NATIONAL INSTITUTE OF TECHNOLOGY, HAMIRPUR

A PROJECT REPORT
ON

“DESIGN OF MANHOLE CLEANING MACHINE”

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR

THE AWARD OF THE DEGREE

BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)

Project Guide Submitted by

Dr. Sunand Kumar Abhinav Mishra (16349)
Associate Professor Arpan Vishnoi (16324)
Mechanical Engineering Department Ajasra Anand (16332)
NIT Hamirpur B. Samanth Rao (16354)

B. Tech (IV Year)

Mechanical Engineering,
National Institute of Technology Hamirpur,
Himachal Pradesh.

Duration: July-December 2019

 CERTIFICATE
This is to certify that the project entitled “Design and Fabrication of Water Audit System” has
been submitted to the Department of Mechanical Engineering, National Institute of
Technology, Hamirpur for the fulfilment of the requirement for the award of the Degree of
Bachelor of Technology in “Mechanical Engineering” by following students of Final Year B.
Tech in Mechanical Engineering.

1.1 Abhinav Mishra (Team Leader)

(16349)

2.1 Arpan Vishnoi

(16324)

3.1 Ajasra Anand

(16332)

4.1 B. Samanth Rao

(16354)
 CONTENTS
ABSTRACT 3

CHAPTER 1 4

INTRODUCTION

CHAPTER 2 6

LITERATURE REVIEW
2.1 6
2.2 6

CHAPTER 3 8

METHODOLOGY
3.1 8
3.2 8
3.3 9

CHAPTER 4 10

ANALYSIS AND RESULTS

4.1 10
4.2 11

CHAPTER 5 12

CONCLUSION AND CLOSURE 12

FUTURE WORK 13

REFERENCES 14
Abstract
Manual scavenging is outlawed in India, yet thousands of people are still engaged in the work
and many die cleaning sewers. According to the Safai Karmachari Andolan, a movement to
eradicate manual scavenging, at least 1,470 manual scavengers died at work between 2010 and
2017. There are an estimated 1.8 lakh people in the country working as manual scavengers.
Manholes are brutal environments that can quickly translate a callous attitude, lack of
emergency response protocols and the absence of basic safety equipment to death.
Contractors have been known to cut costs and to try to get the ‘job’ of cleaning them done
quickly, and not equip workers with ventilators, gas concentration detectors, gloves, face
masks and hard hats (as well as not keep a person on standby on the outside to help in case
of an emergency). As a result, the workers are left exposed to three dangerous environments
conspiring together: chemical, biological and legal.

India has enacted two laws – the Employment of Manual Scavenging and Construction of Dry
Latrines Prohibition Act, 1993 and the Prohibition of Employment as Manual Scavengers and
their Rehabilitation Act, 2013 – to eventually eradicate the practice of manually cleaning,
carrying and disposing human excreta and garbage from sewers. Yet, manual scavengers across
India still clean sewers at great risk to their lives. Most of the time, they are not provided the
mandatory safety gear by their employers, largely municipal agencies, making them vulnerable
to fatal accidents. Even a protective cap is a luxury for most of them, let alone jackets, gloves
and masks. As a consequence, many casualties are reported from inhaling poisonous gases
accumulated inside manholes, oxygen depletion, heat stress or from falling down the pit.

There are several mechanical sewer/manhole cleaning methods proposed in the Standard
operating procedure proposed by the Indian government but due to the lack of applicability,
operational limitations and high investment behind the machineries, manual method still
prevails in society posing as a major concern.

This project deals with the minimisation of human involvement in actual cleaning of
sewer/manholes and replaces it with an exoskeleton arrangement which is capable of going
inside the manhole and perform the cleaning operation.

