Progress e trike

DESIGN AND MANUFACTURING OF E-TRIKE
OPERATED MACHINE FOR ASPHALT CLEANING
YITAGESU TESFAYE ENGR/1256/06
BELETE ABU ENGR/1190/06
ESRAEL TESEGA ENGR/700/06
5TH
YEAR MECHANICAL DESIGN STREAM
DEPARTEMENT OF MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING
INSTITUTE OF TECHNOLOGY
DEBRE BERHAN UNIVERSITY, ETHIOPIA
ADVISOR: DR. C. VIVEK ANANDHAN
DATE OF SUBMISSTION:

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ABSTRACT
Cleaning is one of daily process which is done by human beings to maintain good area and to keep
the health of the society and to increase the beauty of the country that people live in because it has
indirect impact on the economy of the country.
The objective of the project is to combine sweeping process with collecting and storing
mechanism, to minimize the cost of manual sweeper and the time taken to sweep the concrete
asphalt road of Debre Berhan city as well as the whole country Ethiopia.
The machine mainly has two systems which are tricycle system and cleaning system. E-trike
system (Electric Tricycle system) is used as a source of power for sweeping, loading and storing
that is for cleaning system. Roller shaft, belt drive, chain drives, sprockets and bearings are main
components of the machine.
Therefore, to achieve this project design procedures, CAD software (Solid Works) and different
workshop machines are used.

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Table of Contents
ACKNOWLEDGMENTS....................................................................................................................................i
ABSTRACT...................................................................................................................................................... ii
NOMENCLATURE.......................................................................................................................................... vi
CHAPTER ONE ...............................................................................................................................................1
1.1 INTRODUCTION.......................................................................................................................................1
1.2 PROBLEM STATEMENT............................................................................................................................2
1.3 OBJECTIVE OF PROJECT...........................................................................................................................3
1.3.1 General objective.............................................................................................................................3
1.3.2 Specific objective .............................................................................................................................3
1.4 SCOPE......................................................................................................................................................4
A. DELIVERABLES.......................................................................................................................................4
B. TECHNICAL REQUIREMENT...................................................................................................................4
C. ASSUMPTIONS ......................................................................................................................................5
D. LIMITATION...........................................................................................................................................6
1.5 METHODOLOGY ......................................................................................................................................7
1.6 MATERIAL REQUIREMENT AND BUDGET................................................................................................8
A. MATERIAL REQUIRED FOR THE PROJECT..............................................................................................8
B. BUDGET OR COST ESTIMATION ............................................................................................................9
A. COMPONENT COST ESTIMATION..........................................................................................................9
B. LABOUR AND MACHINING COST ..........................................................................................................9
CHAPTER TWO ............................................................................................................................................10
CONCEPTUAL DESIGN .................................................................................................................................10
2.1 LITERATURE REVIEW.............................................................................................................................10
2.1.1 VACUUM TYPE SWEEPER [1]..........................................................................................................10
2.1.2 DEVELOPING MANUALLY DRIVEN STREET CLEANING MACHINE (SCM) [2]...................................11
2.2 CONCEPT GENERATION.........................................................................................................................11
2.2.1 SEARCHING FOR WORKING PRINCIPLES ........................................................................................11
2.2.2 CONCEPT SELECTION .....................................................................................................................14
2.3 MAIN COMPONENTS TO BE DESIGNED AND FUNCTIONAL STRUCTURE..............................................15
2.3.1 MAIN COMPONENTS TO BE DESIGNED .........................................................................................15
2.3.1.1 CONVEYING AND STORING SYSTEM .......................................................................................15
2.3.1.2 TRICYCLE SYSTEM....................................................................................................................15

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2.3.2 FUNCTIONAL STRUCTURE..............................................................................................................16
2.4 LITERATURE BACKGROUND FOR MAIN COMPONENTS........................................................................16
2.4.1 BELTS..............................................................................................................................................16
2.4.2 SPROCKET.......................................................................................................................................18
2.4.3 CHAINS...........................................................................................................................................20
2.4.4 SHAFTS ...........................................................................................................................................22
2.4.5 BEARING.........................................................................................................................................23
2.4.6 ELECTRIC MOTORS.........................................................................................................................25
2.4.7 RECHARGEABLE BATTERIES FOR E-TRIKE.......................................................................................26
2.5 MATERIAL AVAILABLE FOR MAIN COMPONENTS.................................................................................26
2.5.1 MATERIAL AVAILABLE FOR MANUFACTURING BELTS ...................................................................26
2.5.2 MATERIALS AVAILABLE FOR MANUFACTURING CHAIN DRIVE......................................................28
2.5.3 MATERIAL AVAILABLE FOR MANUFACTURING OF SPROCKETS.....................................................30
2.5.4 MATERIAL AVAILABLE FOR MANUFACTURING OF BEARINGS.......................................................31
2.5.5 MATERIAL AVAILABLE FOR MANUFACTURING OF SHAFTS AND KEYS ..........................................32
2.6 MATERIAL SELECTION FOR MAIN COMPONENTS...........................................................................32
2.6.1 MATERIAL SELECTION FOR FLAT BELTS .........................................................................................32
2.6.2 MATERIAL SELECTION FOR All CHAIN DRIVE .................................................................................33
2.6.3 MATERIAL SELECTION FOR ALL SHAFTS AND KEYS........................................................................33
2.6.4 MATERIAL SELECTION FOR ALL SPROCKETS...................................................................................34
2.6.5 MATERIAL SELECTION FOR ALL BEARINGS.....................................................................................34
2.7 WASTE SOURCE AND TYPE....................................................................................................................35
2.7.1 SOURCES OF WASTES [26] .............................................................................................................35
2.7.2 TYPES OF WASTES [26]...................................................................................................................35
CHAPTER THREE..........................................................................................................................................36
EMBODIMENT DESIGN................................................................................................................................36
List of Figures
Figure 1 simple functional structure.........................................................................................................5
Figure 2 simple assumed mechanisms.......................................................................................................5
Figure 3 design procedure for design of manually operated asphalt cleaning machine.......................7
Figure 4 truck vacuum type sweeper [1].................................................................................................10
Figure 5 Manually driven street cleaning machine [2]..........................................................................11
Figure 6 simple Schematic diagram for Concept A...............................................................................11
Figure 7 simple Schematic diagram for Concept B ...............................................................................12

