Animal Driven Gear Box and

Pump

Prof. S.K. Saha (Prof. V.K. Vijay and Dr. S.V. Modak)

Naren Gupta Chair Professor

Dept. of Mech. Eng.

IIT Delhi

Sept.08,’11@RDL722: rural Energy Systems (Prof. V.K. Vijay)

Existing ADGB (Panchal Pumps, Kanpur)

with Water Pump

Water discharge (from 30 feet deep): 7,000-10,000 litre/hr.

Outline

Animal power

Gear box

CAD of Gear Box

Design checking

MS-Excel program

MuDRA

Conclusions

3

Introduction

India is a predominantly an agricultural country,

where about 70% of population lives in rural areas

and depends on the agriculture.

They use animal for farming purposes.

The animal power can be used for other purposes,

e.g., water pumping, chaff cutting, for atta-chakki,

electricity generation, etc.

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Objective

To study each component of Animal Driven Gear Box

(ADGB) in detail and prepare its specifications.

Evaluation of the existing technology by Panchal

Pumps, Kanpur, and standardization of the same.

To study the factors affecting on the efficiency and

improve them as much as possible.

Fabrication and field trials of the standardized design.

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Gearbox & Pump Sold/Installed: 32SN Customer Name City / State Contacted:

Remarks

1. Bioved Research & Communication

CenterAllahabad / Uttar

Pradesh

2. Dr. Punjabrao Deshmukh Krishi

VidyapeetAkola / Maharashtra

3. Mahant Bharatpuri Banda / Uttar Pradesh

4. ISKCON (Goverdhan Krishi Farm) Thane / Maharashtra

5. Bhartiya Govanshrakshan

Savardhan ParishadThane / Maharashtra

6. Shri Santosh Singh Bhadauriya Kanpur / Uttar Pradesh

7. Shri Vivek Chaturvedi Kanpur / Uttar Pradesh

8. Office Of The Project Director,

ATMA

Jamshedpur /

Jharkhand

1 set working

for 1 year

9. Shri Surendra Sharma C/o. -

Gayatri ParivarNoida / Uttar Pradesh Not used

10. Aghor Guru Sewa Peeth Aghor

FoundationVaranasi / Uttar

Pradesh

3 sets working

for 1 year

Co

nta

cte

d o

n

12

/08

/20

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Inside of the Gear box

Output pulley

Pair 3

(helical)

Pair 2 (spur) Pair 1 (spur)

Lever holder

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CAD Modeling of ADGB (Animation)

Gearbox

Lever Holder

V-Pulley

Base Plate

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Analysis of the Gear BoxComponents

1. Gear pairs

2. Shafts

2. Bearings Specification of the existing gear box

Input power 2 hp (~1.5 kw)

Overall gear ratio 1:63

Input velocity 2 rpm

Module of gear pair 1 (spur gear) 6 mm

Face width of gear pair 1 35 mm

Module of gear pair 2 (spur gear) 7 mm

Face width of gear pair 2 70 mm

Module of gear pair 3 (helical gear) 2.5 mm

Face width of gear pair 3 35 mm

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Gear

Properties of the gear pair: Material

Face width

Module

Bending stressSurface fatigue stress

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Factor of Safety (FOS) for Gear Pairs

Pair and

type

Gear or pinion Material FOS in

bending

FOS in

surface

fatigue

Pair 1:

Spur

Gear CI FG-210-Gr 1.29 1.22

Pinion EN-8= AISI 1040 1.25 1.36

Pair 2:

Spur

Gear EN-24= AISI 4340 1.99 1.87

Pinion EN-24= AISI 4340 1.5 1.87

Pair 3:

Helical

Gear EN-24= AISI 4340 6.87 5.16

Pinion EN-24= AISI 4340 5.37 5.16

FOS >> 1 means large size,

high cost, less efficiency

Reduction of FOS for Gear Pair 3

FOS for

different

materials

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FOS for

different

face widths

FOS for

different

modules

Suggestion on Gear Pair 3

To change the type of gear pair 3

From helical gear to spur gear

If the type of gear pair is not changed

Change the face-width of gear pair from 35 mm to 15 mm

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Checking of Shafts

Standard equations

1/ Nf2 = (σa / σe)

2+( 1.73*τm / σy)2

σa = kf*(32*Ma / π*d3) MPa

τm= kfs*(16*Tm / π*d3) MPa

kf = 1+q*(kt-1)

kfs = 1+q*(kts-1)

Free body diagram of shaft 1

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FOS of each shaft

Shaft Material FOS

Cattle drive gear shaft AISI 4340 1.28

Drive gear shaft AISI 4340 1.08

Idler gear shaft AISI 4340 1.52

Driven gear shaft AISI 4340 1.23

FOS > 1 means that the shafts

are safe. No change is required.

