Bekele Chala .ENGR/157/09 2. Elias Ayana ... ENGR/320/10

TITLE: MANUAL OPERATED SCISSOR LIFTING AND TRANSPORTING MACHINE

FINAL INTERNISHIP FROM TO JUNE TO AUGUST AT AMBO MINERAL WATER

SHARE COMPANY
GROUP MEMBER
NAME ID. NO:
1. Bekele Chala…………………………………….ENGR/157/09
2. Elias Ayana……………………………………...ENGR/320/10

ADVISOR: Mr. Gadisa D-----------------
Submission date: 26/12/2013

WOLKITE ETHIOPIA
Manual operated scissor lifting and transporting machine 2013
DECLARATION
Internship program is newly adopted in the educational curriculum of Ethiopia for engineering
students. It is given to students of fourth year and in the second semester. We have done this
internship program for three months at Ambo Mineral Water S.C. we declare that the project work
entitled as ‘Design of manual operated scissor lifting and transporting machine for Ambo Mineral
Water S.C. as required for the three months’ internship semester for the award of ‘Internship eval-
uation’ under the guidance of Our advisor Mr. Gadisa D from June, 2021 to August, 2021.
By:-
Name Signature Date
Bekele Chala …………………….. ………………
Eliyas Ayana ……………………….. ………………..
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ACKNOWLDEGMENT
First we would like to say thanks to God who makes us powerful and strength during internship
to success our project, then we would like to thanks our mentor Dawit for making us confident and
initiative to do our training on time and give us orientations about the project to do easily and we
would like to thanks our advisor Mr. Gadisa for advising us to be innovator and push us to create
new idea in the daily activities and for the success of our internship practice in brief way also we
would like to thanks all of company employers for their assistant to do our specific section on the
production section of the company, and other workers of the company for their willingness to help
us in the progress of our project and support us by explaining about any job in the company and
told us the working principles of machines. Finally, we would like thanks all our teacher who
thought and enforced us to study and to do some project given in the class which help us during
internship.
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EXECUTIVE SUMMARY
Ambo Mineral Water Share Company is one of the oldest factories with its soft and non-alcoholic
beverage factories in Ethiopia. The Ambo mineral water manufacturing plant had two lines which
have a total production capacity of 36,000 per hour. The major benefits that we get from the in-
ternship are classified and stated as, improving practical skill, upgrading theoretical knowledge.
Challenges we have been faced while performing our work tasks are lack of safe, lack of library,
lack of scheduled maintenance, lack of different department together, lack of educated persons.
In the Ambo mineral water, we have seen many problems during internship program, the problems
are: lack of loading and unloading, lack of syrup tank lifter, The problem of washing bottle man-
ually, while design on effective manual operated scissor lifting and transporting that solve problem
of lifting and transporting raw material of production and bottles product or empty glass bottles
with crates in syrup, returnable glass bottle, and PET line rooms that reduce man power. This
project is designed by calculating different calculations and by arranging of the components
properly. There are many results obtained during the design analysis of this machine. The report
contains seven chapters to describe briefly the back ground of hosting company. While the other
part of this report describes the overall internship experience we gained during the practical peri-
ods, the benefits gained from our internship, design with detail design, result and discussion and
finally the conclusion and recommendation.
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Contents
CHAPTER ONE ............................................................................................................................. 1
1.1 INTRODUCTION ................................................................................................................. 1
1.2 Back Ground and History of Ambo Mineral Water S.C ....................................................... 1
1.3 Vision Mission and Goal ....................................................................................................... 2
1.4 Objectives of the Company ................................................................................................... 3
1.4.1General objective................................................................................................................. 3
1.4.2 Specific Objective .............................................................................................................. 3
1.5 Main Products or Services of Ambo Mineral Water Factory................................................ 3
1.6 Main Consumer of Ambo Mineral Water Products .............................................................. 5
1.7 Overall Organization Chart and Management of the Company. ........................................... 6
2 CHAPTER TWO ........................................................................................................................ 8
2.1 Overall Internship Experience ............................................................................................... 8
2.1.1 HowWeGot into the Company ........................................................................................... 8
2.2 The Section of the CompanyWeHave Been Working In ...................................................... 8
2.2.1 Section of RGB Line .......................................................................................................... 8
2.2.2 Unpacker machine .............................................................................................................. 8
2.2.3 Crate Washer machine ....................................................................................................... 9
2.2.4 Bottle washer machine ....................................................................................................... 9
2.2.5 Filler and capper Machine ................................................................................................ 11
2.2.6 Labelling Machine............................................................................................................ 13
2.2.7 Packer Machine ................................................................................................................ 13
2.3 Section of PET line ............................................................................................................. 15
2.3.3 Filler (Rinser and Capper ................................................................................................. 18
2.3.4 Labeler machine ............................................................................................................... 20
2.3.5 Shrink Wrapper ................................................................................................................ 21
2.3.6 Stretching wrapper ........................................................................................................... 22
2.4 Utilities line ......................................................................................................................... 22
2.4.1 Water treatment ................................................................................................................ 22
2.4.2 Steam generation (Boiler) ................................................................................................ 24
2.4.3 Chiller ............................................................................................................................... 25
2.4.4 Air Compressors ............................................................................................................... 26
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2.4.5 Syrup preparation process ................................................................................................ 27

2.5 Work Piece or Task We Have Been Executing................................................................... 30
2.6 Challenges That Have Been Faced During Our Internship ................................................. 31
2.7 Major Task We Takes To Overcome the Challenge ........................................................... 31
CHAPTER THREE ...................................................................................................................... 32
3.1 OVERALL BENEFITS ........................................................................................................ 32
3.2 Overall Benefits Gained From Internship ........................................................................... 32
3.3 In Terms of Improving Our Practical Skills ........................................................................ 32
3.4 In Term Upgrading Our Theoretical ................................................................................... 32
3.5 In Terms of Improving Interpersonal Communication Skills ............................................. 33
3.6 In Term of Improving Team Playing Skills ........................................................................ 33
3.7 In Term of Improving Our Leadership Skill Out Of Working ............................................ 34
3.8 Understanding about work ethics related issues ................................................................. 34
3.9 Personal ethics ..................................................................................................................... 34
3.10 Professional ethics ............................................................................................................. 35
3.11 Entrepreneurship Skill ....................................................................................................... 35
3.12.2 Recommendation ............................................................................................................ 36
CHAPTER FOUR ......................................................................................................................... 38
4. Design of Manual Operated Scissor Lifting and Transporting Machine .............................. 38
4.1 Introduction ......................................................................................................................... 38
4.2 background of the study ...................................................................................................... 38
4.3 Statement of the problem .................................................................................................... 39
4.4 Objectives of the study ........................................................................................................ 39
4.4.1 General objectives ............................................................................................................ 39
4.4.2 Specific objectives............................................................................................................ 39
4.5 Scope of study ..................................................................................................................... 39
4.6 Literature Review ................................................................................................................ 40
4.7 Materials and Methods ........................................................................................................ 41
4.8 Working principle of manual operated scissor lifting and transporting machine ............... 41
4.9 Significance of the study ..................................................................................................... 42
4.10 Material Selection ............................................................................................................. 42
CHAPTER FIVE .......................................................................................................................... 43
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5. DETAIL DESIGN .................................................................................................................... 43

5.1 Conceptual Design .............................................................................................................. 43
5.2 Detail Design and Analysis ................................................................................................. 47
5.3 Design analysis .................................................................................................................... 47
5.4 Design and Analysis of mechanical scissor lifting and transporting machine .................... 48
5.4.1 Force analysis on the linkage assembly ........................................................................... 48
5.4.2 Link angle at minimum position (𝜽𝒎𝒊𝒏) ........................................................................ 48
5.4.3 Link angle at maximum position (𝜽𝒎𝒂𝒙) ...................................................................... 49
5.5 Power screw terminologies and formulas ........................................................................... 51
5.5.1 Terminologies of power screw ......................................................................................... 52
5.5.2 Torque required to lift or lower a load by square threaded screws .................................. 53
5.5.3 Design of the lead screw .................................................................................................. 53
5.6 Design of Nut bar ................................................................................................................ 56
5.7 Design of links and pin ....................................................................................................... 58
5.8 Design of the base frame ..................................................................................................... 60
5.9 Design of the Crank handle ................................................................................................. 61
5.10 Caster Wheel Selection ..................................................................................................... 62
5.11 Prototype Fabrication and Testing, Mathematical Modelling ........................................... 62
5.12 Manufacturing Procedure .................................................................................................. 63
5.13 Financial Estimation .......................................................................................................... 64
CHAPTER SIX ............................................................................................................................. 65
6. Result and Discussion ........................................................................................................... 65
CHAPTER SEVEN ...................................................................................................................... 68
7. Conclusions and Recommendation ...................................................................................... 68
7.1 Conclusions ......................................................................................................................... 68
7.2 Recommendations ............................................................................................................... 69
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List figures
Figure 1. 1 Ambo mineral water ..................................................................................................... 4
Figure 1. 2 Ambo mineral water ..................................................................................................... 4
Figure 1. 3 Main consumer of Ambo mineral water products ........................................................ 5
Figure 1. 4 Overall Organization Chart and Management of the Company ................................... 7
Figure 2. 1:-Bottles Washer Machine ........................................................................................... 11
Figure 2. 2 :-Filling machine ........................................................................................................ 12
Figure 2. 3 Labelling machine ...................................................................................................... 13
Figure 2. 4 Room of general bottling line ..................................................................................... 14
Figure 2. 5 A process flow diagram of the entire PET as general. ............................................... 15
Figure 2. 6 A process flow diagram of the entire PET (polyethylene terephthalate) blowing ..... 17
Figure 2. 7 Stretch blow moulding. .............................................................................................. 17
Figure 2. 8 Blow moulding machine............................................................................................. 18
Figure 2. 9 A flow diagram of operation of filler ........................................................................ 19
Figure 2. 10 Flow diagram of filling process ................................................................................ 19
Figure 2. 11 Water Treatment/Process Flow Diagram ................................................................. 24
Figure 2. 12 Boiler ........................................................................................................................ 25
Figure 2. 13 Flow diagram of chillers ........................................................................................... 26
Figure 2. 14 flow diagram of air compressor ................................................................................ 27
Figure 2. 15 A flow diagram of syrup production process ........................................................... 29
Figure 5.1 Manual bottle washer machine .................................................................................... 43
Figure 5.2 Syrup tank lifter ........................................................................................................... 44
Figure 5. 3 Manual operated scissor lifting and transporting machine ......................................... 45
Figure 5. 4 The force analysis on the linkage assembly ............................................................... 48
Figure 5. 5 The link angle at minimum position ........................................................................... 48
Figure 5. 6 The link angle at maximum position .......................................................................... 49
Figure 5. 7 The force distribution at minimum angle ................................................................... 49
Figure 5. 8 The force distribution at maximum angle .................................................................. 50
Figure 5. 9 The comparing angle of the above two cases ............................................................. 51
Figure 5. 10 Terminologies of power screw ................................................................................. 52
Figure 5. 11 Figure 5. 11 (a) Development of screw. (b) Forces acing on the screw. .................. 53
Figure 5. 12 Design of the screw .................................................................................................. 53
Figure 5. 13 Design of nut bar ...................................................................................................... 56
Figure 5. 14 Force triangle in the linkage ..................................................................................... 58
Figure 5. 15 Design of the base frame .......................................................................................... 60
Figure 5. 16 Design of the Crank handle ...................................................................................... 61
Figure 5. 17 Analysis of human force ........................................................................................... 62
Figure 5. 18 Design of cater wheel ............................................................................................... 62
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List of tables
Table 1. 1The main consumers of Ambo mineral water products. ................................................. 6
Table 4. 1 Material selection for different parts of the machine ................................................... 42
Table 5. 1 Manual operated Scissor lifter, transporter machine ................................................... 45

Table 5. 2 Concept evaluation ...................................................................................................... 46
Table 5. 3 Cost analysis ................................................................................................................ 64
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Abbreviation Full name

Senkele…………………………………….. (The place where found company)
AMW………………………………………. (Ambo mineral water)
S.C………………………………………….. (Share Company)
PET……………………………………….… (Polyethylene terephthalate)
MEA……………………………………….. ..(Mon ethanolamine)
PLC……………………………………..…… (Programmed loading controller)
SSF……………………………………..…… (Special super filtration)
CIP………………………………………… (Clean internal place)
SBM………………………………………... (Stretch blow molding)
AMWF…………………………………… (Ambo mineral water filtration)
RGB................................................................Returnable glass bottle
RO………………………………………… (Reverse osmosis)
ASME………………………………… … (American society of mechanical engineering)
dn ………………………………… …….. (Nominal diameter)
tb………………………………………… (Thickness of base)
F.………………………………………… (Force)
F.s……………………………………… (Safety factor)
Wb …………………………………….. (Width of base)
Lb ………………………………………. (Length of base)
di………………………………………… (Internal diameter)
Pb ………………………………….……. (The maximum fluid pressure)
M ………………………………….…… (Momentum bending)
Fh …………………………………….… (Human force)
Fb …………………………………..… (Applied load)
KN…………………………………..… (Kilo newton)
mm……………………………………... (Millimeter)
Kg……………………………..………….. (Kilogram)
Pcr…………………………………….…critical load (safe load)
A ………………………………………..cross-sectional area
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CHAPTER ONE
1.1 INTRODUCTION
Ambo mineral water factory is one of the oldest factories with its soft and non-alcoholic beverage
factories in Ethiopia. The source of Ambo Mineral Water is a thermo-mineral spring. There are
two line of production those are returnable glass bottle and polyethylene terephthalate line and as
well as utilities line those are air compressor, chiller and ammonia gases, boiler, water treatment,
reverse osmosis, and syrup preparation. There are many machines in Ambo mineral water Share
Company those are Blower Machine, Air Conveyor, Filler Machine, Rinser, Capper, Dryer, La-
beler, Date Coder, Shrink Wrapper, Stretching Wrapper, Unpacker, Packer, Bottle Washer, and
Crate Washer Machine.
1.2 Back Ground and History of Ambo Mineral Water S.C