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Figure 8 simple Schematic diagram for Concept C...............................................................................13
Figure 9 simple schematic diagram for concept D.................................................................................14
Figure 10 General Functional structure for the machine......................................................................16
Figure 11 flat belt drive [6].......................................................................................................................17
Figure 12: Split type Sprocket [29]..........................................................................................................18
Figure 13: Sectional rim sprocket [30]....................................................................................................19
Figure 14:Double pitch sprocket [31]......................................................................................................19
Figure 15 Shear pin sprocket [32] ...........................................................................................................19
Figure 16 Roller chain sprocket [9].........................................................................................................20
Figure 17 Block or bush chain. [5]...........................................................................................................21
Figure 18 Bush roller chain. [5]...............................................................................................................21
Figure 19 Hoisting and hauling (or crane) chains [5]...........................................................................22
Figure 20 transmission shaft [11] ............................................................................................................22
Figure 21 machine shaft (crankshaft) [12]..............................................................................................23
Figure 22 Rolling shaft [39]......................................................................................................................23
Figure 23 Radial Bearing [5] [14]............................................................................................................24
Figure 24 ball and rolling bearing [16] ...................................................................................................25
Figure 25 DC AND A C MOTORS [41] [40]..........................................................................................26
Figure 26 leather used for belt drive [21] ...............................................................................................27
Figure 27 cotton belt drive [22]................................................................................................................27
Figure 28 rubber belts drive [23].............................................................................................................28
Figure 29 balata belt drive [24]................................................................................................................28
List of Tables
Table 1 project deliverable with its work package 4
Table 2 Cost Estimation for components 9
Table 3 concept selection 15
Table 4 weight analysis to select material for flat belt 33
Table 5 weight analysis to select material for chain drive 33
Table 6 weight analysis to select material for shafts and keys 34
Table 7 weight analysis to select material for sprockets 34
Table 8 weight analysis to select material for all bearing 35

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NOMENCLATURE
• E-Trike: electric tricycle system

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CHAPTER ONE
1.1 INTRODUCTION
Cleaning or sweeping is the crucial need of every society. There are different techniques used to
sweep different types of surfaces. Among these surfaces, this project concerns on Asphalt surfaces.
Asphalt sweeping is one aspect of a concrete waste management system. Unfortunately, there is a
little information available in the literature on different features accompanying with asphalt
sweeping or cleaning process. The waste dropped on the asphalt creates health problems,
environmental pollution, destructive visual impacts and thus, it indirectly distresses the economy
of cities, towns and generally the country itself.
There are many types of tools, equipments and methods available for asphalt cleaning process. For
instance, brooms for sweeping, shovels and hand trucks for collecting wastes etc. This project
concerns how to sweep, load (collect), transport and store the wastes at the same time (sweeping,
loading, transporting and storing process on time).
Sweeping, loading, transporting and storing process is done by using mainly conveying system
with cleaning material for transporting and loading, tricycle system as main source of power and
movements and other mechanical systems or components for producing those mechanisms.
When disengaging and engaging is needed this project will set the mechanism to obtain this
system. That means when cleaning is needed the power can be engaged to the system and when
cleaning is not necessary, the power is disengaged.

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1.2 PROBLEM STATEMENT
The purpose of this project is to solve asphalt sweeping problem by designing and manufacturing
of E-Trike machine for asphalt cleaning.
The asphalt cleaning in Debre Berhan city as well as in our country, are done manually by sweeper,
which start the cleaning process from mid time at 9:00 PM (local time) and continues till morning
or up to 1:00 AM (local time).
This manual cleaning process takes significant amount of time and labour and drastically affects
the health of the workers. Also, the cost of maintaining the sweepers or brooming equipments are
high. Therefore, to disentangle the above stated problems, designing a sweeping machine which
will enhance, optimize the above problems has been significate in recent times.

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1.3 OBJECTIVE OF PROJECT
1.3.1 General objective
The main objective of this project is to design and manufacture of E-trike machine for asphalt
cleaning.
1.3.2 Specific objective
❖ To study problems related to cleaning process.
❖ To develop design concepts for sweeping machine.
❖ Develop design calculation for the system or components.
❖ Generating model by using CAD software (solid works).
❖ Analyze the results.
❖ Prototype development or manufacturing.

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1.4 SCOPE
A. DELIVERABLES
This project has five main deliverables which are conceptual design phase, embodiment design
phase, detail design phase, documentation phase and manufacturing prototype phase. The work
package of those deliverables is putted on the table 1 below.
Table 1 project deliverable with its work package
B.TECHNICAL REQUIREMENT
The following are technical requirements that this project needs
✓ To review literatures and other information, internet lab is very essential.
✓ Measuring devices such as meters and calipers are needed.
✓ This project will have specification needed to design process.
✓ This project will take assumption related to design the components. For instance, loading
condition, capacity, factor of safety and other related issues.
DELIVERABLE WORK PACKAGE
CONCEPTUAL DESIGN Concept Generation: the generated concepts
are putted and the working concept is
identified. Identification of components: the
main components for the machine is selected
Literature review: books, journals and
another source are reviewed to develop the
selected concept.
Material selection: the construction material
for the components are selected.
Types and sources of wastes: different waste
types and sources are listed in this section
EMBODIMENT DESIGN Specification assumption: to design
components some assumptions and speciation
are taken by this project.
Component design analysis: design
calculation for each component are done and
dimensions are fixed.
DETAIL DESIGN Part and assembly drawing of the machine is
modeled by solid work software.
DOCUMENTATION Final project design is organized and Printed.
MANUFACTURING PROTOTYPE The designed machine is manufacturing
according to the design part model. By using
welding, grinding, cutting and bending
machine.

