Chapter 3-Methodology

Chapter 3
METHOLOGY
3.1 Introduction:
This chapter presents methods to achieve the researchers purpose of

designing and fabricating a machine that will improve the efficiency and
quality of filtering the sand.
It discusses the instruments and materials to be used and the process flow
of making the machine. It also tackles on the procedures of fabrication and
assembly of machine as well as on determining the machines efficiency and
quality.
3.2 A process flow in making the machine
Study of Sieving Machine
Selecting the Projects

Components Materials
Computation
Methods of Construction
Analyzing the Result
Fig 3.2 Process flow of Design and Fabrication of a Modified Rotary Sand Sieving Machine
Figure 3.2.2 Block diagram of automatic sand filling
The figure 3.2.2 Demonstrate the flow of automatic filling we will be using the
ultrasonic sensor for the detection of the sack. The distance for detecting the
sack can be easily set in the Arduino code based on the requirement. The
Arduino will be repeatedly sending a signal to trigger the ultrasonic sensor
and when the sack is present in front of the sensor then the sensor will output
the total time taken by the sound to travel to and from the object. Then that
signal is read by the Arduino. Based on that signal, we will be writing the code
that when the sensor detects the sack it will open the outlet, and when the
sack is not present in front of the sensor the outlet closed.
3.3 Selection of Projects Components Materials
Component used in Sand Filter:
DC Motor
DC motors are used for many years to machinery although newer AC motors
are being developed to fit this need as well. DC motors and drives have wide
ranges for constant torque speed. They are simplistic in design and some DC
drives can easily be retrofitted for existing DC motors. These also come in
smaller sizes but with larger horsepower ratings.
FRAME
Frame provides structural integrity and stability of a machine. Frame have

required efficiency to hold all the loads of machine parts. Mild steel is used for
the framework of our machine.
PULLEY
Two pulleys of variable dimensions are used. The smaller one is attached to
the motor and the larger one to the shaft holding the screening net and both
are connected with belt drive which transmits the motion from motor to the
drive.
BEARING
Two ball bearings are used in the machine holding the shaft and rotating the
screening net.
BELT
BATTERY
SOLAR PANEL
ADAPTER
POWER SUPPLY CONTROLLER

MESH FRAME
ARDUINO UNO
ULTRASONIC SENSOR HC-SR04
SERVO MOTOR
3.4 PRELIMINARY CALCULATIONS
The preliminary calculations as per the initial design is discussed here. The
calculation can be changed as per the change in design is required. The
mathematical relation or formula are written below:
POWER CALCULATION
P=Force × velocity
Force= Weight = Mass × Acceleration due to gravity.
TORQUE CALCULATION
T = F × r × sinθ
T = torque
F = linear force
r = distance measured from the axis of rotation to where the application of
linear force takes place
theta = the angle between F and r
TORSIONAL FORCE
where:
T = torque or twisting moment, [N×m, lb×in]
J = polar moment of inertia or polar second moment of area about shaft axis, [m 4, in4]
τ = shear stress at outer fibre, [Pa, psi]
r = radius of the shaft, [m, in]
G = modulus of rigidity (PanGlobal and Reed’s) or shear modulus (everybody else), [Pa, psi]
θ = angle of twist, [rad]
L = length of the shaft, [m, in]
RPM CALCULATION
where:
N = speed of rotation in rpm.
P = number of poles.
A = number of parallel paths
Z = total no. conductors in the armature.
MACHINE EFFICIENCY
η = Eout / Ein * 100%
where:
η=is the efficiency (expressed as a percentage),
Eout=is the energy output (in Joules), and
Ein=is the energy input (also in Joules).

BELT MACHINE
Belt length = ((DL + DS) * π / 2) + (DL - DS) * arcsin (DL - DS) / 2L) + 2 *
√(L2− 0.25 * (DL - DS)2)
where:
DL=is the diameter of the large pulley;
DS=is the diameter of the smaller pulley; and
L=is the distance between the pulley axles.
ANGLE OF TWIST
a = ( T * L )/( J * G)
Where a is the angle of twist (radians)
T=is the torque applied (N*m)
L=is the length (m)
J=is the polar moment of inertia
G=is the shear modulus (N/m^2)

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Chapter 3

This chapter presents methods to achieve the researchers purpose of

3.2 A process flow in making the machine

Study of Sieving Machine

Selecting the Projects

Analyzing the Result

Component used in Sand Filter:

Frame provides structural integrity and stability of a machine. Frame have

POWER SUPPLY CONTROLLER

ULTRASONIC SENSOR HC-SR04

3.4 PRELIMINARY CALCULATIONS

T = torque or twisting moment, [N×m, lb×in]

τ = shear stress at outer fibre, [Pa, psi]

r = radius of the shaft, [m, in]

θ = angle of twist, [rad]

L = length of the shaft, [m, in]

N = speed of rotation in rpm.

A = number of parallel paths

Z = total no. conductors in the armature.

η = Eout / Ein * 100%

η=is the efficiency (expressed as a percentage),

Eout=is the energy output (in Joules), and

Ein=is the energy input (also in Joules).

DL=is the diameter of the large pulley;

DS=is the diameter of the smaller pulley; and

L=is the distance between the pulley axles.

Where a is the angle of twist (radians)

T=is the torque applied (N*m)

L=is the length (m)

J=is the polar moment of inertia

G=is the shear modulus (N/m^2)

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