Ambo mineral water factory is one of the oldest factories with its soft and non-alcoholic beverage
factories in Ethiopia. It is located in Oromia regional state, in West Showa, at Ambo town special
place called Senkele; 120 km to south west of Addis Ababa and 5 km from Ambo town.
The main reason behind the selection of the place by the Imperial Government of Ethiopia was
beautiful climate and also, due to the presence of the thermal spring water. Based on the infor-
mation from the documents, Ambo thermos mineral spring water was bottled and secretly sent to
the palace. “The secret was however, revealed when the water was publicly tabled to ambassadors
and dignitaries who came to celebrate the coronation day of Emperor Haile Selassie 83 years ago,
in 1930,” the documents are written. In a rare natural gift, the mineral water flowed directly from
the source to the plant. “The water has its own natural carbonation. The factory was established in
1941 G.C as public enterprise in Ambo town at the time to produce Ambo mineral water only.
Originally the factory was not placed at Senkele but because of health security, in 1970 G.C the
factory is transferred to Senkele and until 1972 G.C planting factory was going on. The company
covers 93,103msq at Senkele. From the beginning the company was public enterprise, but in 2009
G.C the factory has partially given to the private. Currently, the government has a Share 33% and
67% of the factory’s product is on the hand of the private. To precede its work, the factory has 375
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permanent employees and around 80 other daily workers. The company water product plant was
designed to produce 14,400bottles/hr.
The product of the factory is distributed in local market and export market in Africa, Asian and
European countries. Mainly the company produce Ambo mineral water and recently it begins to
produce sweat drinks like water’ (Orange, Fanta, predator, Apple, Pineapple, Lemon-lime) or jiva
in general. The source of Ambo Mineral Water is a thermo-mineral spring, rich in natural calcium,
magnesium, iron, potassium, bicarbonates and carbon dioxide. The water originates in a volcanic
fissure which then peculates through mountainous terrain eventually being tapped at the springs in
Ambo Senkele.
Ambo comes from the Ethiopian highlands, a unique part of the world. It is recognized as the
leading beverage of Ethiopia, a true ‘Ethiopian Icon’. It is popularly consumed during and after
meals as a digestive, also popularly consumed as a thirst quenching ‘soft-drink’ or as a discerning
mixer, specifically with whiskey. The growing demand for Ambo Mineral water both locally and
abroad has resulted in new investments in capacity and packaging variations. The product and pack
range has been extended to include convenience packaging in plastic bottles, as well as new prod-
ucts, ‘Ambo lite’ (lower carbonation and mineralization) and ‘Ambo flavoured water.
Finally, the Ambo Mineral Water manufacturing plant had two lines which have a total production
capacity of 14,400 per hour. The two old lines were renovated and another new line was installed.
The new line of RGB and PET have a production capacity of 24,000 and 12,000 bottles per hour
respectively. [1]
1.3 Vision Mission and Goal

Vision: To be leading beverage business in Ethiopia.
Mission: To produce and deliver consistent high-quality products, penetrating both regional and
international markets whilst behaving in a responsible manner.
Goals:
• Improve technical operations.
• Improve delivery service and availability.
• Develop the Ambo brand.
• Develop organizational culture and capability.
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• Introduce new management techniques and disciplines.
1.4 Objectives of the Company
1.4.1General objective
The general objective of Ambo mineral water factor is to produce and deliver consistent high qual-
ity of Ambo water at regional and international markets whilst behaving in a responsible manner.
1.4.2 Specific Objective

• To increasing water production from two lines 14,400 to alone line of RGB 24,000 bottles
/hour and PET 12,000 bottles/hour.
• To Improving power generation.
• To increasing the production of softy drinks like: Jiva orange, flavored, Pine apple, Lemon,
Fanta, predator etc.
• To provide the customers of Ambo mineral water products distribution service that are to
the standards attained by well rated countries, supports the development and growth of
national economy through the establishment of efficient and responsible distribution net-
work for Ambo water products.
1.5 Main Products or Services of Ambo Mineral Water Factory

The growing demand for Ambo mineral water factor both locally and abroad has resulted in new
investments in capacity and packaging variations. Our product and pack range has been extended
to include convenience packaging in plastic bottles, as well as new products Ambo flavored water’
(Orange, Fanta, predator, Apple, Pineapple, Lemon-lime). [1]
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Figure 1. 1 Ambo mineral water. [1]
The classic Ambo Originating in the Ethiopian highlands, Ambo is the leading beverage of Ethio-
pia, a true ‘Ethiopian Icon’. Now available in a new redesigned bottle with embossed logo and a
new cork. Available in:
• 475 ML returnable glass.
• 330 ML non-returnable plastic.
Figure 1. 2 Ambo mineral water. [1]
Ambo Mineral Water introduces a new and exciting line of flavoured Ambo. Currently available
refreshing fruit flavours: Ambo mineral water, Jiva Fanta, Apple, Lemon-lime and Jiva Predator
Available in:
• 250 ML PET
• 500 ML PET
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Its main service: Basic communication systems, social services and other facilities are available to
facilitate the various activities of the Company. Transportation facility is a satisfactory. Others
infrastructures include:
• A well-built store.
• Comfortable residential houses.
1.6 Main Consumer of Ambo Mineral Water Products

Ambo water is the oldest Mineral water in Ethiopia, still serves with the same fresh and dynamic
excellence from the Company in the Country. The company has many customers in abroad of
Ethiopia. Fortunately for Ambo Mineral Water Share Company, the market has not been that chal-
lenging. This is because of the South Africa Brewery (SAB) investors had established market link
before they come to Ethiopia. They come here with that market access. [1]
Figure 1. 3 Main consumer of Ambo mineral water products. [1]
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[1]
Table 1. 1The main consumers of Ambo mineral water products.
Europe Africa America Middle East Canada
• England • South Af- • California • Saudi • Toronto

• Sweden rica • Denver Arabia
• Djibouti • Las Vegas • UAE
• Kenya • New York
• Sudan • Washington
Dc
1.7 Overall Organization Chart and Management of the Company.

Ambo Mineral Water Share Company has two main categories to precede its work. These are
general manager in Addis Ababa and technical manager at Senkele. General Manager follows the
general work and the technical manager manages technical and product at the Senkele. The overall
organization and work flow of the company can be shown as follow: [1]
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Plant
General
Manager
Finance Manager
Figure 1. 4 Overall Organization Chart and Management of the Company. [1]
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CHAPTER TWO
2. Overall Internship Experience
2.1 How we got into the Company

Before we got in to the company we first met the guards and they took me to the general manager.
The general manager received Our letters and accepted me by good ethics, then we contact with
the person who showed me the sectors we will be working in and we started Our practice by seeing
and asking questions. After few days we became familiar with the employees working in this com-
pany and they helped me on whatever we need their help. When we saw the company from outside
it looks small in size; but after we enter into the company it’s not as it looks like from the outside.
We got a good knowledge from what we have seen in the product section.
2.2 The Section of the Company We have been Working In

There are three line of the company we have been working in these are returnable glass bottles,
Polyethylene terephthalate, Utilities.
2.2.1 Section of RGB Line

Loading is process of load the empties bottles with crates on belt conveyor by manual.
2.2.2 Unpacker machine

Unpacker machine is used for separating crates and bottles each other in order to wash them or
differentiates the dirty crate and the dirty bottles in order to washing a crates and bottles. Purpose
of Unpacker is used to removes (pick up) empties bottles in the crates and put on conveyor which
transport into bottle washer machine. Main component of Unpacker machine is griper head, motor,
sensor, solenoid valve, pneumatic valve. Unpacker machine has 80 gripper head which operating
by pneumatic valve which controlled by solenoid valve. Sensor is detecting bottle present, count
create, space present on conveyor which bottle transport to bottle washer. Main causes of stop-
pages of unpacker is lack of input of raw material and space on conveyor and fault of solenoid
valves, pneumatic valve, and sensor. [1]
Overcomes of this stoppages is maintained and correct the fault, available input of raw material on
time and make space on conveyor which transport bottle toward bottle washer machine. .
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2.2.3 Crate Washer machine

Crate Washer machine is the machine used to wash, sterilize and dry crates before being taken to
packing place by high pressure of water through water tubes. Purpose of crate washer is to clean
or washing crate with applying high pressure of water by water tube through nozzles. Main com-
ponent of crate washer are nozzles, water tube, water tank, motor, conveyor. Main causes of stop-
pages on crate washer is lack of water, fault formed on conveyor and sensor. Overcomes of these
stoppages is available this shortages on times and identified error formed and solves it. [1]
2.2.4 Bottle washer machine

Bottle washer machine is the machine used to wash, sterilize and dry bottles before being filler by
soft water mixes with steam and soda ash. Purpose of bottle washer is to clean or washing bottles
by using hot water, cooled water, fresh water and chemical of soda ash. Main component of bottle
washer: there are three baths of layer through which the bottle pass in order to clean dirty and label
on bottles by hot water, cooled water, fresh water and soda ash. On first bath the bottle washing
by high pressure of water at room temperature, on second bath the bottles washing by high tem-
perature of water and soda ash, on third bath the bottles washing by cooled and fresh water. [1]
Method of operation
From the unpacker, bottles are fed to a bottle washer, which fully washes the returnable glass
bottles to removing any old labels, ink jet coding and small particulates such as sand and dust.
After washing it is necessary to inspect bottles for soiling, chipped necks, residual liquid. Bottles
are fed by conveyor into the washer infeed, where they are channeled into rows and hence into the
washer bottle pockets which are made of either steel or plastic. Bottles are conveyed throughout
the washer in these pockets which are attached to an endless chain. A typical treatment, where the
carrier chains dip in and out of soak tanks (caustic zone), cycle allowing sufficient time to ‘soak’
in each part of the cycle, would be:
1. Pre-warm the bottles to 30°C by rinse water.

2. Empty the residue from the bottles.
3. Pre-rinse using warm water at 55°C.
4. Invert the bottles to empty them.
5. Immerse the bottles in a caustic solution at some (68-72) °C.
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6. Rinse the bottles at some (68-72) °C and then empty the caustic solution out.
7. Repeat steps 5 and 6 at some (73-77) °C.
8. Rinse with warm water at some (68-72) °C and invert the bottles to empty the
contents.
9. Rinse at some 50°C and empty the bottles.
10. Repeat step 9 at 30°C and empty the bottles.
11. Final rinse with clean treated water and empty the contents of the bottle.
Pre-wash: Right after the infeed area the bottles are turned upside-down so that the liquid resid-
uals and loose dirty particles fall out of the bottles. Residuals are collected and discharged out of
the machine separately. A sieve-belt conveyor may be arranged in order to take solid dirt out of
the machine. This sieve-belt is at the same time a filter for the waste water. Behind the dirt removal
area an internal jetting pipe can be located is present so to further remove dirty particles from
inside the bottles as early as possible. Bottles are then submerged and filled with warm water.
Water remains within the bottles until they are turned upside-down in the following jet section.
The water running out returns to the pre-soak through a sieve-belt filter. This is the first occurrence
where the bottles are turned upside down and so broken glass and dirt are collected in the lower
part of the tank.
The bottles are then pre rinsed with a set of internal sprayers and external showers and moved to
the heat recovery submerge bath, where heat is transferred from the cooling zone without any
water mixing. The temperature is gradually raised in this zone, exploiting the residual heat of the
water received from the rinsing zone.
Washing: The bottles are then taken to the actual washing zone which consists of a certain number
of identical detergent soaks – the exact number depends on the required treatment time. Bottle
washing is in three essential stages:
First, the bottle is immersed in the soak, where dirt is chemically attacked by the caustic action of
the soda, increased by high temperature.
At the second stage, the bottle is emptied to remove the dissolved dirt and the used solution.
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At the third stage the mechanical action of the internal jet removes the dirt, which had been chem-
ically attacked, so that the remaining dirt comes into direct contact with the detergent solution of
the next soak.
Rinsing: The bottles then move on to the rinsing zone that usually includes an immersion zone
and a set of spraying zones. In this zone the temperature is gradually lowered and the detergent
solution is removed, both from the bottles and from the carrier beams, through dedicated sets of
sprayers.
All the rinsing water is then recovered to the pre-washing zone. Every spraying zone consists of a
set of high pressure internal sprays and an external shower. Before discharging the bottles a final
injection with fresh water takes place and, after sufficient drip-off time, the unloading system
places the bottle on the conveyor belt.
While the bottles are being washed, crates go through a crate washer that removes any debris and
attempts to keep the crates in reasonable condition. After the washer, the bottles are fed by con-
veyor through an empty bottle inspector to the filler and crowner/capper. [1]
Figure 2. 1:-Bottles Washer Machine. [1].
2.2.5 Filler and capper Machine