The mechanism proposed finds advantage over the suggested SOPs in the way that it’s not only
applicable for mediocre level applications but is easy to operate and way budget friendly
considering all of its versions prevailing in the market or as suggested in the SOPs.
 CHAPTER 1
INTRODUCTION
1.1 Project Background
The process of Manhole cleaning involving manual methods has been proven as a severely
harmful practice considering the risk of lives of the worker involved. The social stigma of
considering people from lower caste sections responsible to be involved in such menial
processes also is a shameful issue in the present date. This project revolves around providing
an efficient and sustainable solution for the same.

1.2 Objective
 To design a semi-automated pneumatically powered mechanical exoskeleton capable
of probing inside a manhole and collect the clogged sewer waste by employing a
symmetrical bucket arrangement powered by pneumatic actuators.
 To reduce the human involvement in the process of manhole cleaning and minimise the
health-related risks of people involved in the process.
 To contribute towards eradication of caste based social stigmas.

1.3 Project Scope

The scope in this project is the implementation of the proposed mechanism nationwide,
especially in sub-urban and rural areas where the process of manual scavenging still prevails .
A more practical and realistic version of manhole cleaning SOPs should be devised by Indian
government including feasible solutions to the problem.

1.4 Problem Statement

If workers are made to enter drains, they will have to be trained to understand the threats
that can arise and equipped such that the best way they can respond can actually be executed
as fast as possible. Such environments often have very little space to move around and
accidents can quickly lead to death, so having a protocol that optimises for time is important.
However, designing and implementing such a protocol for various accident scenarios would
be to assist skilled workers such as engineers, hydrologists, etc. Expecting an unskilled
worker and unequipped worker to enter a confined and septic environment to clean it is to
wilfully endanger their lives.
Hence in order to reduce the risk of workers’ lives and make the process safer and more
effective, a low cost semi-automated mobile manhole cleaning mechanism is required that
can be easily operated by the worker and which does not require high setup cost.
1.5 Overview of Report
Chapter 1 mainly briefs about the background of the project which involves the background
of the projects, objectives, scopes and problem statements. Chapter 2 basically describes
more about the studies of the components involved in this project such as mechanical
exoskeleton, telescopic arm, bucket setup etc. Chapter 3 introduces the design procedures that
shows step by step process from the initial concept of design to final analysis of the frame
with respect to required conditions. Chapter 4 mainly discuss about the results obtained
during the analysis and their significance. Chapter 5 discusses about the conclusions that can
be derived from this report and suggestion for future recommendations.
 CHAPTER 2
LITERATURE REVIEW
2.1 The concept of structural mechanics
Mechanics is the study of bodies in motion. A solid body can be put into motion by any of a
variety of actions. Among the most common causes of motion are the application of force or
heat to the body. In general, a body in motion undergoes some combination of rigid motion
(the distance between two particles does not change) and stretching (the distance between two
particles changes). The motion can be either fast or slow. If the motion is slow enough then the
resistance to motion caused by the inertia of the body (the so-called D'Alembert forces) can be
neglected in the accounting of force equilibrium. We generally refer to this class of motions as
quasi-static.
The working of the designed mechanism also comes under the class of quasi static forces and
hence respected calculations are performed.
The description of the geometry of deformation must begin with a description of the body in
question. For our purposes it is sufficient to imagine a continuous, solid body located in three-
dimensional space. We must be able to completely characterize the geometry of the body in
some configuration in order to make any headway in describing the geometry of deformation.
We will call the known geometry the reference configuration. The reference configuration is
often taken to be the unstressed and unstrained configuration of the body.

