Chapter Three
Chapter Three
METHODOLOGY
In this chapter, we will delve into various elements, encompassing customer requirements, idea
generation, quality function deployment (QFD), idea evaluation, idea rating, and SolidWorks
modeling.
Target
Specification
Concept
Generation
Concept
Selection
Calculation
of the
Project
SolidWorks
Modling Cost
Table
3.2 Target Specification
The ensuing client requisites were derived from an online survey, meticulously conducted, and
further by a critical examination of the existing designs within the extant literature lacuna.
Table 1: Customer Needs
"I want a machine that cleans water Efficient cleaning capability to remove sediments,
tanks." algae, and contaminants.
"Cleaning should be quick and hassle- Time-saving and user-friendly operation for efficient
free." tank cleaning.
"I need a solution for both domestic and Versatility in design to accommodate various tank
industrial tanks." sizes and types.
"The machine should ensure water Effective disinfection and filtration to guarantee water
quality after cleaning." safety post-cleaning.
"I want a machine that is easy to Low maintenance requirements and easily replaceable
maintain." parts for prolonged use.
"I need a cost-effective solution." Affordable initial cost, minimal operating expenses,
and long-term cost efficiency.
"The machine should be durable and Robust construction to withstand frequent use and
long-lasting." harsh cleaning conditions.
"I want a compact design for easy Compact and portable design for convenient storage
storage." and transportation.
"The machine should comply with safety Adherence to safety regulations and inclusion of
standards." safety features for user protection.
3.2.2 Quality Function Deployment (QFD)
The Quality Function Deployment (QFD) methodology was employed to ascertain the significance
of customer requisites, the weightage assigned to engineering specifications, and the intricate
interplay between engineering specifications and customer demands. The outcomes are elucidated
hereunder:
Table 2: Quality Function Deployment (QFD
The preceding table delineates the correlation between customer requirements and engineering
specifications. Each customer needs to undergo a weighting process based on its level of
significance. Subsequent to rating the needs vis-à-vis the specifications, the significance of each
engineering specification is computed. Notably, the tabulated data reveals that the Cleaning Power
(PSI and Flow Rate) holds a paramount importance of 21.58%. Consequently, primary attention
will be directed toward this specification, although other factors such as cost necessitate
consideration. It is imperative to acknowledge that the target values remain subject to potential
alterations contingent upon varying parameters and the ultimate design concept.
3.3 Concept Generation
Derived from the discerned customer requirements, diverse conceptual frameworks have been
formulated with the overarching aim of adeptly and resourcefully addressing their most pivotal
needs.
3.3.1 Concept A
In this avant-garde engineering concept, the overhead tank cleaning device, crafted on the
sophisticated umbrella four-bar mechanism, is principally composed of a robust shaft interlinking
all the pivotal components. The cleaning brushes, seamlessly attached to these links fixed on the
shaft. The shaft interfaced with the motor. Augmented by two precision nozzles and an advanced
suction pump, this state-of-the-art tank-cleaning apparatus is meticulously affixed to the tank,
ensuring optimal contact of the brushes with the internal periphery. Upon activation of the motor
switch, the shaft undergoes rotational motion, catalyzing the brushes to dynamically scrub the
tank's interior walls. Positioned atop the tank, strategically located nozzles disperse water or a
cleaning agent, streamlining the operation for simplicity and efficiency. Complementing this, an
efficient suction pump adeptly extracts and evacuates all the contaminated water from the tank,
culminating in a rapid and thorough cleaning process.
3.3.2 Concept B
The precision-engineered motor shaft seamlessly integrates with an extended vertical arm, housing
a singular elongated brush that reaches the depths of the water tank, establishing direct contact
with the tank's base. Upon activation, the motor-driven aluminum shaft initiates a rotational
motion, orchestrating the cleaning of the internal surfaces of the cylindrical water tank through
strategically positioned high-velocity nozzles along the trajectory of the shaft. When the motor
switch is engaged, the shaft undergoes rotational motion, catalyzing the brush to dynamically scour
the tank's bottom, effectively eliminating accumulated debris. Strategically positioned along the
shaft, specialized nozzles dispense water, streamlining the operation for simplicity and optimal
engineering efficiency. To augment this system, a high-performing suction pump adeptly extracts
and expels all contaminated water from the tank through the outlet valve, resulting in a rapid and
thorough cleaning process.