Filler machine is used to fill the product in the clean bottles. Main component of filler machine is
vent tube, bottle plate, lifting cylinder, product tank, pneumatic valve (air regulator) and cam.
The machine is mainly used in the Ambo mineral water filling operations. Suitable for carbonated
water filling machine.
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Filling operation
The bottle is pressed with filling part. In the lifting process, it checks whether there are bottles on
bottleneck board. If there are bottles, the filling process is started; the bottle is filled with water. If
there is no bottle, the valve remains closed. In this factory maximum of 24,000 bottles can be filled
per hour.
Basic position of bottle pressurization filling phase filling complete snifting CIP
Phase.
Capper machine is a machine that used to fits the corks on the filled bottles or secures the corks
on the mouth of filled bottles. The Main component of the capper is bottle plate, sealing head with
chuck, neck guide, and sensor.
Fits operation
Corks are transferred from cork hopper to sorter by inclined conveyor. Sorter is rearranges corks
and transfer to gripper. Gripper is used to infeed cork into sealing head which punch cork on a
mouth of filled bottle that take from filler machine by transfer star wheel. After that the fits bottle
transfer to worm star by discharge star wheel. [1]
Figure 2. 2 :-Filling machine. [1]
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2.2.6 Labelling Machine

The Cinematic attaches pre-cut paper or film wrap-around labels to glass bottles. The principle of
the machine works on is simple and effective-labels with glue are attached directly to the bottles.
The amount of hot melt the Cinematic uses to do this is very small as the label is held in place by
just two narrow lines of dispensed glue. [1]
Figure 2.3 Labelling machine. [1]
Method of operation
The cinematic has two independently operating hot melt gluing units. To being with, the first la-
belling station applies a vertical line of glue to the vacuum drum. The vacuum drum is revolving
as it passes label from label magazine to gripper. The glue on the vacuum drum takes up a label
from the label magazine into gripper. At the same time, the second labelling station is applying
glue to the trailing label edge on rotating gripper, after that gripper transfer label to the bottle and
label is now wrapped once around the bottles and glued together at the overlap.
2.2.7 Packer Machine

Packer is machine that used to pick up the filled bottle from the bottle table and put down in the
clean crates by gripper head. Gripper head is operating by pneumatic valve which control with
solenoid valve. The main component of packer machine is griper head, motor, sensor, pneumatic
valve. [1]
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Operation method:
Packer is a machine which picks up bottles filled with Ambo mineral water and put in the washed
crates. For packing, the bottles enter on bottle table and are then distributed to lanes. Then packing
heads grab the bottles, move them to the packing position and place them in their pockets of crates.
The bottles are marshaled on a slat conveyor in a configuration to suit the crate pocket arrange-
ment. At the end of the conveying section, bottles are collected, lifted and placed into the crates
by gripper head which operating by pneumatic valve which controlled by solenoid valve.
Empty
crate Bottle
Crate Dirty washer
Unpacker
with bottle machine
machine
bottle
Empty
bottle
Mixer Clean
Date La- Filler bottle
ma-
coder ma- beler ma-
chine
chine machine
chine
Packer
ma- Product End us-
chine ers
Figure 2. 4 Room of general bottling line
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2.3 Section of PET line

A process flow diagram of the entire PET (polyethylene terephthalate) blowing and filling process
from where the preforms are delivered to the back-end of the line to where the full PET bottles are
removed for storage.
Perform Incline Perform Heater Air con-

Sorter Blow
conveyor chute mod- veyor
mold
ule
Rinse
rr
PET
Filler
Cap-
per
Stretch-
Un- Palletizer Shrink Date
ing Labeler Full bottle con-
loader (manual Wrap- coder
Wrapper Dryer veyor
by hand) per
Figure 2. 5 A process flow diagram of the entire PET as general.

Sorter are used to rearrange and transport a preform which come from the preform hopper by
incline conveyor into perform chute.
a. Perform hopper is used to store perform.

b. Inclined conveyor is used to transport perform from the preform hopper into sorter.
c. Sorter is used to rearrange and transport a preform which come from the preform hopper
by incline conveyor into perform chute.
d. Perform chute is used to transport perform from sorter into heater modules.
2.3.1 Blower machine

Blow moulding is a manufacturing process that is used to create hollow plastic parts like bottle by
inflating a heated plastic tube until it fills a mould and forms the desired shape. Perform is then
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clamped between two mould halves and inflated by pressurized air until it conforms to the inner
shape of the mould cavity. Output of blow moulding is plastic bottle that are available in a variety
of shapes and sizes. The preforms are heated (typically using infrared heaters) above their glass
transition temperature, then blown using high pressure air into bottles using metal blow moulds.
[1]
Heating system
Heaters: The number of heaters in the heating module is equipped with varies according to the
machine type. Each heater is equipped with eight vertically arranged infrared radiators for heat-
ing performs. The infrared radiator is controllable i.e. can be ON or OFF. The temperature of the
individual heating levels can be adjusted via touch-screen.
Reflectors: To improve the radiation efficiency, reflectors provide opposite to the heaters and on
the base.
Fans: Air is blown in on the back of the heating box in order to cool the preform surface.
Mouth cooling: on the top of the heating boxes there is an air duct. The mouth of the preform is
cooled above this duct.
Working Process of Blow Moulding Machine.
1. Monitoring the machine with monitoring devices during operation. Example: Touch
screen, Control panel, Pneumatic panel, Warning device (signal beacon post Visual and
noise monitoring).
2. Checking that the machine is supplied with processing and operating materials. Examples:
Performs, Compressed air, Power, Water.
3. Quality of bottles checkers.
4. Ensuring malfunction, free transportation of bottles from the machines.
5. Monitoring the machine components.
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Figure 2. 6 A process flow diagram of the entire PET (polyethylene terephthalate) blowing
1. Preform hopper 2. Inclined conveyor 3. Rolling sorter 4. Preform chute
5. Infeed star wheel 6. Conveyor chain 7. Heating modules 8. Infeed star wheel
blowing wheel 9 Discharge star wheel blowing wheel 10 Blowing wheel
11. Blowing station 12. Discharge unit 13. Control panel (touch screen)
14. Pneumatic panel 15. Hydraulic panel 16. Switch cabinet 17. Chiller
Figure 2. 7 Stretch blow moulding. [1]
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Figure 2. 8 Blow moulding machine. [1]
2.3.2 Air Conveyor

Air conveyor are used to transport the bottles out from blower by a discharges star wheel into filler
and used as cooling system of bottles by decreasing temperature of bottles. Main component of air
conveyors are fans, sensor, guides. Air conveyor is work with pneumatic valve such as fans system
which applied air in conveyor. Air conveyors works by having air flow through louver to an inner
chamber in which bottles are moved.
2.3.3 Filler (Rinser and Capper)

Purpose of Rinser are used to cleaning or washing the bottles by fresh water. Purpose of Filler are
used to filling bottles with a product. Purpose of Capper are used to sealing the mouth of bottles
by cap or securing bottle filled with product by cap.
The Component of Filler are star wheel (gripper), infeed star wheel, rinser, intermediate star wheel,
transfer star wheel, vent tube and spindle (filling valve), product tank, capper, discharges star
wheel etc. The fill level is determined by the length of the vent tube that enters the bottle, during
the filling stage. Generally speaking, to change the level in the bottle, the vent tube must also be
changed. In a mechanically operated valve all movements are controlled mechanically. Compo-
nent parts of the filling valve which are inside the filler bowl (the product valve and gas needle)
are operated by a control lever which, in turn, is raised and lowered by cams external to the ring
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bowl. Pressurization and filling phases are controlled by this operation. The snift phase is operated
by the snift button located at the base of the filling valve being activated by an external cam. Air
pickup during the fill process: Pre-evacuation is the process of evacuating the air from the bottles
to be filled with a product, prior to filling the bottles. Basically, the bottles is charged with an inert
gas (mostly CO2) before final filling. This process protects the product filled in the bottles from
the effects of oxidation. Headspace air with a fobbing unit which foams the product in the bottles
using high-pressure hot water jet while travelling from the filler to the crowner or capper. [1]
Star wheel Infeed star Intermediate

Rinser star wheel Filler
wheel
Full bottle Discharge star Transfer

conveyor wheel Capper
star wheel
Figure 2. 9 A flow diagram of operation of filler
Basic pressuriz filling filling CIP

position Snifting
ation phase complete phase
of bottle
Figure 2. 10 Flow diagram of filling process

Main causes of stoppages of filler (rinser and capper) are:
1. Filler air leakage caused by Fail of connection between filler and air conveyor Misunder-
standing and Misalignment.
2. Filler under fill & leakage problem causes of problem of filler component connection, con-
veyor problem.
3. Filler centering bell problem causes of misalignment (capper not match with bottle).
4. Fault of sensor, and may be if bottle not reached on time and cap is not available by its
order of arrangement.
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Overcome of these stoppages are:

1. Technically connect the filler and air conveyor to avoid the leakage. Make correct align-
ment and do without any complexity with the technicians.
2. Check before starting all filler components and use automatic machine to report the prob-
lem. Use additional filler line rather than stop work.
3. Before using it check whether it is lined or not check as it is prepared with its standard and
problems seen in the production line.
4. Available bottle and cap that keep its arrangement order on time and solved the problem
occur in filler.
Full Bottle Conveyor
Purpose of full bottle conveyor are used to transport the bottles filled with a product and secured
by cap. The main component of the full bottle conveyor is: belt, guide, wear strip, motor, sensor,
full bottle inspection.
2.3.4 Labeler machine

Purpose of the labeler are used to attach the label paper to the filled bottles. The wraparound
labeler transfers a continuous web of labels from a reel on the reel holder to the filled bottles by a
cutting drum and a vacuum drum. The label web is cut to individual labels on the cutting drum and
held by a vacuum drum where hot glue is applied to a strip along the leading and trailing edges.
The labels are then transferred to the bottles by the rotating vacuum drum itself. A label applicator
ensures that the labels are correctly positioned on the filled bottles. Main component of labeler is
label plate (reel holder), centering bells, glue drain (gluing unit), glue tank, servomotor, film
buffer, feed roller, film guider, bottle plate, sensor, label cutter (cutting drum), vacuum drum. [1]
Method of operation: The Infeed worm are rotating by a gear and spaces the bottle to the machine
pitch. Stop star wheel installed immediately before the infeed worm. The bottle present sensor
detects if bottles are supplied to the machine and provides a signal to the control system. Thus, a
label will not be supplied until a bottle is provided in the labelling station.
After infeed star wheel the bottles are transferred to bottle plates in the carrousel and clamped
firmly from above by means of centering bells. The bottle plates must rotate to ensure that the
bottle pick up the label correctly from the vacuum-grip cylinder. They are turned by a servomotor
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using a toothed belt. The cut and glued label is transferred to the bottle. The label is cut when the
cutter meets the cutting strip.
Hot glue is pumped from the bowl to the roller. A glue film is provided through the gap set be-
tween the glue scrapers and the roller. Vacuum bars on the vacuum-grip cylinder take the labels
from the cutter drum, through the contact with the glue roller, a strip of glue is applied to the
leading and trailing edge of the label, afterwards the label is transferred to the bottle.
Main causes of stoppages on labeler are:

1. May be causes of lack of timely available of label paper, glue, full bottles.
2. Glue Heating Temperature Getting Low.
3. Labeler Sensor Fault by causes of Components stops function Adjustment error.
4. Labeler Roller Bearing Damage.
Overcome of these stoppages are:

1. Solves the problem causes of this stoppages by available timely the material that need for
the labeler such as label paper, glue, filled bottles on which the label warp and solves the
problem occurs with labeler machine.
2. Set up the temperature as its standard.
3. Check each components and adjustments required technically.
4. Maintenance or changes roller bearing.
Date coder is machine that used to print expired and production date on bottles. Purpose of date
coder is used to write an expired and production date on full bottle warp with a label paper by
using instruction of the company for date coder with clear visibility and full of color.
2.3.5 Shrink Wrapper

Shrink Wrapper is machine used to wrapping film around a packed of 12 bottles and applied heat
by passing through a heating tunnel to packaging filled bottles. After passing through a heating
tunnel for 5 to 7 seconds, the film would tighten to produce a reasonably firm and stable pack.
Purpose of shrink Wrapper is used to wrapping the filled bottle with a polyethylene film and heat
applied to film through conveyor in heat tunnel to form package. It is used to cover products with
polyethylene film to protect and secure products. [1]
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Method of operation
Bottle order is used to arrange bottle in line and passing into sensor. Sensor is used to detect bottle
present on line and counting. Bottle stopper is used to stop bottle after passed of 12 bottles. Me-
chanical system used to move the packed bottles into film wrapping area and heating tunnel. Heat
tunnel is used to Appling heat to the film by conveyor heat tunnel which catalyzes the film to
shrink tightly around the bottles placed within.
2.3.6 Stretching wrapper

Stretching wrapper is machine used for stretching or film wrapping around a package of product
arranged on pallet by rotating pallet.
Purpose of stretching wrapper machine is used to wrapping stretching or film around package of
products unloaded from roller conveyor by manpower and put on pallet by rotating pallet. Main
component of stretching wrapper are rotating table and pallet, reel holder carriage, pre-stretching
film. [1]
Method of operation
After package of filled bottle run out from heating tunnel by roller conveyor, operator pick up
packages of filled bottle from roller conveyor by hand and put down on the pallet on rotating table,
up to 112 packages of filled bottle out from shrink wrapper, then the operator to be connected film
to the packages on pallet and turn on stretching wrapper machine after that rotating plate are rotate
pallet with packages on it then reel holder moves the film up and down in order to wrapping film
into packages on pallet. Finally fork lift pick up packages of filled bottles on rotating plate with
pallet and put down in storage room.
2.4 Utilities line
2.4.1 Water treatment

Water treatment is a process that improves the quality of water to make it appropriate for a specific
end use such as softener and process water. The main purpose of the water treatment is to prevent
the formation of the various hard scale deposits caused by salts on the internal surface of the boiler
and bottle washer as such deposits causes efficiency loses. Therefore, to keep the water soft, a
cation exchange resin bed together with a chemical solution dose is added in the feed water in the
water treatment plant. [2]

