027 + 1.046 = 1.948Nm
Bending moment due to tangential force (WT) in the horizontal plane,
WT ∗ Dg 17.07 ∗ 0.075
M2 = = = 0.64Nm
3 2
Resultant bending moment on the worm shaft,

Mworm = √M12 + M22 = √1.9482 + 0.642 = 2.05Nm

Equivalent twisting moment on the worm shaft,

2
Tew = √Tworm 2
+ Mworm

= √0.2012 + 2.052 = 2.06Nm

From this we can get diameter of worm shaft
τ = 50N/mm2
π ∗ τ ∗ d3w
Tew =
16
dw =5.94mm but let take 15mm
Let us now check the maximum shear stress induced.
We know that the actual shear stress,
16Tew 16 ∗ 201
τ= = = 4.54MPa
πd3w π ∗ 153
And direct compressive stress on the shaft due to the axial force,
WA 76.67
σc = π = π = 0.433MPa
(4) ∗ d2w (4) ∗ 152

Maximum shear stress,

1 2 1
τmax = √σc + 4τ2 = √0.4332 + 4 ∗ 4.542 = 9.09MPa
2 2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the design of
Worm shaft is satisfactory.

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Fan selection
Fan is used to suck the fine debris or fine sand that the roller brush not clean. So the fan is used
to increase the cleaning capability of the machine. We buy the fun from the market then attach
this fan to the worm gear that rotate at the speed of 2184RPM.

Figure 33 Fan

J. DESIGN OF HANDLE
The handle simply a tube of 25mm diameter. The two ends are welded to the side frame. It is
bended in u-shape. And we can adjust this handle at the wanted height by adjustable. It has
effective height of 700mm to 1200mm.

Figure 34 Handle

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 K. UPPER COVER
Used to cover the inside structure of the machine.

Figure 35 Upper cover

L. DESIGN OF KEY
Material selection: The same material as the shaft
Te = Tbw = 2875Nmm
Diameter of the shaft = 20mm
From table 13.1 Proportions of standard parallel, tapered and gib head keys.
width = w = 8mm
thickness = 7mm
A equivalent torque by permissible shearing stress (τ = 44MPa)
d
Te = l ∗ w ∗ τ ∗
2
2875 ∗ 2
l= = 7.4mm
8 ∗ 44 ∗ 22
By crushing stress (σc = 88MPa)
2 ∗ 2875
l= = 3.7mm
8 ∗ 88 ∗ 22

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Therefore by taking the larger value the key length l = 8mm
Width of the key=8mm
Thickness of the key=7mm

M. Assembly

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 CHAPTER 5

COST ANALYSIS
Cost analysis for the project is prepared to determine the amount of the money that will be saved
instead of investing the manual Asphalt cleaner machine from the other mechanical equipment
cleaning machine. It is because high level of energy consumption spreads the fixed costs over a
greater number of units.
It is a method of determining of cost that expendics starting from its design up to its
manufacture of the design and model of asphalt cleaner machine.
Equipment cost
The material cost is calculated by mass and obtained from standard table pound per kilo gram.
from american sociaty standard table cost per kilogram( dollar or Birr).
Table 5: cost comparisions

Material Approximate price dollar per kg

Mild steel tube 2-2.7 (54- 76 Birr)
304 stainless steel 4.0-6.07(108-195 Birr)
Nylon 1.8-2.3 (44.3-57.5 Birr)
Phosphorus bronze 4.1-6.3(105.9-186 .7Birr)
cast iron 3.44(96.2 Birr)

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 COMPONENT MATERIAL Mass Qtty Price Per Kg Kg of the
(kg) ETB material per
ETB
Shaft Stainless steel 3 3 150 1350birr
Worm Gear phosphorous bronze 5 2 96.2 877birr
Spur Gear Nylon plastic 2.4 2 56 270birr
Front Wheel Nylon rubber 2 2 52.5 170birr
Rear Wheel Nylon rubber 3 2 52.5 170birr
Worm Steel 2.2 2 113 314birr
Container Plastic 3 1 50 150 birr
Upper Cover Plastic 3 1 50 150 birr
Fan On market 2 1 1500 1500 birr
Handle Mild steel tube 3 1 58 150birr
Brushes poly propylene 1.5 1 180 270birr
Brushes wire steel 0.5 1 240 120 birr
Locks On market 0.125 2 30 25 birr
For mfg 2200
Miscellaneous 764
Total 8403birr

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 CHAPTER 6

CONCLUSION AND RECCOMENDATION

6.1 CONCLUSION
Generally debris on asphalt are main problem of cities and towns, and in Mekelle
University in which the cleaning process is conducted manually using brooms, shovels and
handcarts. And for this problem various concepts were generated by employing concept generation
methods. Among these concepts the best concept was selected by setting criteria. The principle
solution was specified by establishing function structures, searching for appropriate working
principles and combining these into a working structure; the basic solution path was laid down
through the elaboration of a solution principle. The street cleaning process has to be mechanized
by implementing machines which help street cleaners to improve the street cleaning quality and
efficiency. For this purpose manually driven asphalt cleaning machine was designed. This machine
have three stage of cleaning in the first the disc brush that rotated by worm gear collect and
dislodge debris that attached to the asphalt. And the disc brush give debris to the roller brush that
rolled by the spur gear and it store debris in the container. Lastly fan is attached to the back of the
machine, it suck the fine debris after the roller brush clean the debris.
The machine have sweeping width of 1200mm, and the estimated weight of the machine is not
more than 28Kg. and the machine will be is 6 times of the broom cleaning system.
Based on the specified principle solution, the basic physical building blocks of the product in terms
of what they do and what their interfaces are to the rest of the device was done. The 3-D model
and part design was done in CATYA software.

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6.2 Recommendation
This thesis project paper can be an interest, who have great need to work more on human powered
machines. It may motivate to design and develop other mechanism which can be driven manually
to solve social problems. Furthermore this study contributes to a better and innovative product
design, assist technological institutions and all those who are interested in product design.
In addition, it is suggested that a mass production of the product will reduce the manufacturing
cost, so any interested person or company may have a better job opportunity with attractive
profitability.

Finally we recommend Mekelle University modify this project to manufacture for him and sell for
other companies.

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 References
1. Erik, O. (n.d.). Machinery's Handbook 26th. New York.

2. Eugene, A. (2007). Mark's Standard Hand Book for Mechanical Engineers.

3. GOOGLE. (n.d.). Retrieved from http://www.google.com

4. GUPTA, R. K. (2005). Machine Design . New Delhi.

5. Shigley, J. (1986). Mechanical Engineering Design. Mcgraw Hill: First Metric Edition.

6. WIKIPEDIA. (n.d.). Retrieved from http://www.wikipedia.com

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 Appendix
1. Back wheel

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 2. Disc brush

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 3. Front wheel

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 4. Handle

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 5. Roller brush

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 6. Shaft

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 7. Pinion gear

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 8. Container

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 9. Spur gear

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 10. Upper cover

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 11. Assembly

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