3.3.3 Concept C
In this concept, we introduce an advanced automated water tank cleaning system. This engineering
marvel employs cutting-edge technology to ensure optimal cleanliness. The robotic apparatus,
equipped with both remote-controlled and autonomous capabilities, initiates its operation by
thoroughly assessing the tank's condition. Utilizing state-of-the-art cleaning mechanisms,
including precision brushes and powerful vacuum systems, it systematically removes impurities
while simultaneously treating the water. Equipped with autonomous navigation, obstacle
avoidance sensors, and robust data collection, the system guarantees precise and efficient cleaning.
Upon completing the process, the robot exits, providing a cost-effective, automated solution for
tank maintenance. This technological innovation significantly reduces the need for extensive
manual intervention, marking a transformative step in water tank cleaning. Furthermore, it can be
enhanced by incorporating a solar panel energy system.
3.3.4 Concept D
In this conceptual framework, the system operates by integrating in a retracted state into the tank.
The foundational brush and side brush are precision-adjusted to align the terminus with the tank
base and side walls. Subsequent to this, meticulous adjustments are executed on the foundational
brush to ensure precise alignment with the tank base. Upon activation of the motor, a seamless
synchronization between the foundational and lateral brushes ensues, instigating highly efficient
scrubbing maneuvers along the inner and bottom surfaces of the tank. Concurrently, a scrubber
facilitates the passage of water and solution through its brushes, ensuring uniform distribution. As
the brush revolves against the tank's inner surface, every bottom section undergoes thorough
cleaning. To address the cleaning of lateral inner walls, a high-pressure nozzle linked to a shaft is
deployed. This sophisticated and systematic methodology ensures a prompt and exhaustive
cleansing process, exemplifying the pinnacle of technological advancement in water tank cleaning
3.3.5 Concept E
This concept shows the machine's structural framework, which is forming rows and columns. In
response to input power derived from the AC Motor, the brushes exhibit continuous rotation,
serving the purpose of cleaning the overhead tank. Diverse rotary brushes, strategically positioned
in both horizontal and vertical orientations, contribute to comprehensive tank cleaning. A shaft is
employed to maintain the brushes' internal and rear positions, incorporating adjustable springs with
tension to modify the dimensions of the side brushes in accordance with the tank's spatial
requirements. The setup stand is meticulously designed to facilitate the convenient installation of
all components. This configuration, consisting of three brushes, achieves combined rotational and
linear motions through a Gear Motor linked to the shaft. The system is fortified with a robust
foundation, ensuring stability and supporting its entire weight, thereby enabling seamless insertion
into the tank for efficient cleaning operations.
3.4 Concept Selection
3.4.1 Concept Screening
Within a screening table, a singular concept is established as a benchmark, facilitating the
comparative analysis of each conceptual framework against the specific customer requirements
associated with the designated reference concept.
Table 3: Concept Screening
Concepts
Sum +’s 0 6 2 6 2
Sum 0’s 7 2 2 1 3
Sum –‘s 0 1 5 2 4
Net Score 0 5 -3 4 -2
Rank 3 1 5 2 4
From the conceptual screening matrix, subsequent to the juxtaposition of conceptual alternatives
with the benchmark concept, diverse evaluative criteria were employed to discern differentials
among the concepts. The analysis revealed that only Concepts A, B, and D exhibit the potential to
advance into the subsequent phases of scoring, evaluation, and ultimate selection. Refinement of
the proposed conceptual framework may be achieved through the introduction of innovative
elements aimed at enhancing overall efficacy.
3.4.2 Concept Scoring
A scoring table is employed to assess the concepts that garnered favorable values in the screening
table, aiming to ascertain the optimal solution among them:
Upon completion of the evaluation process, it becomes evident that Concept E secures a superior
position, claiming the topmost ranking. Therefore, Concept B is designated as the definitive
design concept slated for further development.
3.5 Calculation of the Project
3.5.1 Motor power calculations
To calculate the power required to rotate water with sediment inside a cylindrical water
tank, several factors need to be considered. These factors include the volume of water, the
density of the sediment, the desired rotational speed, and the efficiency of the motor.
First, determine the volume of water in the tank by multiplying the cross-sectional area of
the tank by its height.
To calculate the volume of water inside the cylindrical tank, we can use the formula for the
volume of a cylinder:
V=πr2h
where:
• V is the volume,
• Capacity= 100L
• Height (Ht)=740mm
• Manhole=280mm
• (D) of the tank is 0.445 meters, the radius (r) is 2D.
0.445 𝑚
R= =0.2225 m
2
V= π×(0.2225 m)2×0.74m
V = π×0.04940875×0.74
V = 0.115m3 =115L
2. Calculate the mass of the sediment:
Next, calculate the mass of the sediment by multiplying the volume of water by the density
of the sediment.
First step; we will assume the height of the sediment in the tank which will be around
(20mm).