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a) Degassing Tank: The mineral water pumped to degassing tank is purified from some unwanted
gases like CO2, Cl, and Fe etc. in this tank through vacuum suck which operating by motor which
has fan that forward and back ward condition in order to removes out amount of unwanted gas
from mineral water in degassing tank. Then it is pumped to settling tanks. [2]
b) Settling Tanks (Process and Softener Tanks): Dirt particles gain more weight and settle to
the bottom of the water tank. The mud accumulated at the bottom of the tanker is removed using
cleaning mechanism. In Ambo mineral water Share Company there are four tanks which have
volumes 30,000 liter. Tank one used for softener water but tank two, three, and three are used for
process or production water. After suspend particle settle down in sedimentation tank of 2, 3, 4
waters pumped into filter tank such as big sand, manganese green sand, and activated carbon tank
respectively and finally pure water pumped into production tank which contain 50,000 liters. [2]
c) Filtering Tank: In this there are three tanks: Big sand tank, Manganese filter tank and activated
carbon. In big sand filter tank there are two layers of sand, grain size of sand increase from top to
bottom and water pumped from top to bottom, so the remaining suspensions particles are trapped
by the sand. But, softening is used to avoid the calcium and the magnesium carbonates from the
water by using Sodium Chloride (Nacl) and rinse bed in softener water tank in order to reduce
content of CaCo3 from water. After reduced the content of CaCo3 in water less than or equal to
75kg/l, it is used for boiler, bottle washer, crate washer, cleaning, and other activities in order to
reduces or avoid scale and corrosion of machine and boiler. It has to be further purified by Sodium
Chloride (Nacl). These tanks are cleaned by backwashing. [2]
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Green Activated carbon fil-

Settling Big sand
sand man- ter tank
tank 2.3.4 filter tank
ganese fil-
(process ter tank Product Filler
water) tank
Buffer tank Other
Blender
Bore hole Mineral Degassing
water tank
Sodium chloride Shower
tank
Softener tank 2 Bottle
Settling tank 1 (sof- washe
tener water tank) Softener tank Clean-
r
1 ing
Big sand filter Boiler

tank use
Tank 5
Toi-
let
Tank 6
Figure 2. 11 Water Treatment/Process Flow Diagram

2.4.2 Steam generation (Boiler)
The factory uses two fire-tube boiler which uses air and oxyacetylene with steam production ca-
pacity of 3,000 kg/h at 12bar and 191.7 ℃. It uses diesel oil. The boiler has feed water system,
fuel system, air system and steam system. The boiler is used to develop steam which is directed
through piping system to different points of use such as bottle washer, clean internal place and
syrup room. It produces steam at average temperature of 165 ℃ and 7bar. The boiler is cylindrical
in shape and its three surfaces are exposed to the ambient air.
The objective of this section is to evaluate the energy performance of the boiler in the factory.
Main parts of fire tube boiler are oil burners, fuel pump, forced draft fan, feed pump, boiler mount-
ing and automatic control system.
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Process of boiler: In fire tube steam boiler, heat and gases of combustion pass through the tube
surrounded by water. When water is heated, it increases in volume and becomes lighter, by in-
creasing the heating surface, more heat is taken from the gases of combustion. This results in a
more rapid water circulation and faster formation of steam bubbles. In internal furnace or burner
the fuel and electrical spark meets to produce fire that pass through fire tube surrounded by water
by applied air or oxyacetylene to fire, then steam bubbles formed. [2]
Safety valve sensor detect filled water Fire tube
Fuel pump
fire Burne
r
Water forced draft fan
Feed water
Figure 2. 12 Boiler
2.4.3 Chiller
Chillers are the Cooling process which done by using ammonia gas a refrigerant (coolant). The
compressed ammonia cools the water (ice water) that cools the machine to avoid overheating and
water which is used for production. The ammonia gas cools the water by heat exchanging. The
water which has been cooled (ice water) by ammonia goes to the carbon-cooler and cools the water
that is used for production by heat exchanging. [2]
Process of chiller
Ammonia gas charges into high level ammonia tank, while Water directed into chiller through
piping system from storage tank, then the chiller pumping water into high level ammonia tank and
heat exchanger, after that water and compressed ammonia meets on line to cools the water (ice
water), then Cooled water and production water meets in heat exchanger on line and heat transfer
from production water into cooled water, then temperature of production water decrease to15 ℃.
The chiller water used to cools the machine to avoid overheating.
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Chiller which pump High level ammonia

Storage tank Cool water
water by using motor tank
Water NH3
Cylinder
Heat
exchanger
RGB & Ro Cooled water
Figure 2. 13 Flow diagram of chillers

2.4.4 Air Compressors
Air compressor and its motor is another energy utilizing system in Ambo Mineral Water factory.
This factory uses a single-stage air cooled piston type reciprocating air compressor which has
pressure vessel. The air compressor uses three-phase alternating current induction motor. It is used
to operate pneumatic valves and other parts of the factory. There are two compressor (oil free air)
which filter air by cotton or cloth in order to reject dust and pass free air into the inside of oil free
air, after that moisture formed in air. The mixture of air is flow into air dryer, which filter moisture
from air by filtration, and reject out moisture but dry air flow into air resirver tank. From the air
resirver tank dry air distributed into RGB and PET for pneumatic valve operation. Regular cleaning
of compressor inlet ducts, filter and rearranging air distribution lines can reduce the losses so that
the efficiency of the air compressor can be improved. [2]
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Oil Free Air Air Dryer Air

Resirver
D Dry
A Moisture Air
u
i
s RGB
r
t &
PET
Figure 2. 14 flow diagram of air compressor

2.4.5 Syrup preparation process
Syrup: is a fluid which is prepared from different kinds of chemicals and sugar. Syrup is used to
produce many different kinds of soft drinks. Example predator, pine apple, apple, Jiva orange, Jiva
coca, lemon etc.
Syrup process: is a process which used to produce syrup by using different mechanism and com-
ponents. The component [parts] used to prepare syrup are:
1. Sugar box 5. Steam cylinder 8. Cooler
2. Motors 6. Condenser 9. Storage (3)
3. Dissolving thank 7. Filter (2) 10. Connecters
4. Mixing thanks
In general, the above parts of the syrup preparation have many uses, these are. [2]
1. Sugar box is used to input the sugar and absorb the sugar by pulley gear to belt system in to
storage.
2. Motors it used to give an energy (power) and,
3. Dissolving thank is used to dissolve a sugar with water, use different temperature and steam.
4. Mixing thank is used to dissolve or mix a solute with different chemical.
There are two in number in syrup preparation process.
a. The mixing thank at a filter is used to mix a chemical which is called SSF and PPM
with dissolved sugar to clean or filter the carbon.
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b. The mixing thank at storage of end product is used to mix a chemical which is
called citric acid, sodium benzoate, flavors etc. with filtered solution comes from
storage to give a cooler what we want.
5. Steam cylinder is used to store steam comes from boiler and give to the dissolving thank
regulator.
6. Condenser is used to condense (cool) a solute which is dissolved in dissolving tanker and
give to storage tank, to keep the pressure of tank.
7. Filter is used to filter the solute that means the solute is dissolved with carbon, so the carbon
colour is black, to make this solution colourless and to filter different dirty things. There are
two different filters in syrup preparation process.
a. The filter which is at a first mixer, a big filter using a filtration device.
b. The filter which is small uses cloth to filter the solution.
8. Cooler is used to cool a solution which is filtered by the filter, to keep its temperature for
storage.
9. Storage tanker is used to store the solution up to the time of preference. There are three
storage tankers.
a. The storage tank which is at the sugar box is used to store the dissolved solute in
dissolving tank and come to it.
b. The storage tanker which is at the mixer of different chemicals is used to store a
solution that gets mixed with a chemical in a mixer or the end product road that
goes to a PET line. Example: to the filler of syrup
c. The storage tanker which is at the filler is used to store the product of the company.
10. Connectors is used to connect different lines. Example: product line, CIP (clean internal
place) line etc.
Simple syrup:
1. Fill the pre-coating tank with water, 2.856 kgs KENSIL 90 and 2.856 kgs of KENSIL SSF.
2. Dissolve 1750 kg refined sugar and 2 kg activated carbon in to 1908 liters of RO at 75 0c
and heat up to 85 0c up on mixing.
3. After depositing the filter and the pre-coating is clear, circulate the sugar solution to the
filter until the simple syrup becomes clear and meets specification.
4. Transfer the clear solution to simple syrup storage tank.
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5. Transfer the simple syrup to mixing tanks.
Final Syrup Mixing Instructions:

1. Avail the concentrate, sodium benzoate preservative and citric acid as per the batch size.
2. Add sodium benzoate to concentrate tank, mix and shift to mixing tank.
3. Add some proportional number of products concentrate and citric acid into ingredient mix-
ing tank. Mix well and transfer to mixing tank
4. Final volume and brix of the final syrup should be checked after two hours of de-aeration
and mixing.
5. Release the final syrup for production.
Production wa-
Sugar
ter tank in RO
Sugar box
Steam from Heat

exchanger Dissolving tank (up to 85 0c)
boiler
mixture of water
and sugar at 85 0c
Coolant (cooled water)
filteration back filter tank

Heat exchanger(coolant)
Concentration tank
simple syrup at 35
0c store tank mixer tank (1) mixer tank(2 &3)
3000L 6000L
Syrup for
production
Figure 2. 15 A flow diagram of syrup production process
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2.5 Work Piece or Task We Have Been Executing

Let us now discuss about over view of maintenance and machine assembly in Ambo mineral wa-
ter Share Company (AMW S.C) one by one. Maintenance is an act of keeping something in good
condition by checking and repairing it regularly. It is a technique of solving problem when fail-
ures occur in something. There are five kinds of maintenance: -
1. Weekly maintenance (50 operating hours)
2. Monthly maintenance (200 operating hours)
3. Quarterly maintenance (500 operating hours)
4. Yearly maintenance (2000 operating hours)
5. Maintenance every six years (15000 operating hours)
Maintenance in every six years can be done with in long time. But weekly, monthly, quarterly
and yearly maintenance are important in a factory to be done with in specific time continuously
Even if there is a program done for maintenance and clearing in the factory.
In AMWF maintenance is applied may be after failures occur we were also able to do weekly and
monthly maintenance after failures are fixed in a machine. [2]
Weekly maintenance: -
➢ Conveyor belts
➢ Gears
➢ Checking pump seals, pump pressure, piping, pneumatics, lubrication lines and check-
ing motor temperature
1. Monthly maintenance
➢ Machine and machine parts
➢ Jetting units
➢ Control cabinet cooling unit
2. Quarterly maintenance
➢ Pumps, pipes, heating systems
➢ Valves
➢ Jetting units
➢ Electrical system
3. Yearly maintenance
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➢ Pumps, motors, electrical system

➢ Drive
4. In every six years maintenance
➢ Main drive
➢ Additional maintenance instruction
Gears oils: All gears are filled with synthetically. Synthetically reduce friction retain a relatively
consistent viscosity at varying temperatures, enable higher out puts to provide a high degree of
protection against wear and tear are stable with regard to ageing. Therefore, as opposed to mineral
2]
oils, they can be used for longer periods of time. This reduces maintenance costs substantially.
2.6 Challenges That Have Been Faced During Our Internship

1. Lack of safety.
The company was unable to give me safety clothes, safety shoes, etc.
2. Lack of library.
The company has no library and adequate reference material that describes how the machine as-
sembles, operating principles and how maintenance is programmed.
3. Lack of scheduled maintenance.
The company does not use programmed maintenance, but they maintain the machine after the
problem occurs.
2.7 Major Task We Takes To Overcome the Challenge

To overcome lack of safety
➢ By using our own clothes, shoes and others.
To overcome lack of library
➢ We were communicating and discussing with experienced operator to know the machines
working principles.
➢ We were working with our technician and staff members to know how the maintenance is
done.
➢ We were referring different materials.
To overcome these challenges
When operator gets a free time he or she shows me different part of machines and explained
function of them briefly.
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CHAPTER THREE
3. OVERALL BENEFITS
3.1 Overall Benefits Gained from Internship

Internship is one method of making opportunity for University students potentially valuable and
explores general career avenues as well as specific companies. Such arrangements can provide us
with valuable work experience (both practical and for résumé enhancement) and an opportunity to
line up a job before graduation, in addition to securing good work experience. The major benefits
that we get from the internship are classified and stated as below briefly
3.2 In Terms of Improving Our Practical Skills

During these three months we got the opportunity to learn different aspects of practical skills. We
were able to maintain different machines such as conveyors. We gain practical experience of ap-
plying our engineering judgment and working successfully with others. However, the skills and
qualities nurtured by studying mechanical engineering suit (convenient for) many other profes-
sionals setting equally well. We can offer: -
➢ Creativity and innovative approach to solving problems.
➢ The ability to analyse and interpret diverse.
➢ Critical thinking and the ability to evaluate problem.
➢ Effective assessment and management of resources and time.
➢ Interpersonal sensitivity, persuasiveness and the ability to work as part of a team.
➢ Awareness of ethical issues and the wider impact of work.
3.3 In Term Upgrading Our Theoretical

We have been able to gain a great deal of knowledge in this internship experience. When it comes
to up grading the theoretical knowledge that we possess on the field of mechanical engineering the
program did help by providing ideas that are proven to be quite helpful when it comes to solving
practical problems. There were ideas that we never got the chance to know about when attending
regular classes.
The internship experience didn’t totally bring brand new ideas to the table; instead it helped in
improving the already available ways and ideas of problem solving skills to a great level.
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It is obvious that in order to improve one’s theoretically based knowledge he or she has to be able
to grasp every information that is forwarded during the internship program and being able to inte-
grate this newly acquired knowledge with the previous one and use this information to solve any
problem that may arise on the course of time.
3.4 In Terms of Improving Interpersonal Communication Skills