Checking of Bearing Life

Equivalent load on the Bearings - P = X*V*Fr + Y*Fa

Life of the Bearing - L = (C / P) 3 X 106 revolutions

Bearing type Desired life

(revolutions)

Calculated life

( revolutions)

Taper roller bearing

SKF-300356

1.7*106 4.2*1010

Ball bearing SKF 6215 1.7*106 4.56*108

Ball bearing large SKF 6310 5.9*106 2*109

Ball bearing small SKF 6306 1.05*108 2.3*109

Life of the different bearings

Calculated life of bearings > desired life (based on

for 8 hrs/day for 10 yrs.). No change is required.

Additional Suggestions Provide a wheeled support under the wooden beam to reduce

the load on the bullocks.

A test facility be created at IIT Delhi to compare the gear boxes

for standard tests.

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• Company (Panchal Pumps) has taken most of the

suggestions (i.e., all spur gears, and less face-width

for gear pair 3).

• The water flow rates only require 0.8 kW power

input (not 1.5 kW) the company reduced diameters

of gears Gear box is much lighter.

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Lever Holder

Wheel Arrangement

BullockWooden Lever

Water Pump

Gear Box

Water Discharge

Design checks can be done very quickly using MS-Excel

programs developed by us. Anybody can check design.

Test of Standardized ADGB Water Pump

(For Sprinklers)

August 11, 2011

MS-Excel Program

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Set-up for Evaluation of ADGB

(at IIT Delhi)

Gearbox

Digital Ammeter

Speed Sensor

Digital

Counter

Alternator12V -Battery

Chain Sprocket

Cover

Support frame DC Motor-Gear Assembly

(To Simulates bullocks motion)

Noise Testing

Point Indicates

(Noise level

measured in that

area of the gear box)

1 2 3 4 5 6 7 8 9 10

Noise level in

db (decibel)

73.5 75.45 74.25 75.35 74.85 74.5 75.15 73.65 74.25 72.5

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Vibration Testing

(a) Voltage (b) Frequency

Point Indicates (Vibration

level measured in that area

of the gear box)

1 3 5 7 9

Vibration level in

mV (milivolts)112 102 372 128 232

Vibration frequency in

MHz (Mega hertz)22.73 5.00 20.83 92.59 4.46

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

Publications

[1] Gupta, R.K., Singh, S., Jain, A., Sharma, M., Saha, S.K., 2010,

“Computer aided analysis of animal driven gear box,” Proc. of

10thNat. Conf. on Industrial Problems on Machines and

Mechanisms (IPRoMM), MNIT, Jaipur, Dec. 17-18, pp. 35-38.

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Future Applications

Major applications other than pumps are:

Chaff cutting

Thrasher

Wheat-grinding (Atta chakki)

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MuDRA: Multibody Dynamics for

Rural Problems

MuDRA: Multibody Dynamics for Rural Applications

! LET’S TAKE LEAD AT LEAST IN THESE AREAS !

US Entry in this field (see next slide)

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Conclusions

All components of animal-driven gear box were checked for

safety

Design suggestions were made for reduction of weight and to

increase efficiency

CAD modeling was done in Autodesk Inventor to study the

designs

MS-Excel programs were written for easy/quick design checks

Standardized gear box was tested in Kanpur.

Contact has been made with ICAR, Patna for further field testing

and certification to be able to recommend for subsidy (presentcost is around ₹1.25 lakhs)

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Acknowledgements

1. Mr. Rajkumar Gupta

2. Mr. Mangal Sharma

3. Students

• Mr. Amit Jain

• Mr. Sanjay Singh

• Mr. Joyti Bahuguna

• Mr. Mayank Agrawal, Applied Mechanics

• Mr. Vinayak, Applied Mechanics

Thank Yousaha@mech.iitd.ac.inhttp://web.iitd.ac.in/~saha

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