Second; we will calculate the ratio of sediment inside due to total height of the tank:
To calculate the ratio of clay sediment height to the total height of the tank, considering the given
specifications, you can use the following steps:
Hsediment=Htotal−Hmanhole
• Htotal=740mm
• Hmanhole=280mm
• Hclay sediment=20mm
1. Calculate Hsediment:
Hsediment=740mm−280mm=460mm
Ratio = 0.0435
So, the ratio of clay sediment height to the total height of the tank is approximately 0.0435 or
4.35%. This means that the clay sediment occupies about 4.35% of the available height within
the tank.
Third; To calculate the volume of clay sediment inside the tank in cubic meters, we can follow
these steps:
Fourth; To calculate the mass of the clay sediment, we will use the following table of Densities
of Sedimentary to get the value of clay sediment:
Mass=Density ×Volume.
Therefore, the estimated mass of the clay sediment inside the tank is approximately
10.5697kg.
Fifth; To calculate the gravitational force required to remove the sediment,
Force=Weight=Mass × Gravity.
Force = 10.5697kg×9.8m/s2.
Force = 103.70706N
Therefore, the estimated gravitational force required to remove the sediment is approximately
103.70706N.
445mm
Area = π×( )2
2
Area = 155030.979mm2
Area = 0.155030.970m2
103.70706N
Pressure = 0.155030979m2
Pressure = 669.91172Pa
To calculate the torque required to rotate the sediment, we can use the following steps:
• The lever arm is the radius of the tank, which is half of the diameter. Lever Arm
Diameter 455
= = = 222.5mm= 0.2225m
2 2
B. Calculate the Torque:
• τ = 103.70706N×0.2225m=23.06Nm
To calculate the angular speed (ω) in radians per second, we can use the relation between angular
speed and revolutions per minute (rpm):
2𝜋×Revolutions per Minute
ω=( )
60
From literature review; N=60rpm, we can substitute this into the formula:
2𝜋×60
ω= 60
ω=2π
It's important to note that angular speed is not affected by the system's torque, mass, or
gravitational force; it is solely determined by the rate of revolutions per minute.
To calculate the power (P) required to rotate the sediment, we will use this formula:
P=τ×ω
where:
• P is power,
• τ is torque,
• ω is angular speed.
P=23.06Nm×2πrad/s
P=144.9W
Therefore, the power required to rotate the sediment is approximately 144.9W.
6. Adjust the power calculation for motor efficiency:
where:
Padjusted= 161W
Therefore, adjusting for motor efficiency, the power required to rotate the sediment is
approximately 161W
where π is the mathematical constant (approximately 3.14159), r is the radius of the tank,
and h is the height of the tank.
2. Determine the target pumping rate:
where V is the volume of sludge to be evacuated and t is the desired time to empty the tank
completely.
• Time = 30s
0.0049975m3
Target Pumping Rate = 30s
Using the formula for volume flow rate (Qv) and then convert it to mass flow rate (Q) using
density (ρ):
𝑉
Qv = 𝑡
Qv= 0.0001666m3/s
Now, use the formula to convert volume flow rate to mass flow rate:
m = Qv×ρ
where:
To calculate the friction head loss in the pipeline, we will follow these steps using the
Darcy-Weisbach equation:
𝐿 𝑉2
hf =𝑓 𝐷 2𝑔
where:
𝜋(0.0254m)2
A= = 5.0675×10−4m2
4
0.0001666
V=5.0675×10−4
V= 0.328m/s
(2115kg/cm3+1000kg/m3)× 0.328m/s×0.0254
Re= = 29161.8
8.90×10−4 Pa⋅s
Where:
f = 0.0235
0.74 0.3282
hf =0.0235 0.0254 2×9.81
hf = 3.754×10-3m
The dynamic viscosity of clay can vary widely based on factors such as clay type,
concentration, and the specific composition of the drilling mud. However, the dynamic
viscosity of clay suspensions in water-based drilling mud typically falls in the range of 5 to
30 centipoise (cP).
6. Determine the total head (H):
Note that :
HT=HF
However, to determine whether the given head loss is valid in the given pipe length, we need to
calculate the head loss per unit length of the pipe.
Total head loss (hf)
Head loss (hL) per unit length of pipe =
Pipe length (L)
Where,
Therefore, the head loss of 3.754×10-3 m is valid in the pipe length of 0.740m.
The efficiency of centrifugal pumps typically ranges from 50% to 80%. High-quality pumps
and well-designed systems tend to be more efficient, according to that we will assume
efficiency equal to 70%.