2.1.1 Flexure theory

Bending theory is also known as flexure theory is defined as the axial deformation of the beam
due to external load that is applied perpendicularly to a longitudinal axis which finds
application in applied mechanics.
For a material, flexural strength is defined as the stress that is obtained from the yield just
before the flexure test. It represents the highest stress that is experienced within the material at
the moment of its yield. 𝜎 is used as the symbolic representation of flexural strength.
2.1.2 Flexure equation
2.2 The Concept of Pneumatics
The reason for using pneumatics, or any other type of energy transmission on a machine, is to
perform work. The accomplishment of work requires the application of kinetic energy to a
resisting object resulting in the object moving through a distance. In a pneumatic system,
energy is stored in a potential state under the form of compressed air. Working energy (kinetic
energy and pressure) results in a pneumatic system when the compressed air is allowed to
expand. For example, a tank is charged to 100 PSIA with compressed air. When the valve at
the tank outlet is opened, the air inside the tank expands until the pressure inside the tank equals
the atmospheric pressure. Air expansion takes the form of airflow.
To perform any applicable amount of work then, a device is needed which can supply an air
tank with a sufficient amount of air at a desired pressure. This device is positive displacement
compressor.

2.2.1 Positive Displacement Compressor

A positive displacement compressor basically consists of a movable member inside a housing.
The compressor has a piston for a movable member. The piston is connected to a crankshaft,
which is in turn connected to a prime mover (electric motor, internal combustion engine). At
inlet and outlet ports, valves allow air to enter and exit the chamber.

2.2.2 How a Positive Displacement Compressor Works

As the crankshaft pulls the piston down, an increasing volume is formed within the housing.
This action causes the trapped air in the piston bore to expand, reducing its pressure. When
pressure differential becomes high enough, the inlet valve opens, allowing atmospheric air to
flow in. With the piston at the bottom of its stroke, inlet valve closes. The piston starts its
upward movement to reduce the air volume which consequently increases its pressure and
temperature. When pressure differential between the compressor chamber and discharge line
is high enough, the discharge valve opens, allowing air to pass into an air receiver tank for
storage.

2.2.3 Control of Pneumatic Energy

Working energy transmitted pneumatically must be directed and under complete control at all
times. If not under control, useful work will not be done and machinery or machine operators
might be harmed. One of the advantages of transmitting energy pneumatically is that energy
can be controlled relatively easily by using valves.

2.2.4 Control of Pressure

Pressure in a pneumatic system must be controlled at two points - after the compressor and
after the air receiver tank. Control of pressure is required after the compressor as a safety for
the system. Control of pressure after an air receiver tank is necessary so that an actuator
receives a steady pressure source without wasting energy.

2.2.5 Control of Pressure after A Compressor

In a pneumatic system, energy delivered by a compressor is not generally used immediately,
but is stored as potential energy in air receiver tank in the form of compressed air. In most
instances, a compressor is designed into a system so that it operates intermittently. A
compressor usually delivers compressed air to a receiver tank until high pressure is reached,
then it is shut down. When air pressure in the tank decreases, the compressor cuts in and
recharges the tank. Intermittent compressor operation in this manner is a power saving benefit
for the system. A common way of sensing tank pressure and controlling actuation and de-
actuation of relatively small (2-15 HP) compressors, is with a pressure switch

2.2.6 Pressure Switch

System pressure is sensed with a spring-loaded piston within the switch housing. When
pressure in the system is at its low level, the spring pushes the piston down. In this position a
contact is made causing an electrical signal to turn on the compressor. As pressure in the
receiver tank rises, it forces the piston upward. With system pressure at its high level, the piston
breaks the electrical contact shutting down the compressor.

2.2.7 Pressure Regulator

In a pneumatic system, energy that will be used by the system and transmitted through the
system is stored as potential energy in an air receiver tank in the form of compressed air. A
pressure regulator is positioned after a receiver tank and is used to portion out this stored energy
to each leg of the circuit. A pressure regulator is a normally open valve. With a regulator
positioned after a receiver tank, air from the receiver can expand (flow) through the valve to a
point downstream. As pressure after the regulator rises, it is sensed in an internal pilot passage
leading to the underside of the piston.
This piston has a large surface area exposed to downstream pressure and for this reason is quite
sensitive to downstream pressure fluctuations. When downstream pressure nears the present
level, the piston moves upward pulling the poppet toward its seat. The poppet, once it seats,
does not allow pressure to continue building downstream. In this way, a constant source of
compressed air is made available to an actuator downstream.