During the work we had been able to ask different peoples from all works. During this time we
have gained confidence on how to:
➢ Ask different questions.
➢ Make discussions.
➢ Answer questions when asked.
➢ Respond to superior and etc.
3.5 In Term of Improving Team Playing Skills

During performing different tasks, it is very important to play as a team. If there are disagreements
between the operators and the supervisors it is very difficult to go ahead with the working pro-
cesses of the whole machines.
In order to have working environment at industry the operators and the supervisors should have a
“give and take” approach towards resolving problems that occur at the industry. During these past
month we had been able to see how different labour workers and operators in the industry did their
job as a team.
Generally, a person with good team playing skill has the following qualities.
➢ Demonstrates reliability
➢ Communicates constructively
➢ Listens actively.
➢ Functions as an active participant.
➢ Shares openly and willingly.
➢ Cooperates and helps others.
➢ Exhibits flexibility.
➢ Shows commitment to the team.
➢ Works as a problem solver.
➢ Treats others in a respectful and supportive manner.
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3.6 In Term of Improving Our Leadership Skill Out of Working

At the factory we have been able to see different engineers in hierarchy work and lead the site
workers and the engineers under them. During these times we have been able to observe that one
should have great skills to be a leader. What we gain from the internship regarding improving
leadership is that to inspire workers into higher levels of team work. There are certain things must
be known to do that. These are:
➢ Know our selves-seek self-improvement
➢ Be technically proficient
➢ Seek and take responsibility for actions
➢ Make sound and timely decisions.
➢ Know peoples and look out for their well-being.
➢ Keep workers informed.
➢ Develop a sense of responsibility in workers.
3.7 Understanding about work ethics related issues

In today’s complex world, Ethical conduct of workers is very important for developing healthy
working environment and increasing productivity. Ethical work conduct enables us in order to
posses’ appropriate behavior in the work and so we develop proper relationships with co-workers
and it helps us to create good working environment.
There are two common types of ethics. These are:

➢ Personal ethics and
➢ Professional ethics.
3.8 Personal ethics

These principles of personal ethics are values which are expected to be possessed by all individuals
in their life and contribute a lot for a smooth interaction among individuals and peaceful co-exist-
ence of a society.
What we gained in the company principles of personal ethics include:
➢ Concern for the well-being of others.
➢ Honesty.
➢ Fairness.
➢ Compliant to the law.
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➢ Benevolence (doing well).

➢ Refusing to take un-fair advantage.
3.9 Professional ethics

Professional ethics: -Professional ethics refers to the standards or a set of moral principles for
regulating behavior of a certain defined profession.
The following are some of the common professional ethical principles what we gained in the
internship period.
Punctuality: - is means keeping the companies work beginning and ending time and to com-
plete a given task within the given period.
Reliability: - is the worker should be qualified for the part he is supposed to be performing.
He/she must have appropriate skill and knowledge for the task assigned.
Honesty: - is regarding this value each worker regardless of its status should abstain from bad
behaviors such as cheating, bias, corruption etc.
Cooperation: - is each worker should interact and cooperate with each other while working.
That is because it is through such system problems could be easily solved.
Impartiality.
➢ Transparency and openness.
➢ Avoiding potential or apparent conflict of interests.
➢ Accountability.
3.10 Entrepreneurship Skill

Participating in an internship allows us to gain a better perspective of post-graduation employment
by applying the principles and theories we are developed in the classroom. This practical applica-
tion creates an easier transition for us from the classroom to the working world.
3.11 Conclusion and Your Recommendations for the Company.
3.11.1 Conclusion.
Above all the internship program is the crucial or mandatory option to make the compatible Tech-
nology students experience in terms of improving our real practical skills, critical thinking, prob-
lem identification, problem solving, enhancing interpersonal communication abilities, leadership
system, understanding professional ethics.
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We observed the principle operation of different machines in the company. Such as washer ma-
chine, mixer machine, filler machine, labeler machine, unpacker and packer machine, and molder
machine. In addition to develop our skill the company also benefit from our practical application.
We got practical work experiences and benefits at the Ambo mineral water share company some
of the benefits the internship offered to us include:
➢ Allow us to both make and develop professional contacts for our future job search,
➢ Assist me in developing greater understanding of our own strength and weakness,
➢ The company’s work flow, Upgrade our theoretical knowledge at school,
➢ Improves our leadership skill,
➢ Knowing working standards,
➢ Work ethics,
➢ Team playing skills.
3.11.2 Recommendation
Some of the recommendations suggested to the company are as follows:
➢ There is lack of staffs in different department working together. Problem solving will be
much easier department work together
➢ Maintenance is the primary thing in the company, but schedule to maintenance is not in-
troduced in this company. So, we suggest the company to give at least one day maintenance
in week.
➢ There is no library to read different manual needed for maintenance as well as for installa-
tion so we suggest the company to have library with different book and manuals.
➢ Most operators are no educated or not skilled operators we suggest to the company to give
trainer to the operators. And since the company produces soft drinking safety also neces-
sary especially safety closes, but we did not get any safety material and many operator
works on the machine only by experience. Operator must know each part of the machine
and we all information.
➢ The company should improve the man power educational level and give for them full train-
ing capability of the machines maintenance, principle operation, safety and they should
have focused to enhance the maintenance before the failures occur rather than expend time
and money after the huge problem.
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➢ Since the target of university is to build student with various skills, so internship program
should be encouraged to have quality and effectively result.
Generally, the internship program should be expressed in detail and aware for the company
to overcome applicable industrial technology.
Finally, recommendation goes to mentor, supervisor and other who are responsible to internship
during their stay in the organization; to share their knowledge properly and to control the students
on their duty. In addition to this they should be responsible to guide the students as per their interest
and to help them to do what they fill.
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CHAPTER FOUR
4. DESIGN OF MANUAL OPERATED SCISSOR LIFTING AND TRANS-
PORTING MACHINE
4.1 Introduction
A scissor lift is a type of platform that can only move vertically. The mechanism to achieve this
is the use of linked folding supports in a criss -cross “X” pattern, known as a pantograph or Scissor
mechanism. A scissor lifting machine is a portable device consisting of a screw mechanism used
to raise or lowers the load. The operation of the scissor action can be obtained by hydraulic, pneu-
matic or mechanical means (via a lead screw or rack and pinion system). The hydraulic lifting
consists of cylinder and piston mechanism and the movement of the piston rod is used to raise or
lower the load. While the mechanical lifting can be either hand operated or power driven. The
mechanical screw lifting which raises and lowers the load by applying small force in the horizontal
plane through the screw thread. We have to use lighter but stronger metals; that is to reduce the
force applied by the person that is pushing our machine.
4.2 background of the study

The lifting and transporting equipment in the industrial engineering are recommended for lifting
and transporting large weight of material and product for different purpose. The most important
consideration often is the selection of the type of scissor lifting that performs the required services
in developing the design. The most satisfactory manner of other criteria must be considered such
as the properties of material used, the induced stress, the elastic stability and the aesthetic appear-
ance of the unit. The cost of scissor lifting and transporting is also important to its service and
useful life. The main components of mechanical scissor lifting and transporting are Base frame,
Top Table, Caster wheel, Nut, Link, Lead screw, Crank handle. In the design of mechanical scissor
lifting and transporting the components can be welded by fusion welding, fillet weld, throat, double
welded butt joint and single welded butt joint.
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4.3 Statement of the problem

In the Ambo Mineral Water, we have seen many problems during internship program, the prob-
lems are:
• Lack of machine that loading raw material of production and bottle with crate.
• Lack of manual operated scissor lifting and transporting machine.
In the Ambo mineral water S.C the most problem is the problem of lifting and transporting of raw
material of production, bottles product, crates and other material for different purpose. In syrup,
PET, and RGB room there are many workers participate to transporting and lifting sugar, other
material used for syrup preparation, bottles product, crates and other material. Previously in this
work shop, these materials were lifted and transported by manpower and this leads to reduction
quality and resulted in safety problem. In general, the problems are:
• It needs great human power to transporting and lifting.
• Damage of crates.
• Time wastage.
• Low productivity (according to time).
• Poor safety and production quality
The end of this project is to overcome (solve) those problems listed above.
4.4 Objectives of the study
4.4.1 General objectives

Design on effective manual operate scissor lifting and transporting machine that reduce man
power.
4.4.2 Specific objectives
➢ To perform conceptual design.
➢ To design and analysis mechanical components of the manual operated scissor lifting and
transporting machine.
➢ To design the 3D model of a machine and assembly of the completed machine.
4.5 Scope of study

To providing the manual operated scissor lifting and transporting for Ambo mineral water S.C.
To provide simple operating machine for operators in syrup, RGB, and PET room.
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Also, the design conditions are to meet the following specifications;

➢ Maximum weight to be lifted = 710kg = 0.71tone = 7100N. Based on the problem we seen
in the company these are lack of lifting and transporting sugar which required for simple
syrup preparation and bottle with crate for washing again. For one shift of simple syrup
preparation,1710kg of sugar is required for 1908 liters of RO at 75 0c.
➢ Maximum lifting height = 150 cm = 1.5m
➢ Minimum lifting height = 20 cm = 0.2m
➢ Length of links = 170cm = 1.7m
➢ Length of the power screw = 105cm = 1.05m
➢ Top Table and base frame dimension = 180cm x 110cm = 1.8m x 1.1m
4.6 Literature Review

In(AMWSC) there are many material handling equipment. This material handling is used for dif-
ferent function to save manpower, time, minimize cost etc. When we come to our project we focus
on raw material, bottle product and empty bottle for lifting and transporting machine. Before doing
this project, we sew literature review. The operation of the scissor lift action can be obtained by
hydraulic, pneumatic or mechanical means (via a lead screw or rack and pinion system). The me-
chanical lifting can be either hand operated or power driven. The mechanical screw lifting which
raises and lowers the load by applying small force in the horizontal plane through the screw thread.
There was some scissor lift type before manually operated scissor lift such as: -
a. Slanted hydraulic scissor lift: -
This lifter consists of two scissor legs one of the legs of each of the scissor will be free to slide
across the length of the base and across the length of the platform. The legs are connected with
connecter rod that is where the hydraulic actuator push and pull the legs; simultaneously the load
moves up/dawn. Main advantage of hydraulic lifter is force multiplication is higher than screw
mechanism.
b. Vertical hydraulic scissor lift: -
The only difference with the above mechanism is the position of the hydraulic piston actuation
position.
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Hydraulic piston manufacturing process is difficult due to fluid linkage control valve manufactur-
ing and high-pressure cables needed but those things need high cost so we changed our attitude to
mechanical actuated system.
NOTE: - we chose screw scissor lifter which is consists of less number of components. Due to
material availability, easy to manufacture, less cost, rigidity and easy to access.
4.7 Materials and Methods

Methodology
This project is designed by calculating different calculations and by arranging of the components
properly. The data we use in our calculation are collected by different methods of data collection.
These are:
1 Primary source
• Direct observation.
• Interviewing employees of different expert.
2 Secondary sources
• Literature review.
• Reference.
• Different websites.
• By referring design book.
3 Data analysis tools
SOLIDWORKS software
4.8 Working principle of manual operated scissor lifting and transporting machine
When the power screw rotates to clockwise direction, machines lift to lower position and when
the power screw rotate to direction, counterclockwise machine lift to the maximum position. The
lifter raised and lowered with a Crank handle that is inserted into the screw head. When operator
turns the Crank handle in a clockwise direction the screw rotates that makes the inside threaded
cross bar to push the two side-by-side scissors. One legs of each scissor will be free to slide
across along the base and plat frame. As it does this, the angle between the legs of the scissor de-
creases so legs became get closer, this push up the top plat as well as load. Rotate the Crank han-
dle until the load move up and reaches required level. In order to lower the load; turn the Crank
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handle in the opposite direction (anti clock direction). Due to the threads of screw the input force
is a little bit multiplied. The scissor legs have slider which allows the load to be lifted easily.
4.9 Significance of the study

The main concern of the study the designed machine can facilitate the following significant;
• Easy to operate.
• Easy to lifting and transporting.
• Relatively cost effective.
• Increase production rate.
• Manual effort is reduced.
• Operating time is less.
4.10 Material Selection

Material selection is a step in the process of designing any physical object. In the context of product
design, the main goal of material selection is to minimize cost while meeting product performance
goals. Systematic selection of the best material for a given application begins with properties and
costs of candidate materials.
Table 4. 1 Material selection for different parts of the machine
S/n Component Material selected Reason(s) for selection
1 Lead screw Mild steel machinability, corrosion resistance
and high strength
2 Nut Mild steel machinability, corrosion resistance
and high strength
3 Base frame Mild steel machinability, corrosion resistance
and high strength
4 Top Table carbon and alloy steel High strength
5 Links High carbon steel High strength and shear resistance
6 Crank handle carbon and alloy steel High strength
7 Pin Mild steel machinability, corrosion resistance
and high strength
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CHAPTER FIVE
5. DETAIL DESIGN
5.1 Conceptual Design

The need for the design of manual operated scissor lifting and transporting machine was mentioned
previously. Conceptually the design of the manual operated scissor lifting and transporting ma-
chine involved a lifter and transporter capable of maintaining its strength at specific operating
conditions. The design parts of manual operated scissor lifting and transporting machine could be
done by calculation and 3D analysis of the lifter and transporter. Various scissor lifting and trans-
porting machine parts could be of welded construction or could be seamless.
Concept-1
This design concept having a problem manually performed.
Figure 5.1 Manual bottle washer machine
Concept-2
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This design concept having a problem manually performed.
Figure 5.2 Syrup tank lifter