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C. ASSUMPTIONS
This project assumes there is cleaning, loading or collecting, transporting or conveying and storing
process at the same time. The core assumption taken is the machine works both manually and
using electric tricycle therefore it is not fully automated. Since there is tricycle system, the source
of power to cleaning process, loading or collecting process and storing process are taken from the
two rear wheels of the tricycle not directly from the pedal, this is because to minimize the effort
of the rider and also to assist the effort dc motor is used in tricycle system. Therefore, it is assumed
that when the rider rides the tricycle the cleaning and other process listed above is done by using
other mechanical mechanisms.
The other assumption taken is the machine should have engaging and disengaging power system.
That is, when cleaning process is needed the cleaning system will be engaged and when it is not
necessary it will be disengage and the cleaning process stops but riding the tricycle continues; so
that the machine serves as transportation system.
The simple functional structure is putted on the following figure 1. below.
The mechanism assumed is summarized below on the figure 2.
Electric
Tricycle(E-trike)
• Cleaning
• Loading or
Collecting
• Storing process
• Power
transferring
mechanism form
tricycle, two rear
wheels
Figure 1 simple functional structure
Chain drive
Cleaning mechanism
Collecting mechanism
Storage system.
Electric
Tricycle
System
Figure 2 simple assumed mechanisms

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Generally, the following are some of assumptions of this project
✓ The machine is manually operated.
✓ The source for cleaning system is from tricycle rear wheels.
✓ The machine is driven by only one operator.
✓ The volumetric capacity of the storage will be 1000mm × 500mm × 500mm.
✓ The total length of the machine including the tricycle system will be 3000mm.
✓ The safety of the rider is assumed, for instance, shelter and comfort saddle will be added.
D. LIMITATION
The following are limitations of the project
✓ Some components are not available so that they must be bought. They are listed in
material requirement.
✓ If the material required is not bought the budget should be supplied to this project. The
budget detail is available in budget section.
✓ This project is limited for concrete asphalt surfaces, for other roads like Cobble stones
and non-concrete asphalts it is not functional this is the other limitation of this project.

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1.5 METHODOLOGY
This project is done by observation and reviewing some literatures available, such as books,
journals and websites. That is for the desired part of project some related literatures are reviewed
in conceptual design or concept generation.
After generating concepts and completing conceptual design, the analytical design and other
specifications are settled at embodiment design. Finally, machine components are modeled by
solid works and part drawing and assembling drawing are located at detailed design.
The general procedures for design of this project are shown in figure 1 below
Introduction
concetual
design
Embodiment
design
Detailed design
Documentation
Figure 3 design procedure for design of manually operated asphalt cleaning machine

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1.6 MATERIAL REQUIREMENT AND BUDGET
A. MATERIAL REQUIRED FOR THE PROJECT
The following are components of machine which are required for the project.
Standard tricycle smaller size sprocket: 5 pieces
Standard tricycle medium size sprocket: 5 pieces
Standard tricycle bigger size sprocket: 2 pieces
Standard tricycle chain drive: 6 pieces
Standard tricycle wheels: 3 pieces (2 rear wheels and 1 front wheel)
Medium size Ball bearing with cap: 10 pieces
Standard tricycle pedal: 1 pair
Standard tricycle full brake components
Standard flat belt: 1m x 4m
100mm diameter hollow tubular bar: 6 meters
Steel hollow rectangular bar: 6 meters
Standard sheet metal: 3 pieces
48v Dc Motor:1 piece
48v rechargeable lithium battery: 1 piece
The following are main manufacturing equipments and other devices that this project requires:
✓ Full Welding machine with Safety google glass and hand groves and aprons: used
for joining of desired components.
✓ Grinding Machine: it is used for the components to get the desired surface finishing.
✓ Drilling machine with its different size drilling bits: this is very essential to get the
desired holes.
✓ Bending machine: it is used to bend to get the desired shape of the raw material.
✓ Cutting machine (For instance, Circular sawing machine, grinder and if any, other
devices): these machines are very essential for cutting of the raw material to get the
desired dimension
✓ Measuring devices (for instance, meter and Verner Calipers.): for measuring purpose
✓ Computer lab with internet connection: to collect data and information from internet
that is for literature review and other necessary data.

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B. BUDGET OR COST ESTIMATION
A. COMPONENT COST ESTIMATION
Table 2 Cost Estimation for components
No. Component name Quantity Unit price
(Birr)
Total price
(Birr)
1. 48v Dc Motor 1 3000 4000
2. 48v rechargeable lithium battery with
controller
1 12,000 12,000
3. Ball Bearing 10 100 1,000
4. Sprocket (Bigger size) 2 200 400
5. Sprocket (medium size) 5 150 750
6. Sprocket (smaller size) 5 130 650
7. Wheels 3 300 900
8. Flat belt (1000 x 4000) 1 300 300
9. Chain drive 6 100 600
10. Hollow Tubular bar (3m) 1 300 500
11. Hollow Rectangular bar (4m) 1 300 500
12. Standard Sheet metal 3 700 2,100
13. Standard tricycle pedal 1 pair 200 200
14. Full standard tricycle brake system 1 100 100
Total
24,000
B. LABOUR AND MACHINING COST
This project estimates the labour and machining cost to be 3000 Birr. Therefore, the total cost
estimation for this project is 27,000 Birr including the cost of components.