2.2.8 DCV arrangement

To change the direction of airflow to and from the cylinder, we use a directional control valve.
The moving part in a directional control valve will connect and disconnect internal flow
passages within the valve body. This action results in a control of airflow direction. The typical
directional control valve consists of a valve body with four internal flow passages within the
valve body and a sliding spool. Shifting the spool alternately connects a cylinder port to supply
pressure or the exhaust port. With the spool in the position where the supply pressure is
connected to port A and port B is connected to the exhaust port, the cylinder will extend. Then,
with the spool in the other extreme position, supply pressure is connected to port B and port A
is connected to the exhaust port, now the cylinder retracts. With a directional control valve in
a circuit, the cylinder's piston rod can be extended or retracted and work performed.
2.2.9 Two-Way Directional Valve
One method of classifying a directional control valve is by the flow paths that are set up in its
various operating conditions. Important factors to be considered are the number of individual
ports, the number of flow paths the valve is designed for and internal connection of ports with
the movable part.
A two-way directional valve consists of two ports connected to each other with passages, which
are connected and disconnected. In one extreme spool position, port A is open to port B; the
flow path through the valve is open. In the other extreme, the large diameter of the spool closes
the path between A and B; the flow path is blocked. A two-way directional valve gives an on-
off function.

2.3 The concept of Belt and rope drives

The belt or rope drives are used to transmit power from one shaft to another via pulleys. A rope
drive is a form of belt drive, used for mechanical power transmission. Rope drives use a
number of circular section ropes, rather than a single flat or vee belt.

2.3.1 Belt Drive

This type of drive is used when the power is to be transmitted from one shaft to other which is
at a distance. Pulleys are mounted on the driver and driven/follower shafts and an endless belt
are fitted tightly over these pulleys. The frictional resistance between these pulleys and belt is
the reason for the power transmission, which depends on the velocity of belt, tension of the belt
and arc of contact of the belt in the smaller pulley. There are flat belt and V- belt used for the
power transmission.

2.3.4 Rope Drive

Steel ropes of circular in cross section are used for power transmission. They are arranged in
groves of the pulley. The grove angle varies from 40 degree to 60 degree. More than one drive
can be taken is the main advantage. For transmitting large power wire ropes are used.

2.4 The Concept of snatch blocks

A snatch block is a heavy-duty pulley inside a metal casing. It is primarily designed for
handling heavy goods, working as a pulley point that can redirect the course of a winch line.
Snatch blocks are also used to increase the lifting or pulling capacity of wire hoists and
winches. It's common for this method to produce a 100% increase in pulling or lifting
capacity. Snatch blocks allow you to change the direction of a winch’s cable by off-setting
the anchor point, allowing you to pull in a three-point motion. Sturdy and durable, snatch
blocks are ideal for transferring loads over short distances and are commonly used in
recovery situations. When used in conjunction with a winch, a snatch block can increase the
winch’s power considerably, allowing for a smoother, easier winching process.