Concept-3
This design concept having some components; Lead screw, Nut, Base frame, Top Table, Link,
Pin, and Crank handle.
There are many problems are found in Ambo mineral water share company special in syrup, PET,
and RGB room such as: -
➢ It needs great human power to transporting and lifting raw material and bottles products.
➢ Damage of crate and bottles.
➢ Time wastage.
➢ Low productivity (according to time).
➢ Poor safety and production quality.
The problem we had seen in syrup preparation room is it need great human power to transporting and
lifting raw material such as sugar, flavors, Avail the concentrate, sodium benzoate preservative
and citric acid.
The problem we had seen in PET and RGB rooms are Poor safety and production quality of bottles
product, time wastage, damage of crate and bottles.
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Figure 5. 3 Manual operated scissor lifting and transporting machine
Table 5. 1 Manual operated Scissor lifting and transporting machine

construction Component Material Head type
Inclined Link High carbon steel rectangular
Horizontal Base frame Mild steel rectangular
Horizontal Pin Mild steel circle
Horizontal Nut Mild steel circle
horizontal Top Table Carbon and Alloy rectangular
steel
horizontal Lead screw Mild steel circle
horizontal Crank handle Carbon and Alloy circle
steel
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Concept Evaluation
Table 5. 2 Concept evaluation
C3
Value of C1 C2
Number Criteria criteria Gate value Gate value Gate value
by % point point point
1 Loading resistance 27 5 1.35 4 1.08 6 1.62
2 Portability 12 8 0.96 6 0.72 7 0.84
3 Cost 34 7 2.38 9 3.06 8 2.72
4 Welding 13 6 0.76 7 0.91 9 1.17
5 Easily manufactur- 14 9 1.26 8 1.12 6 0.7
ing
Sum 100% 35 6.73 34 6.89 36 7.06
Selecting Solution concept

❖ From the three-concept evaluation the Comfortable and interesting one is concept-3 be-
cause it has good strength, wall thickness and has high load resistance, requires low costs,
having high welding and easily manufactured.
For this reason, selecting the concept-3 that have: -
❖ Lead screw,
❖ Nut bar,
❖ Base frame,
❖ Top Table,
❖ Links and Pin
❖ Crank handle suitable for our design.
The selection of the concept is shows as our concept is assumed. Our assumption depends on the
projects, what types of it, and what the design of we expected to done. Therefore, our assumption
is given for us more results in concept 3. Thus, our selection solution concept is suitable for the
design of concept-3.
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5.2 Detail Design and Analysis

Components of manual operated scissor lifting and transporting machine. All parts of the machine
are designed carefully in step by step form. There are seven major components of this simple
mechanical device which are listed below
❖ Lead screw
❖ Nut
❖ Base frame
❖ Top Table
❖ Links
❖ Pin
❖ Crank handle
5.3 Design analysis

The following are the most important components of the machine which are selected to be de-
signed.
➢ The main power screw.

➢ The Nut
➢ The links and Pin
➢ Crank handle
➢ Top Table
➢ Base frame
Design requirements
Input and assumptions

➢ Maximum weight to be lifted = 710kg = 0.71tone = 7100N
➢ Maximum lifting height = 150 cm = 1.5m
➢ Minimum lifting height = 20 cm = 0.2m
➢ Length of links = 170cm = 1.7m
➢ Length of the power screw = 105cm = 1.05m
➢ Top Table and base frame dimension = 180cm x 110cm = 1.8m x 1.1m
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5.4 Design and Analysis of mechanical scissor lifting and transporting machine
Part of design are Mechanical system design.
Mechanical scissor lifting and transporting has design of mechanical system design such as;
➢ Design of nut and power screw.
➢ Design of Top Table and base frame.
➢ Design of link and pin.
➢ Design of Crank handle.
5.4.1 Force analysis on the linkage assembly

It is assumed the maximum weight (Wmax) the device can lift is 7100N and is concentrated on the
Centre for the design purpose. This weight is equally distributed on each links as it can be seen
from the figure below
Figure 5. 4 The force analysis on the linkage assembly

The angle θ (the angle between the side links and the base frame) is maximum when the device is
at its maximum lifting height and is minimum when the device is at its minimum position. One of
this angle variation we have different force distribution on the links. First let’s find the angles at
the two extreme positions. [5]
5.4.2 Link angle at minimum position (𝜽𝒎𝒊𝒏 )

When the lift is at its minimum position the following important dimensions are obtained.
Figure 5. 5 The link angle at minimum position
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Where L=length of the link

ℎ𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑒𝑖𝑔ℎ𝑡
𝜃𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑎𝑛𝑔𝑙𝑒
From the trigonometry, we know that;

𝑜𝑝𝑝 ℎ𝑚𝑖𝑛 20
sin 𝜃𝑚𝑖𝑛 = ℎ𝑦𝑝 = = 170
𝐿
20
𝜃𝑚𝑖𝑛 = 𝑠𝑖𝑛−1 (170) = 𝟔. 𝟕𝟔°
5.4.3 Link angle at maximum position (𝜽𝒎𝒂𝒙 )

When the lift is at its maximum height the maximum angle is obtained from trigonometry:
Figure 5. 6 The link angle at maximum position

𝑜𝑝𝑝 ℎ𝑚𝑎𝑥 150
sin 𝜃𝑚𝑎𝑥 = ℎ𝑦𝑝 = = 170
𝐿
150
𝜃𝑚𝑎𝑥 = 𝑠𝑖𝑛−1 (170) = 𝟔𝟏. 𝟗𝟑°
Now we have sufficient information to check the force on the linkage in both position (case)
Case I: Force distribution at minimum angle
Figure 5. 7 The force distribution at minimum angle
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Where 𝐹𝑙 = 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑎 𝑠𝑖𝑛𝑔𝑙𝑒 𝑙𝑖𝑛𝑘
𝐹𝑎𝑥 = 𝑡ℎ𝑒 𝑎𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡
𝑤 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑤𝑒𝑖𝑔ℎ𝑡 𝑡𝑜 𝑏𝑒 𝑙𝑖𝑓𝑡𝑒𝑑
Again, from trigonometry, we know that
𝑜𝑝𝑝 𝑤⁄4
sin 𝜃𝑚𝑖𝑛 = ℎ𝑦𝑝 = 𝐹𝑙
Rearranging the above equation yields

𝑤 7100𝑁
𝐹𝑙 = 4𝑠𝑖𝑛𝜃 = 4𝑠𝑖𝑛6.76° = 15079.34𝑁 Similarly
𝑚𝑖𝑛
𝑤 7100𝑁
𝐹𝑎𝑥 = 4𝑡𝑎𝑛𝜃 = 4𝑡𝑎𝑛6.76° = 14794.5𝑁
𝑚𝑖𝑛
Case 2: force distribution at maximum angle
Figure 5. 8 The force distribution at maximum angle

𝑜𝑝𝑝 𝑤⁄4 𝑤
𝑠𝑖𝑛𝜃𝑚𝑎𝑥 = ℎ𝑦𝑝 = = 4𝐹
𝐹𝑙 𝑙
𝑤 7100𝑁
Then 𝐹𝑙 = 4𝑠𝑖𝑛𝜃 = 4𝑠𝑖𝑛61.93° = 2011.62𝑁
𝑚𝑎𝑥
The axial force also can be obtained using a simple trigonometric since all the forces as well as
angles in the force triangle are known.
𝑤⁄4
From the triangle 𝑡𝑎𝑛𝜃𝑚𝑎𝑥 = 𝐹𝑎𝑥
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𝑤 7100𝑁
𝐹𝑎𝑥 = = = 946.57𝑁
4𝑡𝑎𝑛𝜃𝑚𝑎𝑥 4𝑡𝑎𝑛61.93°
Comparing the above two cases, we see that the axial force is maximum when the angle between
the link and the base frame is minimum. Hence we use this force to calculate the power screw and
the nut. The following figure shows this force in action when the device is lifting a material.
Figure 5. 9 The comparing angle of the above two cases

𝐹𝑅 Represents the resultant of the two axial forces exerted by the two links.
From summation of vectors the magnitude and direction of the resultant force can be calculated:
𝐹𝑅 = 𝐹𝑎𝑥 + 𝐹𝑎𝑥 = 2𝐹𝑎𝑥
= 2 × 14794.5𝑁
= 𝟐𝟗𝟓𝟖𝟗𝑵
5.5 Power screw terminologies and formulas

Power screws are used to convert rotary motion into translator motion. To achieve this, power
screws use either of the two mechanisms described below. In most of the power screws the nut has
axial motion against the resisting axial force while the screw rotates in its bearings. In some screws,
the screw rotates and moves axially against the resisting force while the nut is stationary. There
are three types of screw threads mostly used for power screws: square thread, acme or trapezoidal
thread, and buttress thread.
Acme threads are the most common form of the threads. They are used when rapid movements are
required. The disadvantage of these threads includes their low efficiency and difficulty in predict-
ing service. The buttress thread is a combination of both square and acme thread. They are not
mostly used in power screws because they transmit power only in one direction. Square threads
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on the other hand are adapted for the transmission of power in either direction. This thread results
in maximum efficiency and minimum radial or bursting pressure on the nut. [5]
5.5.1 Terminologies of power screw. [5]

1. Pitch (p): it is the distance measured parallel to the axis from a point on a thread to the axis
from a point on a thread to the corresponding points on adjacent thread forms in the same
axial plane and on the same side of axis.
2. Crest: it is the top most surface joining the two sides.
3. Root: it is the bottom of the groove between the two flanks.
4. Flank: flanks are straight edges which connect the crest with root of the thread.
Figure 5. 10 Terminologies of power screw

5. Major diameter (do): is also known as nominal diameter. It is the largest diameter of the
screw.
6. Minor diameter (dc): is also known as core diameter. It is the smallest diameter of the screw
thread. Mathematically it is expressed as:
𝑝 𝑝
𝑑𝑐 = 𝑑 (2 + 2)
𝑑𝑐 = 𝑑 − 𝑝
7. Pitch diameter (𝑑𝑚 ): it is a theoretical diameter between the major and minor diameter of
the screw. It is also known as the mean diameter of the screw.
𝑑 + 𝑑𝑐
𝑑𝑚 =
2
𝑑+(𝑑−𝑝)
𝑑𝑚 = 2
8. Helix angle (α): is an angle made by the helix of the thread with a plane perpendicular to
the axis of the screw. It is related to the pitch and the mean diameter of the screw as:
𝑝
𝑡𝑎𝑛𝛼 =
𝜋𝑑 𝑚
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5.5.2 Torque required to lift or lower a load by square threaded screws

When the power screw completes one full turn, it forms the following imaginary inclined plane.
Figure 5. 11 Figure 5. 11 (a) Development of screw. (b) Forces acing on the screw.
5.5.3 Design of the lead screw
Figure 5. 12 Design of the Lead screw

The material selected for the screw is mild steel with the following Material properties:
𝜎𝑐(𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒) = 175𝑀𝑝𝑎
𝜎𝑡(𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒) = 100𝑀𝑝𝑎
𝜏𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = 105𝑀𝑝𝑎
The direct compressive stress is given by:
𝐹𝑅
𝜎𝑐 = 𝑤ℎ𝑒𝑟𝑒 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑎𝑡 𝑡ℎ𝑒 𝑐𝑜𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝐴𝑐
𝐹𝑅
𝜎𝑐 =
𝜋𝑑𝑐2
P a g e 53 | WKU
Rearranging and solving for the core diameter

4𝐹𝑅
𝑑𝑐2 =
𝜋𝜎𝑐
4𝐹 4×29949𝑁
𝑑𝑐 = √ 𝜋𝜎𝑅 = √3.14×175𝑀𝑝𝑎
𝑐
𝑑𝑐 = 14.76𝒎𝒎
Since the screw is subjected to torsional shear stress, to account for this, let’s adopt;
𝑑𝑐 = 17𝑚𝑚.
From standard table basic dimensions for square threads in mm (normal series) according to IS:
4694-1968(reaffirmed 1996) for core diameter 𝑑𝑐 =17mm, the corresponding appropriate pitch is
5mm. Hence the outer (nominal) diameter of the screw;
𝑑𝑜 = 𝑑𝑐 + 𝑝 = 17𝑚𝑚 + 5𝑚𝑚 = 22mm

The mean diameter of the screw:
𝑝
𝑑𝑚 = 𝑑 − = 22𝑚𝑚 − 5⁄2 𝑚𝑚 = 19.5mm
2
To find the helix angle of the screw,
𝑝 5𝑚𝑚
𝑡𝑎𝑛 ∝= = = 0.08
𝜋 × 𝑑𝑚 𝜋 × 19.5𝑚𝑚
From this, ∝= tan−1 (0.08) = 4.66° ≈ 5°
The coefficient of friction for a power screw with good lubrication, best running condition and
average workman ship may be assumed to be 0.15 (from textbook of machine design R.S.
KHURMI J.K. GUPTA table 17.5: coefficient of friction under different condition).
Now, we know the coefficient of friction;

𝜇 = 𝑡𝑎𝑛𝜃
0.15 = 𝑡𝑎𝑛𝜃
θ = tan−1 (0.15) = 8.53 ≈ 9°
A screw is said to be self-locking if and only if the friction angle, 𝜃 is greater than or equal to
helix angle ∝.
i.e. 𝜃 >∝ ↔ 8.53° > 4.66° 𝑤ℎ𝑖𝑐ℎ 𝑡𝑟𝑢𝑒 𝑠𝑖𝑛𝑐𝑒 𝑡ℎ𝑒 𝑠𝑐𝑟𝑒𝑤 𝑖𝑠 𝑠𝑒𝑙𝑓 − 𝑙𝑜𝑐𝑘𝑖𝑛𝑔.
The turning moment required to rotate the screw under the design load is given by,
P a g e 54 | WKU
𝐹𝑅 tan(∝ +𝜃) 𝑑𝑚
𝑇1 =
2
19.5
= 29949𝑁 tan(5° + 9°) ×
2
= 72804.5Nmm
Now let’s check if the human force applied on the cranked lever of the device can lift the assumed
maximum weight.
From the figure shown below;
The length the crack, l=30cm=300mm
The average human force 𝐹𝑎𝑣𝑒 can be taken as 245N
Now, we know that turning moment at point O
𝑇 = 𝐹𝑎𝑣𝑒 × 𝑙 = 245𝑁 × 300𝑚𝑚 = 7𝟑𝟓𝟎𝟎𝑵𝒎𝒎