𝜌⋅𝑔⋅𝑄⋅𝐻
P= 𝜂
• P is the power
• ρ is the density of water+ density of clay
• g is the acceleration due to gravity
• Q is the pumping rate
• H is the total head
• η is the efficiency of the pump
P =0.027watt
3.5.3 Brush calculation
The rotating force required by a brush to clean clay sediment in a cylindrical water tank
depends on several factors, including the type of brush, the bristle material, the angle of
contact, and the properties of the clay sediment. A simplified equation to estimate the
rotating force can be derived from the basic principles of friction and mechanical
equilibrium.
In this equation:
2×((12×106 )−(101.35×103 ))
v2= √ 1000
v2= 154.33m/s
nozzle spray calculations involve determining the flow rate, spray angle, and other
parameters based on the specific requirements of the application. Here's a basic outline of
the calculations:
. Flow Rate (Q):
• Define the desired flow rate of the nozzle, typically in liters per minute (LPM) or
gallons per minute (GPM).
• Use the formula: Q=A×V, where A is the cross-sectional area of the nozzle opening,
and V is the desired velocity.
Where,
V=Desired velocity=
Q=A×V
=(6.291×10−7m2)×(154.26m/s)
Q= 9.686×10−5m3/s
. Spray Angle:
• Choose the spray angle based on the application requirements. Common angles are
15°, 25°, 40°, and 60°.
• The spray angle is typically measured from the centerline of the nozzle to the outer
edge of the spray pattern.
• Determine the operating pressure required for the nozzle based on the desired flow
rate and spray angle.
where K is a constant for the specific type of nozzle, and Pc is the ambient pressure.
. Velocity (V):
𝑄
Calculate the initial velocity of the fluid leaving the nozzle using the formula: V= 𝐴.
To calculate the initial velocity (V) of the fluid leaving the nozzle, we can use the nozzle flow rate
(Q) and the cross-sectional area (A) of the nozzle. The formula for calculating the initial velocity
𝑄
V = 𝐴.
Where,
• Nozzle flow rate (Q) =9.686×10−5m3/s
• Cross-sectional area of the nozzle (A) =6.291×10−7m2
Substitute these values into the formula:
𝑄 9.686×10−5m3/s
V = 𝐴.= V= 6.291×10−7m2
V= 154.03m/s
So, the initial velocity of the fluid leaving the nozzle, based on the provided specifications, is
approximately 154.03m/s. This value is close to the final velocity (154.26 m/s), indicating that the
nozzle is efficient and nearly all the energy from the pump is transferred to the fluid.
D= 8.959×10−4m
3.6 SolidWorks Molding
3.7 Holistic Cost Assessment of Water Tank Cleaning Machine Components in
Omani Rial
This exhaustive graphical analysis delves into the rigorous cost estimation, denominated in Omani
Rial, for integral components pivotal to an advanced water tank cleaning apparatus. Encompassing
a slurry pump, removable shaft for height adjustment, high-pressure nozzle, brush, small water
tank, and valve, this investigation intricately navigates the intricate terrain steering the
development of an efficacious cleaning solution for water tanks.
➢ Slurry Pump:
The slurry pump commands an estimated cost ranging from - OMR to - OMR. This investment
reflects considerations of power, efficiency, and resistance to corrosion, vital for enduring
performance.
➢ High-Pressure Nozzle:
The high-pressure nozzle, imperative for precision cleaning, carries an estimated cost between -
OMR and - OMR. This pricing considers the deployment of materials resistant to corrosion and
0precision engineering, crucial for delivering the force required in water tank cleaning operations.
➢ Brush:
The robust cleaning brush, vital for removing contaminants, is estimated to cost between - OMR
and - OMR. Material selection and precision engineering contribute to its efficacy, ensuring
sustained performance over time.
➢ Removable Shaft for Height Adjustment:
Engineered for adaptability, the removable shaft is a crucial component with a cost estimate
ranging from - OMR to - OMR. This component ensures the versatility required for effective
cleaning across a spectrum of tank sizes.
➢ Valve:
The integration of a valve, an essential element for facilitating water removal, is projected to
involve an expenditure ranging from - OMR to - OMR. Precision engineering and durability
reflections significantly enhance its efficacy in governing the outflow of water throughout the
cleansing procedure.
➢ Water Tank:
Incorporating a usage of water tank into the machine for cleaning agents requires a thoughtful
financial assessment. In Omani Rial, the estimated cost for a small water tank ranges from - OMR
to - OMR, considering factors such as capacity, material durability, and compatibility with cleaning
agents.
In conclusion, the table delineates the expenses and estimated worth of employed components, as
presented in the subsequent table:
Brush 20 OMR
Shaft 30 OMR
Valve 10 OMR
Tank 18 OMR