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CHAPTER TWO
CONCEPTUAL DESIGN
In this chapter, the project identifies, the working principle and main components which are
available in the cleaning machine by reviewing literatures, material used to construct the
components, formulas used to design the machine components and other related systems.
2.1 LITERATURE REVIEW
2.1.1 VACUUM TYPE SWEEPER [1]
A truck mounted vacuum type sweeper constructed for dual operation employs identical street
cleaning apparatus on each side of the machine and an extension broom which may be swiveled
from one side of the machine to the other for left hand and right-hand street cleaning operations.
The extension broom is mounted such that its axis of rotation is always parallel to the pavement
being swept. A control system is provided for programming the operation of the machine and
includes means for transferring from, for example, a left hand sweeping operation to a right hand
sweeping operation by merely operating a toggle switch. The control system further includes
means for automatically lifting the suction nozzles when the operator of the sweeper shifts into
reverse in order to prevent damage to the nozzle supporting structure. This sweeping machine is
very huge and expensive.
Figure 4 truck vacuum type sweeper [1]

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2.1.2 DEVELOPING MANUALLY DRIVEN STREET CLEANING MACHINE
(SCM) [2]
This type of machine is used to sweep streets. It is manually driven by hands. Therefore, one of
limitation of this machine is very low storage system, very high human effort is needed to sweep
the streets
.
2.2 CONCEPT GENERATION
2.2.1 SEARCHING FOR WORKING PRINCIPLES
Throughout suggesting how the machine works, the following concepts were generated:
Concept-A: cleaning system with small collector
Figure 6 simple Schematic diagram for Concept A
Figure 5 Manually driven street cleaning machine [2]

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✓ The power is transmitted by chain drive from rear wheels to roller cleaner
✓ The purpose of roller cleaner is sweeping and moving to simple collector
✓ Smaller collector is used to store the wedges
✓ There is no engaging and disengaging the power from rear wheels.
Concept B: cleaning system with sprocket and chain drive only
✓ The power is transmitted by chain drive from rear wheels to Driver sprocket
✓ The purpose of driven sprocket is to transmit power from driver sprocket to chain drive
✓ On chain drive the cleaning material is mounted, due to the rotation of driven sprocket
the chain rotates at the same time the cleaning process is held.
✓ Storage tank is used to store the wedges
✓ There is no engaging and disengaging the power from rear wheels.
Concept C: cleaning system with flat belt drive
As illustrated on the figure 8 below
✓ The purpose of pulley is to transmit power from driver sprocket to flat belt pulley.
Figure 7 simple Schematic diagram for Concept B

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✓ On flat belt drive the cleaning material is mounted, due to the rotation of driven sprocket,
pulleys rotate and at the same time the cleaning process is available.
✓ There is engaging and disengaging the power from rear wheels.
Concept D: cleaning system with rolling shaft and electric tricycle system
✓ The purpose of rolling shaft is to transmit power from driver sprocket to the flat belt.
✓ On flat belt drive the cleaning material is mounted, due to the rotation of driven sprocket,
the rolling shaft rotates flat belt mounted on it and cleaning process is done at the same
time.
Figure 8 simple Schematic diagram for Concept C

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✓ There is engaging and disengaging the power from rear wheels.
2.2.2 CONCEPT SELECTION
The following are criterias used to select working principle from the concept generated on section
2.2.1.
✓ Cost
✓ Size and Compatibility
✓ Ergonomic
✓ Reliability
✓ Maintainability
The ranking method used is illustrated below:
Poor: 1
Good:2
Very Good:3
Excelent:4
Figure 9 simple schematic diagram for concept D

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Table 3 concept selection
Criteria used Concept generated
Concept A Concept B Concept C Concept D
Cost 4 3 3 2
Storage capacity 1 4 4 4
Ergonomic 1 2 3 4
Reliability 2 2 3 4
Maintainability 3 2 2 3
Size and
compatibility
3 1 3 4
Total 14 12 18 21
Score 3rd 4th 2nd 1st
According to table 3 concept d is selected for this project.
2.3 MAIN COMPONENTS TO BE DESIGNED AND FUNCTIONAL STRUCTURE
2.3.1 MAIN COMPONENTS TO BE DESIGNED
2.3.1.1 CONVEYING AND STORING SYSTEM
It consists the following components:
A. Two Idle Rolling shafts
B. One drive rolling shaft for cleaning system
C. Two sprockets for driver rolling shafts
D. Shafts and bearing for idle rolling shafts
E. Shafts and bearings for driver rolling shaft
F. Two chains for driver sprockets
G. Flat Belt
H. Cleaning material mounted on belts and other related accessories
I. Sloped plate for transporting purpose
J. Container for storing
K. Frame used to hold components
L. Casters and wheels
2.3.1.2 TRICYCLE SYSTEM
A. Two rears and one front cycle wheels
B. sprockets and bearings
C. two rears and one front wheel fender
D. two pedals

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E. Comfort Saddle
F. Frame
G. Rear and front brake and brake lever
H. Handle bar
I. Pedal chain
J. Shaft connecting rear wheels
K. 48v DC motor
L. 48v Rechargeable Lithium Battery
2.3.2 FUNCTIONAL STRUCTURE
The following figure shows the general functional structure of the machine.
2.4 LITERATURE BACKGROUND FOR MAIN COMPONENTS
2.4.1 BELTS
A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most
often parallel. Belts may be used as a source of motion, to transmit power efficiently, or to track
•Rotational Motion From two Rear wheels of the
cycle.Input
•to clean
•to load
•to transport and
•store debris
Function
•cleaned surface of Asphaltoutput
Figure 10 General Functional structure for the machine

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relative movement. Belts are looped over pulleys and may have a twist between the pulleys, and
the shafts need not be parallel. [3]
There are three types of belt drive according to their feature:
1. Flat belt drive
2. V-belt drive
3. Circular belt drive
1. Flat belt drive: - Flat belts drives can be used for large amount of power transmission and
there is no upper limit of distance between the two pulleys. Belt conveyer system is one such
example. These drives are efficient at high speeds and they offer quite running. [4]
Types of flat belt drive [5]:
a) Open belt drive: is used with shafts arranged parallel and rotating in the same
direction.
b) Crossed or twist belt drive.
c) Belt drive with idler pulleys
d) Compound belt drive
Figure 11 flat belt drive [6]
2. V-belt drive: V belts solved the slippage and alignment problem. It is now the basic belt for
power transmission. They provide the best combination of traction, speed of movement, load
of the bearings, and long service life. They are generally endless, and their general cross-
section shape is roughly trapezoidal (hence the name "V"). The "V" shape of the belt tracks in
a mating groove in the pulley (or sheave), with the result that the belt cannot slip off. [3]
3. Circular belt drive: The circular belt or rope is mostly used in the factories and workshops,
where a great amount of power is to be transmitted, from one pulley to another, when the two
pulleys are more than 8 meters apart. [3]

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2.4.2 SPROCKET
Sprockets are rotating parts with teeth that are used in conjunction with a chain and, almost always,
at least one other sprocket to transmit torque. Sprockets and chain can be used to change the speed,
torque, or original direction of a motor. In order for sprockets and chain to be compatible with
each other they must both have the same thickness and pitch. In order for the sprockets and chain
to work effectively, all of the sprockets should be on parallel shafts with their corresponding teeth
on the same plane. [7]
Sprockets are used in bicycles, tricycle, motorcycles, cars, tracked vehicles, and other machinery
either to transmit rotary motion between two shafts where gears are unsuitable or to impart linear
motion to a track, tape etc. Perhaps the most common form of sprocket may be found in the bicycle,
in which the pedal shaft carries a large sprocket-wheel, which drives a chain, which, in turn, drives
a small sprocket on the axle of the rear wheel. Early automobiles were also largely driven by
sprocket and chain mechanism, a practice largely copied from bicycles. [8]
The following are common types of sprockets:
1. Split sprocket: this type of sprocket is divided in to two to allow installation or assembly
with other components.
2. Sectional rim sprockets: in this type of sprocket the rim is sectioned into three parts to all
for replacement without uninstalling the sprocket.
Figure 12: Split type Sprocket [29]

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3. Double pitch sprocket: in this type the sprocket drives the chain by using two teeth.
4. Shear pin sprocket: in this type of sprocket the hub is keyed to the shaft, the sprocket
rotates on the shaft.
5. Roller chain sprocket: Roller chain sprockets are toothed gears used with roller chain to
transmit mechanical power. The teeth of the sprocket interlock with the individual chain
components. As the sprocket rotates, it pulls the chain along and transfers power from the
Figure 13: Sectional rim sprocket [30]
Figure 14:Double pitch sprocket [31]
Figure 15 Shear pin sprocket [32]

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driver end to the driven end of a system. Roller chain sprocket types include bushing bore,
finished bore, machinable bore, and idler. [9]
2.4.3 CHAINS
The chains are mostly used to transmit motion and power from one shaft to another, when the
center distance between their shafts is short such as in bicycles, motor cycles, agricultural
machinery, conveyors, rolling mills, road rollers etc. The chains may also be used for long center
distance of up to 8 meters. The chains are used for velocities up to 25 m / s and for power up to
110 kW. In some cases, higher power transmission is also possible. [5]
Classification of Chains [5]
The chains, on the basis of their use, are classified into the following three groups:
1. Power transmitting (or driving) chains
2. Hoisting and hauling (or crane) chains,
3. Conveyor (or tractive) chains, and
1. Power transmitting chains: - These chains are used for transmission of power, when the distance
between the centers of shafts is short. These chains have provision for efficient lubrication. The
power transmitting chains are of the following three types.
A. Block or bush chain: - This type of chain was used in the early stages of
development in the power transmission.
It produces noise when approaching or leaving the teeth of the sprocket because of rubbing
between the teeth and the links. Such type of chains is used to some extent as conveyor chain at
small speed.
Figure 16 Roller chain sprocket [9]

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Figure 17 Block or bush chain. [5]
B. Bush roller chain. A bush roller chain is consisting of outer plates or pin
link plates, inner plates or roller link plates, pins, bushes and rollers.
A pin passes through the bush which is secured in the holes of the roller between the two sides of
the chain. The rollers are free to rotate on the bush which protect the sprocket wheel teeth against
wear. A bush roller chain is extremely strong and simple in construction. It gives good service
under severe conditions. There is a little noise with this chain which is due to impact of the rollers
on the sprocket wheel teeth. This chain may be used where there is a little lubrication.
Figure 18 Bush roller chain. [5]
2. Hoisting and hauling (or crane) chains: These chains are used for hoisting and hauling
purposes and operate at a maximum velocity of 0.25 m / s.

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Figure 19 Hoisting and hauling (or crane) chains [5]
3. Conveyor (or tractive) chains: these chains are used for elevating and conveying the
materials continuously at a speed up to 2 m / s. The conveyor chains are of the following
two types:
1. Detachable or hook joint type chain,
2. Closed joint type chain,
2.4.4 SHAFTS
A shaft is a rotating machine element, usually circular in cross section, which is used to transmit
power from one part to another, or from a machine which produces power to a machine which
absorbs power. The various members such as pulleys and gears are mounted on it. [10]
Types of Shafts [5]
The following two types of shafts are important from the subject point of view
1. Transmission shafts: These shafts transmit power between the source and the machines
absorbing power. The counter shafts, line shafts, overhead shafts and all factory shafts are
transmission shafts. Since these shafts carry machine parts such as pulleys, gears etc., therefore
they are subjected to bending in addition to twisting.
Figure 20 transmission shaft [11]
2. Machine shafts: These shafts form an integral part of the machine itself. The crank shaft is
an example of machine shaft. Figure 21 below shows one of machine shaft, that is crankshaft.

Page | 23
Figure 21 machine shaft (crankshaft) [12]
Rolling shaft: this type of shaft is commonly used in flat belt conveyors. It is illustrated below
on figure 22.
2.4.5 BEARING
A bearing is a machine element which support another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while carrying
the load. A little consideration will show that due to the relative motion between the contact
surfaces, a certain amount of power is wasted in overcoming frictional resistance and if the rubbing
surfaces are in direct contact, there will be rapid wear. In order to reduce frictional
resistance and wear and in some cases to carry away the heat generated, a layer of fluid (known as
lubricant) may be provided. [5]
Classification of Bearings [5]
Figure 22 Rolling shaft [39]

Page | 24
1. Depending upon the direction of load to be supported. The bearings under this group are
classified as:
a. Radial bearings, and
b. Thrust bearings.
Radial bearing. the load acts perpendicular to the direction of motion of the moving element.
The purpose of a radial bearing is to reduce rotational friction and support loads. [13]
Figure 23 Radial Bearing [5] [14]
Thrust bearings. Thrust bearings are designed for side or axial loads and cannot handle much
radial load at all. The rolling element in a thrust bearing can be a ball, needle or roller. [13]
2. Depending upon the nature of contact: The bearings under this group are classified as:
I. Sliding contact bearings, and
II. Rolling contact bearings.
I. Sliding contact bearings: The sliding contact bearings in which the sliding action is
guided in a straight line and carrying radial loads. Such type of bearings is usually
found in cross-head of steam engines. [5]
II. Rolling contact bearings: is the wide variety of bearings that use spherical balls or
some other type of roller between the stationary and the moving elements. The most
common type of bearing supports a rotating shaft, resisting purely radial loads or a
combination of radial and axial (thrust) loads. [15]