For the load on the table to be lifted, the turning moment required to rotate the screw must be less
than turning moment induced due to the applied human force
i.e. 𝑇1 < 𝑇
72261.92<73500Nmm which is true. Hence assumed load can be lifted by human force.
The shear stress in the screw due to the torque 𝑇1
𝟏𝟔𝑻𝟏
𝝉=
𝝅𝒅𝟑𝒄
16 × 72804.5𝑁𝑚𝑚
=
𝜋(17𝑚𝑚)3
𝝉 = 𝟕𝟓. 𝟓𝑵/𝒎𝒎𝟐
The direct compressive stress in the screw;
4𝐹𝑟
𝜎𝑐 =
𝜋𝑑𝑐2
4×29949𝑁
𝜎𝑐 = 𝜋×(17𝑚𝑚)2
𝜎𝑐 = 𝟏𝟑𝟐𝑵/𝒎𝒎𝟐
P a g e 55 | WKU
The maximum principal (compressive)

𝜎𝑐 1
𝜎𝑐(𝑚𝑎𝑥) = + 2 (√𝜎𝑐2 + 4𝜏 2 )
2
132𝑁
2 1
= 𝑚𝑚 + (√(1322 + 4 × 75.52 ))
2 2
= 𝟏𝟔𝟔. 𝟑𝑵/𝒎𝒎𝟐
Which is safe or less than 𝜎𝑐(𝑎𝑙𝑙𝑜𝑤) = 175𝑁/𝑚𝑚2
The maximum shear stress,
1 1 𝟏𝟎𝟎. 𝟑𝑵
𝜏𝑚𝑎𝑥 = (√𝜎𝑐2 + 4𝜏 2 ) = (√1322 + 4 × 75.52 ) =
2 2 𝒎𝒎𝟐
Which is less than the allowable shear stress
𝜏𝑎𝑙𝑙𝑜𝑤𝑎𝑙𝑏𝑒 = 𝟏𝟎𝟓𝑵/𝒎𝒎𝟐 , hence the design safe.
Since the maximum shear stresses are within safe limit. Therefore the design of square thread
screw is satisfactory.
5.6 Design of Nut bar
Figure 5. 13 Design of nut bar
The nut is produced from cast iron with the following material properties.
Bearing pressure, Pb = 26.09N/mm and,
P a g e 56 | WKU
Allowable compressive stress induced in the nut, σc (allowable) = 570N/mm2. In order to reduce
wear of the screw and nut, the bearing pressure on the thread surfaces must be within limits. As-
suming that the load is uniformly distributed over the threads in contact, the bearing pressure on
the threads is given by:
𝐹𝑅
𝑝𝑏 = 𝜋∗𝑑 Where FR = the resultant axial force =29,949N
𝑚 ∗𝑡∗𝑛
dm = mean diameter of the screw = 19.5mm

t = thickness of the thread
n = number of threads of nut in contact with the screw
𝑝 5𝑚𝑚
The thickness of thread; 𝑡= = = 2.5𝑚𝑚
2 2
Now the bearing pressure;
𝐹𝑅
𝑝𝑏 = 𝜋∗𝑑
𝑚 ∗𝑡∗𝑛
26.09𝑁 29,949𝐍
=
𝑚𝑚2 𝜋 × 19.5 × 2.5𝑚𝑚 × 𝑛
Solving for n, we get 𝒏 = 𝟕. 𝟓
In order to proper stability of nut we take n =8

Therefore the total number of thread of nut in contact with the screw is 9.
The height of the nut:
𝐻 = 𝑛 × 𝑝 = 8 × 5 = 40𝑚𝑚
The width of the nut:
𝐵 = 1.5 × 𝑑𝑜 = 1.5 × 22 = 33𝑚𝑚
The compressive stress induced in the nut is given by:
4𝐹𝑅
𝜎𝑐 =
𝜋(𝑑𝑜2 − 𝑑𝑐2 )
4 × 29,949𝐍
=
𝜋((22𝑚𝑚)2 − (17𝑚𝑚)2 )
= 𝟏𝟗𝟓. 𝟔𝟓𝑵/𝒎𝒎𝟐
Which is less than the allowable compressive stress for the material 𝜎𝑐(𝑎𝑙𝑙𝑜𝑤) = 570𝑁/𝑚𝑚2 .
Hence the design is satisfactory.
The safety factor for the nut is also calculated by the formula
P a g e 57 | WKU
𝜎𝑐(𝑎𝑙𝑙𝑜𝑤) 570𝑁/𝑚𝑚2
F.S= =195.65𝑁/𝑚𝑚2 =2.91=3
𝜎𝑐
5.7 Design of links and pin

For any scissor mechanism to be functional, two paired links connected by pin are required. The
scissor table in this project has totally four links and two connecting pins. The length of the links
is assumed to be 170cm Now from the above figure, let t = thickness of the side link
t1= thickness of head of pin
d = diameter of the pin
d1 = diameter of the head of pin
B = width of the side link
σc = compressive stress
σcr = crushing stress
τ = shear stress
Fs= shear force on the pin
To determine the diameter of the pin first the shear force on the pin, Fs must be computed. This
force can be obtained by applying some simple trigonometric rules on the force triangle drawn
below.
Figure 5. 14 Force triangle in the linkage

From the above force triangle:
𝐹𝑠1 = 𝐹𝑙 𝑡𝑎𝑛𝜃𝑚𝑖𝑛 Where 𝜃𝑚𝑖𝑛 = 6.760
𝑊 𝐹𝑠1
=
4𝑠𝑖𝑛6.76° 𝐹𝐿
P a g e 58 | WKU
𝐹𝑠1 ∗4∗𝑠𝑖𝑛6.76°
FL= then substitute FL value in term of 𝐹𝑠1
𝟕𝟏𝟎𝟎𝑵
𝐹𝑠1 ∗4∗𝑠𝑖𝑛6.76°
𝐹𝑠1 = then 𝐹𝑠1 = 1787.43𝑁
7100𝑁
1787.43N = 𝐹𝐿 ∗ 𝑡𝑎𝑛6.76°
1787.43N
FL= 𝑡𝑎𝑛6.76° =15079.34N
𝐹
𝐴𝑛𝑑 𝐹𝑠2 = 𝑐𝑜𝑠𝜃𝑙
𝑚𝑖𝑛
15079.34𝑁
𝐹𝑠2 = 𝑐𝑜𝑠6.76°
𝑭𝒔𝟐 = 𝟏𝟓𝟏𝟖𝟒. 𝟗𝟏𝐍
We see that both 𝐹𝑠1 and 𝐹𝑠2 tend to shear the pin. But compering the magnitude this two forces
𝐹𝑠2 > 𝐹𝑠1 .
Now considering the shear failure of the pin,
𝐹𝑠2
𝜏𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 =
𝐴𝑠
𝑤ℎ𝑒𝑟𝑒, 𝐴𝑠 = 𝑡ℎ𝑒 𝑎𝑟𝑒𝑎 𝑢𝑛𝑑𝑒𝑟 𝑡ℎ𝑒 𝑠ℎ𝑒𝑎𝑟
𝜋 × 𝑑2
𝐴𝑠 =
4
4𝐹𝑠2
Thus, 𝜏𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 =
𝜋𝑑2
Rearranging and solving for the pin diameter

4𝐹𝑠2 4×15184.91𝑁 4×15184.91𝑁
𝑑 = √𝜋𝜏 =√ =√188.4𝑁⁄𝒎𝒎𝟐
𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝜋×60𝑀𝑝𝑎
= 𝟏𝟕. 𝟗𝟔𝒎𝒎 ≈ 𝟐𝟎𝐦𝐦
To check the induced stress in the pin, consider crushing of pin
Let 𝐴1 = 𝑎𝑟𝑒𝑎 𝑢𝑛𝑑𝑒𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 = 𝑑 × 𝑡
Assuming the thickness of the link to be 1.5cm=15mm
𝐴1 = 20𝑚𝑚 × 15𝑚𝑚 = 𝟑𝟎𝟎𝒎𝒎𝟐
𝐹𝑠2 𝟏𝟓𝟏𝟖𝟒.𝟗𝟏𝑵
Now 𝜎𝑐𝑟 = =
𝐴1 300𝑚𝑚2
𝜎𝑐𝑟 = 𝟓𝟎. 𝟔𝟐𝑵/𝒎𝒎𝟐
P a g e 59 | WKU
Which is within safe limit of 𝜎𝑐𝑟 = 𝟏𝟐𝟎𝑵/𝒎𝒎𝟐. Hence the design is satisfactory
To determine the width of link “B” let’s consider tearing of side link at section N-N
𝐴 = 𝑎𝑟𝑒𝑎 𝑢𝑛𝑑𝑒𝑟 𝑡𝑒𝑎𝑟𝑖𝑛𝑔 = (𝐵 − 𝑑)𝑡
During raising or lowering any load the side link at section N-N is subjected to both tensile and
compressive stress. Since the compressive stress of the material is great than the tensile stress the
calculation is based on this stress. This will yield satisfactory result.
𝐹𝑐
Now, 𝜎𝑐 = 𝑏𝑢𝑡 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑓𝑜𝑟𝑐𝑒 𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒 𝑖𝑡 𝑐𝑎𝑛 𝑏𝑒 𝑓𝑎𝑖𝑟𝑙𝑦 𝑡𝑎𝑘𝑒𝑛 𝑎𝑠 𝐹𝑐 = 𝐹𝑠2
𝐴
𝟏𝟓𝟏𝟖𝟒.𝟗𝟏𝑵
𝜎𝑐 = (𝐵−20𝑚𝑚)15𝑚𝑚
Rearranging for the width of the side link

𝟏𝟓𝟏𝟖𝟒.𝟗𝟏𝑵
𝐵 = 175𝑀𝑝𝑎×15𝑚𝑚 + 20𝑚𝑚 = 25.28𝑚𝑚 ≈ 𝟑𝟎𝒎𝒎
Other dimensions of the pin as follows

The thickness of head of the pin 𝑡1 = 0.3𝑑 = 0.3 × 20𝑚𝑚 = 6𝑚𝑚
Diameter of head of the pin 𝑑1 = 1.5𝑑 = 1.5 × 20𝑚𝑚 = 3o𝑚𝑚
5.8 Design of the base frame
Figure 5. 15 Design of the base frame

The base frame is used to support the whole manipulator components and as a housing of caster
wheel.
Assumption
• Its length depends on the link height and the mechanical system components
• Since the base is mobile that is not grounded it can be affected by stress. Therefore,
strong materials that withstand the stress needed.
Material selection
Considering the carbon content, Mach inability, corrosion resistance and high strength; the mate-
rial selected is:
P a g e 60 | WKU
• Annealed(hardened) steel
• Tensile strength, 𝜎𝑡 = 394 𝑀𝑝𝑎
• Yield strength, 𝜎𝑦 = 294.8 𝑀𝑝𝑎
Design analysis
The minimum thickness of the base is given by:
, 𝒕𝒃𝒇 = 𝟒𝒐𝒎𝒎
Base frame dimensions
𝑤𝑏 = Width of the base, in the direction to the front wheel
𝐿𝑏 = Length of the base, which is transverse with the link
Note: The numbers given in the above formula are the dimensions found from assumption and
from the design of the other components of the machine.
5.9 Design of the Crank handle
Figure 5. 16 Design of the Crank handle

The Crank handle is used to control and manipulate the machine according to our desirable direc-
tion and sections.
Assumption
• The maximum human force is to be 245N.