2.5 Properties of AISI 1020 (Mild steel)

AISI 1020 has low hardenability properties and is a low tensile carbon steel with a Brinell
hardness of 119 – 235, and a tensile strength of 410-790 MPa. It has high machinability, high
strength, high ductility and good weldability. It is normally used in turned and polished or a
cold drawn condition. Due to its low carbon content, it is resistant to induction hardening or
flame hardening. Due to lack of alloying elements, it will not respond to nitriding. However,
carburization is possible in order to obtain case hardness more than Rc65 for smaller sections
that reduces with an increase in section size. The core strength will remain the same.
Alternatively, carbon nitriding can be performed, offering certain benefits over standard
carburizing. AISI 1020 steel can be largely utilized in all industrial sectors in order to enhance
weldability or machinability properties. It is used in a variety of applications due to its cold
drawn or turned and polished finish property.
2.6 Properties of 6063-T1 (Aluminium)
Aluminium alloy 6063 is a medium strength alloy commonly referred to as an architectural
alloy. It is normally used in intricate extrusions. It has a good surface finish, high corrosion
resistance, is readily suited to welding and can be easily anodised. Most commonly available
as T6 temper, in the T4 condition it has good formability.
 CHAPTER 3
METHODOLOGY
3.1 Schedule
The project is majorly divided into 3 major phases, the conceptual design, the embodiment
design and the detail design.
3.1.1 Conceptual Design
Design is initiated, carried to the point of creating a number of possible solutions, and narrowed
down to a single best concept. Feasibility study is done which requires the greatest creativity
and involves the most uncertainty. It requires problem to be defined create a statement
describing what to be done to satisfy customer needs.
Gathering information, Conceptualization, creating a broad set of concepts that potentially
satisfy the problem statement, Concept selection, evaluation of design concepts, modifying and
evolving into a single preferred concept are some basic issues covered under Conceptual
Design.
3.1.2 Embodiment Design
It refers to the structured development, flesh is placed on the skeleton of the design concept
decisions are made on strength, material selection, size, shape, and spatial compatibility. It
includes three major tasks which are –
Product architecture which includes dividing the overall design system into subsystems or
modules. Configuration design of parts and components which determine what features (holes,
ribs, splines, and curves) will be present and how those features are to be arranged in space
relative to each other. Parametric design of parts which configuration of the part and aims to
establish its exact dimensions and tolerances and to examine the part, assembly, and system for
design robustness and how consistently a component performs under variable conditions in its
service environment.
3.1.3 Detail Design
Details regarding final stages of design are finalised. Ways to ensure mobility of the mechanism
are calculated and pneumatic air-line networking is finalised. It also includes the changes and
reviews made in order to keep the design conditions optimum. Material selection is a major
task which is done under detailed design.

3.1.4 Gantt chart

3.2 Iteration 1
3.2.1 Design of Mechanical exoskeleton

3.2.2 Design of Telescopic arm arrangement

3.2.3 Design of Frame assembly

3.3 Iteration 2
3.3.1 Design of Mechanical exoskeleton
3.3.2 Design of Telescopic arm arrangement

3.4 Iteration 3
3.4.1 Design of Mechanical exoskeleton
3.4.2 Design of Telescopic arm arrangement

3.5 Final Iteration (Iteration 4)

3.5.1 Design of Mechanical exoskeleton
3.5.2 Design of Telescopic arm

3.53 Final assembly

3.4 Design of beam supporting Pulley.

3.5 Design of Clamp Bucket.

3.5 Factor of safety consideration.

3.6 Material selection consideration.

3.7 Pneumatic air-line networking.

 CHAPTER 4
ANALYSIS AND RESULTS
4.1 Structural analysis of Frame
4.2 Structural analysis of Telescopic arm
4.3 Structural analysis of Brackets
4.4 Motion simulation of telescopic arm

CHAPTER 5
 CONCLUSION AND CLOSURE

References
1. Central Public Health and Environmental Engineering Organization (CPHEEO),
“Standard Operating Procedure (SOP) for Cleaning of Sewers and Septic Tanks”.
Ministry of Housing and Urban Affairs Government of India (November 2018) p. 10

2. Keith D. Hjelmstad, “Fundamentals of Structural Mechanics” University of Illinois at

Urbana-Champaign, Illinois. p. 57

3. John R. Groot and John Nagohosian, “Introduction to Pneumatics and Pneumatic

Circuit Problems for FPEF Trainer”. Fluid Power Education Foundation.

4. R K Bansal, “A textbook of Strength of Materials”. (Chapter 7 - Bending stress in

beams)

5. V B Bhandari, “Design of machine elements”. (Chapter 13 - Belt drives)

6. https://www.azom.com/article.aspx?ArticleID=6114
7. https://www.azom.com/article.aspx?ArticleID=2812
8. http://www.genrobotics.org
9. http://www.fpef.org/