Page | 25
Types of Rolling Contact Bearings [5]
Following are the two types of rolling contact bearings:
1. Ball bearings; and
2. Roller bearings.
The ball and roller bearings consist of an inner race which is mounted on the shaft or journal
and an outer race which is carried by the housing or casing. In between the inner and outer race,
there are balls or rollers. A number of balls or rollers are used and these are held at proper
distances by retainers so that they do not touch each other.
Figure 24 ball and rolling bearing [16]
2.4.6 ELECTRIC MOTORS
An electric motor is an electrical machine that converts electrical energy into mechanical energy.
The reverse of this is the conversion of mechanical energy into electrical energy and is done by an
electric generator, which has much in common with a motor. Electric motors are used to produce
linear or rotary force (torque), and should be distinguished from devices such as magnetic
solenoids and loudspeakers that convert electricity into motion but do not generate usable
mechanical powers, which are respectively referred to as actuators and transducers. [17]
Mainly there are two types of electric motors depending on current flow:
A. AC Motor: it is an electric motor driven by an alternating current (AC). The AC motor
commonly consists of two basic parts, an outside stator having coils supplied with
alternating current to produce a rotating magnetic field, and an inside rotor attached to
the output shaft producing a second rotating magnetic field. The rotor magnetic field may
be produced by permanent magnets, reluctance saliency, or DC or AC electrical
windings. [18]

Page | 26
B. DC Motor: A DC motor is any of a class of rotary electrical machines that converts
direct current electrical energy into mechanical energy. The most common types rely on
the forces produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic, to periodically change the direction
of current flow in part of the motor. [19]
2.4.7 RECHARGEABLE BATTERIES FOR E-TRIKE
Battery systems used for E-bike and E-trike include sealed lead-acid (SLA), nickel-cadmium
(NiCad), nickel-metal hydride (NiMH) or lithium-ion polymer (Li-ion). Batteries vary according
to the voltage, total charge capacity (amp hours), weight, the number of charging cycles before
performance degrades, and ability to handle over-voltage charging conditions. The energy costs of
operating e-bikes are small, but there can be considerable battery replacement costs. The lifespan
of a battery pack varies depending on the type of usage. Shallow discharge/recharge cycles will
help extend the overall battery life. [20]
2.5 MATERIAL AVAILABLE FOR MAIN COMPONENTS
2.5.1 MATERIAL AVAILABLE FOR MANUFACTURING BELTS
The following are the types of material used in manufacturing of belts:
1. Leather
2. Cotton / fabric
3. Rubber
4. Balata
Figure 25 DC AND A C MOTORS [41] [40]

Page | 27
1. Leather: The most important material for flat belt is leather. The best leather belts are made from
1.2 meters to 1.5 meters long strips cut from either side of the back bone of the top-grade steer
hides. The leather belts must be periodically cleaned and dressed or treated with a compound or
dressing containing neat’s foot or other suitable oils so that the belt will remain soft and flexible.
[5]
Figure 26 leather used for belt drive [21]
Cotton / fabric belts: Most of the fabric belts are made by folding canvass or cotton duck to
three or more layers (depending upon the thickness desired) and stitching together. These belts
are woven also into a strip of the desired width and thickness. [3]
Figure 27 cotton belt drive [22]
2. Rubber belts: the rubber belts are made of layers of fabric impregnated with rubber composition
and have a thin layer of rubber on the faces. These belts are very flexible but are quickly destroyed
if allowed to come into contact with heat, oil or grease. One of the principle advantage of these
belts is that they may be easily made endless. These belts are found suitable for saw mills, paper
mills where they are exposed to moisture. [5]

Page | 28
Figure 28 rubber belts drive [23]
3. Balata belts: These belts are similar to rubber belts except that balata gum is used in place of
rubber. These belts are acid proof and water proof and it is not affected by animal oils or alkaline.
The balata belts should not be at temperatures above 40°C because at this temperature the balata
begins to soften and becomes sticky. The strength of balata belts is 25 per cent higher than rubber
belts.
Figure 29 balata belt drive [24]
2.5.2 MATERIALS AVAILABLE FOR MANUFACTURING CHAIN DRIVE
1. Stainless steel: It is defined as that steel which when correctly heat treated and finished,
resists oxidation and corrosive attack from most corrosive media. [5] The different types
of stainless steels are discussed below:
Martensitic stainless steel: The chromium steels containing 12 to 14 per cent chromium
and 0.12 to 0.35 per cent carbon are the first stainless steels developed. Since these steels
possess martensitic structure, therefore, they are called martensitic stainless steels. These

Page | 29
steels are magnetic and may be hardened by suitable heat treatment and the hardness
obtainable depends upon the carbon content. These steels can be easily welded and
machined. When formability, softness, etc. are required in fabrication, steel having 0.12 per
cent maximum carbon is often used in soft condition. With increasing carbon, it is possible
by hardening and tempering to obtain tensile strength in the range of 600 to 900 N/mm2,
combined with reasonable toughness and ductility. In this condition, these steels find many
useful general applications where mild corrosion resistance is required. Also, with the
higher carbon range in the hardened and lightly tempered condition, tensile strength of about
1600 N/mm2 may be developed with lowered ductility. [21]
Ferritic stainless steel: The steels containing greater amount of chromium (from 16 to 18
per cent) and about 0.12 per cent carbon are called ferritic stainless steels. These steels
have better corrosion resistant property than martensitic stainless steels. But, such steels
have little capacity for hardening by heat treatment. However, in the softened condition,
they possess good ductility and are mainly used as sheet or strip for cold forming and
pressing operations for purposes where moderate corrosion resistance is required. They may
be cold worked or hot worked. They are Ferro-magnetic, usually undergo excessive grain
growth during prolonged exposure to elevated temperatures and may develop brittleness
after electric arc resistance or gas welding. These steels have lower strength at elevated
temperatures than martensitic steels. However, resistance to scaling and corrosion at
elevated temperatures are usually better. The machinability is good and they show no
tendency to inter crystalline corrosion. [21]
Austenitic stainless steel: The steel containing high content of both chromium and nickel
are called austenitic stainless steels. There are many variations in chemical composition of
these steels, but the most widely used steel contain 18 per cent chromium and 8 per cent
nickel with carbon content as low as possible. Such a steel is commonly known as 18/8
steel. These steels cannot be hardened by quenching; in fact, they are softened by rapid
cooling from about 1000°C. They are nonmagnetic and possess greatest resistance to
corrosion and good mechanical properties at elevated temperature. These steels are very
tough and can be forged and rolled but offer great difficulty in machining. They can be
easily welded, but after welding, it is susceptible to corrosive attack in an area adjacent to
the weld. This susceptibility to corrosion (called inter crystalline corrosion or weld decay)

Page | 30
may be removed by softening after welding by heating to about 1100°C and cooling rapidly.
These steels are used in the manufacture of pump shafts, rail road car frames and sheathing,
screws, nuts and bolts and small springs. Since 18/8 steel provide excellent resistance to
attack by many chemicals, therefore, it is extensively used in chemical, food, paper making
and dyeing industries. [21]
2. Plastics: Possibly the largest number of different polymeric materials come under the
plastic classification. Polyethylene, polypropylene, polyvinyl chloride, polystyrene, and
the fluorocarbons, epoxies, phenolics, and polyesters may all be classified as plastics. They
have a wide variety of combinations of properties. Some plastics are very rigid and brittle;
others are flexible, exhibiting both elastic and plastic deformations when stressed, and
sometimes experiencing considerable deformation before fracture. [21]
3. Steel [21]: It is an alloy of iron and carbon, with carbon content up to a maximum of 1.5%.
The carbon occurs in the form of iron carbide, because of its ability to increase the hardness
and strength of the steel. Other elements e.g. silicon, Sulphur, phosphorus and manganese
are also present to greater or lesser amount to impart certain desired properties to it. Most
of the steel produced now-a-days is plain carbon steel or simply carbon steel. A carbon
steel is defined as a steel which has its properties mainly due to its carbon content and does
not contain more than 0.5% of silicon and 1.5% of manganese. The plain carbon steels
varying from 0.06% carbon to 1.5% carbon are divided into the following types depending
upon the carbon content:
A. Dead mild steel — up to 0.15% carbon
B. Low carbon or mild steel — 0.15% to 0.45% carbon
C. Medium carbon steel — 0.45% to 0.8% carbon
D. High carbon steel — 0.8% to 1.5% carbon
2.5.3 MATERIAL AVAILABLE FOR MANUFACTURING OF SPROCKETS
1.Cast iron: Cast Iron is the most common and economical material for flat wire belt
sprockets, they are accurately cast from high grade iron. It is obtained by re-melting pig iron
with coke and limestone in a furnace known as cupola. It is primarily an alloy of iron and
carbon. The carbon contents in cast iron varies from 1.7 per cent to 4.5 percent. It also
contains small amounts of silicon, manganese, phosphorous and Sulphur. [5]
Most common types of cast iron [25]
A. Gray Iron: The carbon and silicon contents of gray cast irons vary between 2.5 and 4.0 wt
% and 1.0 and 3.0 wt %, respectively. For most of these cast irons, the graphite exists
in the form of flakes (similar to corn flakes), which are normally surrounded by an

Page | 31
ferrite or pearlite matrix. Because of these graphite flakes, a fractured surface takes on a
gray appearance, hence its name.
Mechanically, gray iron has the following properties:
✓ Comparatively weak and brittle in tension as a consequence of its microstructure
✓ The tips of the graphite flakes are sharp and pointed and may serve as points of stress
concentration when an external tensile stress is applied.
✓ Strength and ductility are much higher under compressive loads.
✓ They are very effective in damping vibrational energy.
B. Ductile (or Nodular) Iron: Adding a small amount of magnesium and/or cerium to the
gray iron before casting produces a distinctly different microstructure and set of
mechanical properties. Graphite still forms, but as nodules or sphere like particles instead
of flakes. The resulting alloy is called nodular or ductile iron.
• Castings are stronger and much more ductile than gray iron
• ductile iron has mechanical characteristics approaching those of steel. For example,
ferritic ductile irons have tensile strengths ranging
between 380 and 480 MPa (55,000 and 70,000 psi), and ductilities (as percent
elongation) from 10 to 20%.
• Typical applications for this material include valves, pump bodies, crankshafts, gears,
and other automotive and machine components.
C. White Iron and Malleable Iron: For low-silicon cast irons (containing less than 1.0 wt
% Si) and rapid cooling rates.
White iron is extremely hard but also very brittle, to the point of being virtually un machinable.
Its use is limited to applications that necessitate a very hard and wear-resistant surface, and
without a high degree of ductility, for example, as rollers in rolling mills.
Generally, white iron is used as an intermediary in the production of yet another cast iron,
malleable iron. Heating white iron at temperatures between 800 and 900C (1470 and 1650F)
for a prolonged time period and in a neutral atmosphere (to prevent oxidation) causes a
decomposition of the cementite, forming graphite, which exists in the form of clusters or
rosettes surrounded by a ferrite or pearlite matrix, depending on cooling rate.
2. Plastic: most of the time they are used in food processing industries. This materials property is
discussed in portion 2.5.2
3. Steel and Stainless steel: this material property is discussed in portion 2.5.2
2.5.4 MATERIAL AVAILABLE FOR MANUFACTURING OF BEARINGS
The following are manufacturing materials widely used for bearing [5]:
1. Copper-base alloys,
2. Lead-base alloys,
3. Tin-base alloys, and
4. Cadmium-base alloys.

Page | 32
1. Copper base alloys: are the most important bearing alloys. These alloys are harder and stronger
than the white metals (lead base and tin base alloys) and are used for bearings subjected to
heavy pressures.
2. Lead base alloys: are employed where a cheap and corrosion resistant material is required. An
alloy containing 83% lead, 15% antimony, 1.5% tin and 0.5% copper is used for large bearings
subjected to light service.
3. Tin base alloys: It can be rolled into very thin sheets. It is used for making important alloys, fine
solder, as a protective coating for iron and steel sheets and for making tin foil used as moisture
proof packing. A tin base alloy containing 88% tin, 8% antimony and 4% copper.
4. Cadmium base alloys: the cadmium base alloys contain 95% cadmium and 5% silver. It is
used for medium loaded bearings subjected to high temperature.
Most common materials used for manufacturing of rolling contact bearing are the following
✓ Stainless steel
✓ Steel
✓ Brass
A bearing material should have the following properties [5]:
✓ It should have low coefficient of friction.
✓ It should have good wearing qualities.
✓ It should have ability to withstand bearing pressures.
✓ It should have ability to operate satisfactorily with suitable lubrication means at the
maximum rubbing speeds.
✓ It should have a sufficient melting point.
✓ It should have high thermal conductivity.
✓ It should have good casting qualities.
✓ It should have minimum shrinkage after casting.
✓ It should have non-corrosive properties.
✓ It should be economical in cost.
2.5.5 MATERIAL AVAILABLE FOR MANUFACTURING OF SHAFTS AND KEYS
✓ Cast iron: already discussed on portion 2.5.3
✓ Stainless steel: already discussed on portion 2.5.2
✓ Steel: already discussed on portion 2.5.2
2.6 MATERIAL SELECTION FOR MAIN COMPONENTS
2.6.1 MATERIAL SELECTION FOR FLAT BELTS
The following are selecting criteria for flat belt drive:
Strength

Page | 33
Flexibility
cost
Table 4 weight analysis to select material for flat belt
✓ As shown in table 3 the material selected for flat belt is rubber
2.6.2 MATERIAL SELECTION FOR All CHAIN DRIVE
The following are selecting criteria for chain drive:
✓ Strength
✓ Corrosion resistance
✓ Cost
Table 5 weight analysis to select material for chain drive
Material Strength 50% Corrosion resistance
20%
Cost
30%
Total (100%)
Stainless
steel
45% 20% 14% 79%
plastics 25% 20% 25% 70%
Steel 40% 15% 25 80%
✓ As shown in table 4 the material selected for chain drive is steel.
2.6.3 MATERIAL SELECTION FOR ALL SHAFTS AND KEYS
The following are selecting criteria for shafts and keys:
• Manufacturability
• Corrosion resistance
• Cost
• Strength
Material Strength 50% Flexibility 30% Cost 20% Total (100%)
Leather 45% 15% 10% 70%
Cotton 25% 20% 18% 63%
Rubber 40% 25% 15 80%
Balata 35% 23% 13 71%

Page | 34
Table 6 weight analysis to select material for shafts and keys
✓ As shown in table 5 the material selected for shafts and keys is stainless steel.
2.6.4 MATERIAL SELECTION FOR ALL SPROCKETS
The following are selecting criteria for sprockets
Cost
Strength
Manufacturability
Table 7 weight analysis to select material for sprockets
As shown in table 6 the material selected for all sprockets is steel.
2.6.5 MATERIAL SELECTION FOR ALL BEARINGS
The following are selecting criteria for bearings:
Manufacturability, Strength, Heat resistance, corrosion resistance and Cost
Material Manufacturability
(30%)
Corrosion
resistance
(15%)
Cost
(15%)
Strength (40%) Total
(100%)
Stainless
steel
25% 10% 13% 28% 76%
Cast iron 20% 15% 5% 35% 75%
Steel 15% 10% 10% 33% 66%
Material Cost 20% Strength 50% Manufacturability
30%
Total
(100%)
Steel 15% 40% 29% 84%
Plastic 11% 25% 10% 46%
Stainless steel 18% 40% 25% 83%
Cast iron 14% 42% 23% 79%

Page | 35
Table 8 weight analysis to select material for all bearing
As shown in table 7 the material selected for all beatings is steel.
2.7 WASTE SOURCE AND TYPE
2.7.1 SOURCES OF WASTES [26]
The general sources of waste are illustrated below.
1. Residential: generated from living households (domestic), generally contain non-
hazardous solid wastes; kitchen waste, ‘‘Ketema”, and ash are common in Ethiopia.
2. Agricultural: solid wastes due to agricultural activities: food residues, animal dung, crop
residues, etc. Such wastes are usually non-hazardous and negligible in rural Ethiopia.
3. Commercial: wastes generated from business establishments: food establishments, shops,
etc., that generate generally non-hazardous waste such as paper, cardboard, wood, metals
and plastic.
4. Industrial wastes: from various types of industrial processes. The nature of the waste
depends on the type of industry and kind of raw material involved. There may be toxic and
hazardous wastes that have adverse effects to the environment.
5. Institutional solid waste: generating from public and government institutions: offices,
religious institutes, schools, universities, etc.; generally, not hazardous.
6. Hospital solid wastes: discarded, unwanted solid wastes from hospitals. It consists of both
non-hazardous and hazardous waste. The above classification helps to identify whether the
waste is hazardous or not.
2.7.2 TYPES OF WASTES [26]
The most common types of wastes that come from the above sources are listed below:
Food waste
Paper, Cardboard and Plastics
Textile, Rubber and Lather
Garden trimming, Animal dungs
Wood, Glass, Tin cans and Metals
Dirt ash and bricks and stones.
Material
Manufact
urability
20%
Strength
25%
Heat
resistance
15%
Corrosion
resistance
20%
Cost
20%
Total (100%)
Stainless
steel
18% 24% 14% 20% 10% 86%
Steel 16% 22% 13% 18% 18% 87%
Brass 15% 23% 14% 19% 10% 81%

Page | 36
CHAPTER THREE
EMBODIMENT DESIGN

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