• The Crank handle is assumed as horizontal hollow beam.
Length of Crank handle is 300mm
Material Selection
Due to the force exerted on the Crank handle, we select carbon and alloy steel (AISI No
1050)
P a g e 61 | WKU
Tensile strength,𝜎𝑡 = 813.7𝑀𝑝𝑎

Yield strength, 𝜎𝑦 = 482.6 𝑀𝑝𝑎
Design analysis
𝐹𝑜𝑟𝑐𝑒 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑏𝑦 ℎ𝑢𝑚𝑎𝑛, 𝐹ℎ = 245𝑁
Fh2 Fh1
150mm 150mm
Figure 5. 17 Analysis of human force
Since it is welded with the power screw at its center, it has a reaction force at its center when the
human force is rest on both ends.
5.10 Caster Wheel Selection
Figure 5. 18 Design of cater wheel

There is no sample or formula that can be followed to select the proper caster or wheel for a specific
application. The best choice for the longest service life and smooth operation is influenced by
several factors, including the environment, impact loading, wheel size, wheel composition and
bearing selection. The following are some of the important factors to consider in your selection
process.
5.11 Prototype Fabrication and Testing, Mathematical Modelling

Model building is used to gather additional information and test design ideas. In this stage of the
process Engineers l; it looks and functions just like the finished product.
P a g e 62 | WKU
5.12 Manufacturing Procedure

Generally, the industrial manufacturing process follows the following steps:
Planning
Material preparation shop
Fabrication
Assembly
Final product
The overall construction of the machine is subdivided in to three stages.
Stage-I: construction of each machine separately
Stage-II: assembly
Stage-III: finishing operation
Stage-I
In the first stage, the construction of each of the above-mentioned part is going to be implemented.
The first step in this stage is constructing the base frame in which the other parts directly or indi-
rectly connected and mounted to this. The Top Table, link, nut, pin, Crank handle, and lead screw
components are then constructed as per the desired dimension and length.
Stage-II
The second stage is assembling the individual components produced in Stage-I. It is going to be
achieved using:
• Fastening
• Electric arc welding and
• Direct fitting
Once the base frame, lead screw, and Top Table assembly is completed and the links are welded
and connected. The overall mechanical system components are going to be settled.
This process is the most important part of manufacturing process since all the individual parts are
brought as one structure which produce a meaningful and useful effect. Any dimensional error
during the part construction can be corrected at this stage and appropriate reconditioning can also
be made.
P a g e 63 | WKU
Stage-III
At this stage great care is given to the external appearance of the machine rather than the inside
structure. This stage includes manufacturing activities such as:
• Painting
• Filing and
• Grinding
5.13 Financial Estimation

Cost Analysis
Table 5. 3 Cost analysis
Component Dimension in mm Material Quantity Price in Birr
Link 20×15, t=15 High carbon steel 2 1600
Lead screw do=22, dm=19.5, t=4 Mild steel 1 1500
Pin d=20, d1=30 t= 6 Stainless steel 1 500
Crank handle t=15, L=300 Carbon and Alloy 1 700
steel
Caster wheel 4 1000
Top Table 1800 × 1100, ttt=40 Carbon and Alloy 1 2500
steel
Base frame 1800 × 1100, Lbf=40 Mild steel 1 1200
Nut H=40, B=33,t=2.5, dm=19.5 Mild steel 2 300
Total cost 9,300
P a g e 64 | WKU
CHAPTER SIX
6. RESULT AND DISCUSSION
There are many results obtained during the design analysis of this machine. Among these results,
improvement of lifting process in terms of proper positioning, proper balancing, reduce time, re-
duce man power, simple operation and control system and other related functions that satisfy the
company needs are the major ones. The result is obtained so:
The design of nut has:
• Diameter= 22mm diameter
• Bearing pressure is 26.09N/mm2
• Allowable compressive stress = 570N/mm2
• Compressive stress induced in the nut is 195.65Mpa
• total number of thread of nut in contact with the screw is 9
• height of the nut is 400mm, and
• width of the nut is 33mm
Design of pin has:
• load 7100N
• diameter is 20mm
Design of link has:
• A=300mm2,
• Thickness 15mm,
• σc =175Mpa (compressive stress),
• σcr = 50.62Mpa (crushing stress),
• Fs= 15184.91N (shear force on the pin),
• Width(B)=30mm,
• Total applied force 245N;
Design of the base frame has
• Tensile strength( 𝜎𝑡) = 394 𝑀𝑝𝑎,Yield strength,

• 𝜎𝑦 = 294.8 𝑀𝑝𝑎,
• Minimum thickness of the base frame is 40mm;
P a g e 65 | WKU
Design of the crank handle has:
• maximum human force is to be 245N,

• Length of Crank handle is 300mm,
• Tensile strength (𝜎𝑡) = 813.7𝑀𝑝𝑎
• Yield strength(𝜎𝑦 ) = 482.6 𝑀𝑝𝑎
Design of power screw has:
• S 𝜎𝑐(𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒) = 175𝑀𝑝𝑎
• 𝜎𝑡(𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒) = 100𝑀𝑝𝑎
• 𝜏𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = 105𝑀𝑝𝑎
• 𝑑𝑐 = 14.76𝒎𝒎
For the load on the table to be lifted, the turning moment required to rotate the screw is
72804.5Nmm, turning moment induced due to the applied human force is 73500Nmm, shear stress
in the screw is 75.5N/mm2, compressive stress in the screw is 132N/mm2, maximum principal(
compressive) is 166.3N/mm2, 𝜏𝑎𝑙𝑙𝑜𝑤𝑎𝑙𝑏𝑒 = 𝟏𝟎𝟓𝑵/𝒎𝒎𝟐 , Maximum shear stress is 100.3N/mm2,
Allowable shear stress is 105N/mm2.
We have discussed that almost that have been join out parts of mechanical scissor lifting and trans-
porting raw material of production and bottle product in Ambo Mineral Water Share Company. In
each parts of our machine we tried the best to express each and every component of machine
briefly. we hope that this internship program gives detail information for manufactures about all
parts machine that it contains. Also, we tried to clarify to any reader that introduces our design to
application activities to different aspects of mechanical engineering works. In our design of manual
operated scissor lifting and transporting machine we use 245N maximum man power to lifting or
transporting raw material that used for production and botte product, empty bottle and crate for
different purpose by the help of Crank handle and hallow handle. Using this machine reduces
Damage of crate and glass bottle, Time wastage, Low productivity (according to time), Poor safety
and production quality and, needs great human power to transporting and lifting. By using this
machine company can save its capacity, money which leads the employee to change their status.
P a g e 66 | WKU
The design of this machine involves efforts to improve every necessary function of the traditional
lifting and transporting method. This manually operated scissor lifting and transporting machine
must have an excellent working principle compared to that of the traditional one. The machine
construction concept is generated by identifying the lifting and transporting raw material of pro-
duction after we made a lot of observation in the syrup, RGB, PET rooms and establishing target
product specification.
In concept selection the concept is evaluated with respect to the company need and other criteria,
comparing the relative strengths and weakness of the concepts, for further investigation. Other
concepts are rated. Final product and specification is then refined according to the chosen concept
before the development of the detail design of this machine.
P a g e 67 | WKU
CHAPTER SEVEN
7. Conclusions and Recommendation
7.1 Conclusions
As we have seen the process of the Ambo Mineral Water Share Company, there are wastes
generated from mainly four different units. From water treatment units, washing of ma-
chineries, and bottle unit. All of these cause hazards to environment. But the factory does
not treat any kinds of waste generated.
From our design we can conclude that the design of manual operated scissor lifting and transport-
ing machine is initialized with the specification requirement based on standards given on our in-
ternship program. Our design of manual operated scissor lifting and transporting machine mainly
considers on the basic procedures of each and every component designed. Regarding the lifting or
transporting capacity of load for manual operated scissor lifting and transporting system should be
preferred due to its simplicity, better sensitivity, higher reliability, low maintenance, compactness
for the source and similar capacity. The selection of the materials based on ASME standard does
not take more time consuming, complex replacement, more cost etc.
We are so lucky to participate in the qualified internship program because we gained a lot of
knowledge and experiences which probably we may not get when we were in campus and we have
developed what we had learnt before by relating theoretical knowledge with the practical
knowledge. And we gained additional skills which are not in formal education but they are skills
to be learnt. After the manufacturing of this machine the problems will be solved and also the
working conditions will also comfortable, time wastage to lifting and transporting of raw material
of the production and bottle product or empty glass bottles with crates the blank will be reduced
and the production will increase and the company will profitable.
We would like to say that Ambo mineral water share company (AMWSC) is one of the top com-
pany which we were pride to work in. AMWSC is a company which produce different products
which gives our different knowledge and experience. Therefore, this company has a lot of
knowledge to offer especially for the department of Mechanical Engineering.
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The three month internship program has provided a good experience which can change our career
life. It has greatly increased our maturity levels and improved our self- confidence and self-con-
cepts. It has also assisted us the students in developing relationships with experts in fields of strong
interest to us. Many concepts which we have blurred vision towards to understand were clarified
when we relate them with we see in actual world. The paper also encompasses all the procedural
processes followed in the project. Our design and manufacturing knowledge starting from ma-
terial selection to the assembly of the machine. We have tried to make the machine very simple in
construction.
7.2 Recommendations
The factory should be build treatment unit for each of pollution sources such as gasses
emitted to atmosphere, strong using for washing purpose and wastes generated from sed-
imentation. The good thing is that the quality control manager told us as they want to build
treatment plant. They should find market for glass waste from abroad for recycling pro-
cess, because of the factory is popular as the World.
We would like to recommend signing up our design project which is used to solve the problems
that exist in our internship program, in addition to this designing some new projects and improving
the existing ones plays a vital role on improving the qualities and quantities of the products. This
could be done by the joint effort of the optimization, planning, financing materials cost and price
and the production schedule estimates of a components and products respectively.
We recommend that designing and making analysis of machine or component is nothing if it is not
translated into a working machine. This project should be continued until it will be manufactured
and observing results checks in fields. We also recommended that this manual operated scissor
lifting and transporting machine is designed for Ambo Mineral Water Share Company. It is further
recommended that the development program be continued. Program Continuation would involve
the detailed design, production and testing of prototype assemblies.
There are lots of problems in the Ambo mineral water share company, its productivity affecting
directly or indirectly to function below its full capacity. So, then the industry shall try to implement
the following solutions. The company should come up with a way to reuse rejected work pieces
P a g e 69 | WKU
and chips through melting and making them available for applications that does not require mate-
rial properties such as medals. Air conditioning system is necessary because the condition of the
atmosphere greatly affects the performance of the employees. Using the same machines in the day
and night shifts must be avoided. Since most of the machines work continues, the components are
easily subjected to wear and fatigue failure. Since lifting and transporting devices are not available
as the work environment requires, the workers are obliged to exert some unnecessary effort in
heavy jobs loading and unloading.
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Reference
[1]. Ambo Mineral Water reference 1923 S.c.
[2]. About Ambo mineral water” An Ethiopian Icon"". Ambo mineral water. Retrieved.
(January 7, 2013).
[3]. D. Gandy, “ASME B31.1. (America Society of Mechanical Engineering,).” New York: March,
2007.
[4]. Jonas, A. b. (June 3, 2015). "Export”. Ambo mineral water Retrieved.
[5]. A text book of machine design, R.S. Khurmi and J.K. Gupta-2005
[6]. Design of Machine Elements, G.K. Vijayaraghavan and S. Vishnupriyan.

[7]. Shigley Mechanical Engineering Design, Budynas Nisbett − eight edition
[8]. Shirley’s mechanical engineering design, MC Graw Hill, Budynas Nisbelt, 8th edition
[9]. Strength of Material, Surya Patnaik and Dale Hopkins

[10]. Mechanical Engineering Design, 5th Edition, Joseph Edward Shigley & Charles R.Mischke
P a g e 71 | WKU
APPENDIX
Figure: 1 Design of manual operated scissor lifting and transporting machine by assembly.
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Figure: 2 Design of Hollow bar in 2D
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Figure: 3 Design of Lead screw in 2D
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Figure: 4 Design of Link in 2D
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Figure: 5 Design of nut attached to side frame in 2D.
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Figure: 6 Design of nut in 2D
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Figure: 7 Design of link in 2D
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Figure: 8 Design of top table in 2D
P a g e 79 | WKU

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TITLE: MANUAL OPERATED SCISSOR LIFTING AND TRANSPORTING MACHINE

FINAL INTERNISHIP FROM TO JUNE TO AUGUST AT AMBO MINERAL WATER

ADVISOR: Mr. Gadisa D-----------------

Submission date: 26/12/2013

Name Signature Date

Bekele Chala …………………….. ………………

Eliyas Ayana ……………………….. ………………..

2.4.5 Syrup preparation process ................................................................................................ 27

5. DETAIL DESIGN .................................................................................................................... 43

Table 4. 1 Material selection for different parts of the machine ................................................... 42

Table 5. 1 Manual operated Scissor lifter, transporter machine ................................................... 45

Abbreviation Full name

1.2 Back Ground and History of Ambo Mineral Water S.C

1.3 Vision Mission and Goal

• Introduce new management techniques and disciplines.

1.4 Objectives of the Company

1.4.2 Specific Objective

1.5 Main Products or Services of Ambo Mineral Water Factory

(Orange, Fanta, predator, Apple, Pineapple, Lemon-lime). [1]

Figure 1. 1 Ambo mineral water. [1]

Figure 1. 2 Ambo mineral water. [1]

1.6 Main Consumer of Ambo Mineral Water Products

Figure 1. 3 Main consumer of Ambo mineral water products. [1]

Europe Africa America Middle East Canada

• England • South Af- • California • Saudi • Toronto

1.7 Overall Organization Chart and Management of the Company.

Figure 1. 4 Overall Organization Chart and Management of the Company. [1]

2.1 How we got into the Company

2.2 The Section of the Company We have been Working In

2.2.1 Section of RGB Line

2.2.2 Unpacker machine

valves, pneumatic valve, and sensor. [1]

2.2.3 Crate Washer machine

2.2.4 Bottle washer machine

1. Pre-warm the bottles to 30°C by rinse water.

Figure 2. 1:-Bottles Washer Machine. [1].

2.2.5 Filler and capper Machine

transfer to worm star by discharge star wheel. [1]

Figure 2. 2 :-Filling machine. [1]

2.2.6 Labelling Machine

just two narrow lines of dispensed glue. [1]

Figure 2.3 Labelling machine. [1]

2.2.7 Packer Machine

Figure 2. 4 Room of general bottling line

2.3 Section of PET line

Perform Incline Perform Heater Air con-

Figure 2. 5 A process flow diagram of the entire PET as general.

a. Perform hopper is used to store perform.

2.3.1 Blower machine

Figure 2. 7 Stretch blow moulding. [1]

Figure 2. 8 Blow moulding machine. [1]

2.3.2 Air Conveyor

2.3.3 Filler (Rinser and Capper)

Star wheel Infeed star Intermediate

Full bottle Discharge star Transfer

Figure 2. 9 A flow diagram of operation of filler

Basic pressuriz filling filling CIP

Figure 2. 10 Flow diagram of filling process

Overcome of these stoppages are: