A

PROJECT REPORT ON
DESIGN AND ANALYSIS OF COMPACT BORE WELL
MOTOR LIFTING MACHINE
Bachelor of Technology in Mechanical Engineering
To
Punyashlok Ahilyadevi Holkar Solapur University, Solapur
By
1. Shelar Yuvraj Vinod
2. Chavan Samarth Suresh
3. Chavare Sumeet Suhas
4. Kadasare Saurabh Bandu
Under the guidance of
Prof. U. L. Anuse

DEPARTMENT OF MECHANICAL ENGINEERING

SVERI’s COLLEGE OF ENGINEERING,

PANDHARPUR 2021-22

SVERI’s COLLEGE OF ENGINEERING, PANDHARPUR

 SVERI’s COLLEGE OF ENGINEERING, PANDHARPUR

CERTIFICATE
This is to certify that the project report entitled

“DESIGN AND ANALYSIS OF COMPACT BORE WELL MOTOR

LIFTING MACHINE”
has been submitted by
1. Shelar Yuvraj Vinod
2. Chavan Samarth Suresh
3. Chavare Sumeet Suhas
4. Kadasare Saurabh Bandu
For partial fulfillment of Bachelor Degree in Mechanical Engineering as per curriculum
laid by the Punyashlok Ahilyadevi Holkar Solapur University, Solapur during the
academic year 2021-2022.

( Prof. U. L. Anuse ) ( Dr. S. S. Wangikar )

Guide Head, Dept. of Mech. Engg.

( Dr. B. P. Ronge ) External Examiner

Principal

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 UNDERTAKING

We hereby declare that the details furnished above are true and correct to the best of our
knowledge and belief and we undertake to inform authorities about any changes therein,
immediately. In case any of the above information is found to be false or untrue or misleading
or misrepresenting, we are aware that we may be held liable for it.

Sr. Name Of Student Roll Sign

No. No.
1
Shelar Yuvraj Vinod 29

2
Chavan Samarth Suresh 15

3
Chavare Sumeet Suhas 19

4
Kadasare Saurabh Bandu 38

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 ACKNOWLEDGEMENT

The idea of this project work, we got help from many people in both direct-
indirect manner & in numerous ways. Through this acknowledgement, we are trying to express
my gratitude to all the people who were part of the successful completion of this project.

It gives us immense pleasure to present our report on mini project titled as

“Design and Analysis of Compact Bore Well Motor Lifting Machine”. we are very thankful
to our guide Prof. U.L.Anuse Department of Mechanical Engineering for hisencouragement.
we are very obliged to him for his valuable guidance.

At the last we would like to say thank to my family and all my missing elements which were
much valuable for me in my life.

1. Shelar Yuvraj Vinod

2. Chavan Samarth Suresh
3. Chavare Sumeet Suhas
4. Kadasare Saurabh Bandu

SVERI’s COLLEGE OF ENGINEERING, PANDHARPUR

 ABSTRACT

Bore well is major water source in ruler India for domestics well as agriculture field.
Installation and lifting a bore well motor is not an easy task. If we try to do same work with
human power then there is need of 5-6 people and it is very time consuming. So that it is
required to design a suitable small mechanism to carry out installation and lifting process of
bore well motor, also which will reduce the human work at low operating cost? This mechanism
is very simple and can be operated by single man with very low cost of operation.
Especially the motor installation and lifting takes more time as it is heavy. A new,
compact and low cost bore well motor installation and lifting machine is mainly developed to
overcome the problem. This mechanism is developed by using various mechanical components
like shaft, gears, belt drives, solar panel. Firstly this machine was operated with electricity but
after discussing with my project team, we realized that if we operate this machine solar panel
then it will become more efficient.

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 List Of Figures

Sr.
Fig. No. Name of Figure Page No.
No

1 1.1 Actual machine 4

2 1.2 Design Review Of Machine 5

3 1.3 Design Of Machine Components 8 - 13

4 1.4 Meshing Of Machine Components 14 - 20

5 1.5 Analysis Of Machine Components 21 - 28

6 1.6 Comparison Of The Result 29 - 32

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 INDEX

Chapter Title Page No.

Abstract i
List of Figures ii
List of Tables iii

01 Introduction 01
1.1 Project Management
1.2 Working Principle
1.3 Objectives
1.4 Methodology
1.5 Design (Top View)

02 Literature Review

03 Machine Components And 08

Specifications

04 Theory Of Design And FEA 09

4.1 Modelling
4.2 Software Available For Modelling
4.3 Software Used For Modelling
4.4 Torque Calculation
4.5 FEA
4.6 Meshing
4.7 Types Of Analysis Available

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 4.8 Type Of Analysis Used
4.9 Type Of Software Used

05 Modelling And Analysis

5.1 Modelling of machine components
5.1.1 Modelling of gear
5.1.2 Modelling of shaft
5.1.3Modelling of plate
5.1.4 Modelling of gear assembly
5.1.5 Modelling of Frame
5.1.6 Modelling of machine
5.2 Meshing Of Machine components
5.2.1 Meshing Of Gear Assembly
5.2.2 Meshing Of Machine
5.3 Analysis Of Machine components
5.3.1 Work flow for solving problem
5.3.2 Analysis Of Gear Assembly
5.3.3 Analysis Of Machine

Application
Future Scope
Conclusion
6.1 Results Calculated on ANSYS
06 References

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Chapter :- 1
1] INTRODUCTION

One of the important commodities, which is indispensable for all living beings, is water.
Therefore, it is necessary to store the water in dams,ponds and bore well for future use and make
the use of that water using pumps, motors, etc. Now a day’s Bore well is the very popular and
major water source in India for domestic as well as agriculture fields. For development of bore
well, a bore well drilling machine is used to dig the hole of about diameter 4 to 12 inches. And
it also requires replacement of pipes, pump, motor at some times. Now a days there are shortage
of the labours, so that it very difficult to do the process like installation and lifting of the motor,
pumps, pipes, etc. Now a days to make the use of labour or human power for the process of
installation and lifting the bore well equipment is time consuming and as well as costly.

There are various machines and mechanisms are available to carry out these process. But
the major problem is that there operating cost is high and also in the restricted space they cannot
be installed or unable to work due to his large size. To overcome above mentioned problem we
have designed a compact mechanism. In this mechanism it is easy to operate and adjust whole
mechanism. This mechanism includes two gears, belt drives, belt, shaft, solar panel, DC motor
and many more. The machine if fully eco-friendly because it will be goingto operate on the
energy stored by the solar panels by means of battery.So today’s need is to design and develop a
suitable small mechanism to carry out both installation and lifting process at low operating cost.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

1.1] PROJECT MANAGEMENT

This project constituted mechanical design as its major part as well as electrical
embedded system design and solar panel arrangement. So the work had to be
divided accordingly.

MECHANICAL DESIGN

Members Remark
Components
Discussion were
1. Gear All group members made in group
regarding the
dimension and
structure.
To design his part there is
2. Shaft All group members need of 3d design like Catia
andtrials for exact fit

To design his part there

3. Supporting is need of 3ddesign like
plate All group members Catia andtrials for exact
fit.
To design his part there
4. Frame All group members is need of 3ddesign like
Catia andtrials for exact
fit.

Table No. 1

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

1.2] WORKING PRINCIPLE

The weight of the motor pump is considered as load on the shaft which partially act as
pulley. Using gear and belt drive mechanism a constant feed is given with the help of DC motor.
According to the process of installation or lifting the feed is adjusted. If one want to install the
motor pump into the bore well then there is need of constant direct feed. And on theother hand
if one want to lift the motor pump from bore well the he/she have to give constant revere feed.

Fig. Motor Lifting Machine

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

1.3] OBJECTIVES:

1. Design of the machine components by using CAE software like

solidworks.
2. To perform design calculation by analytical method.
3. Selecting the suitable materials to analyze the machine components.
4. Analysis of the machine components by using FEA software like
ANSYS.

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1.4] DESIGN (Top View)

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Chapter :- 2

2] Literature Review:-

In olden days in order to remove the broken bore pipe from underground was a difficult task. Initially
U-type vertical hook was used in well to bucket or any other vessels that falls in to the wells. Using the
same concept ,in this present investigation SPRhook is designed in order to lift the broken bore pipes
from underground presented by S.Prithiviraj et al. [1]

Ajeet Bergaley et al [2] prepared the model of hook by using CAE software having dimension and
material similar to the crane hook which was purchased from the market. The results obtained were
compared with theoretical analysis. Then cross section in which minimum stress induced for given load
was modified through FEM.

Prithiviraj S et al [3] describes that now days we are facing more issues in bore pipe arrangement
structure. A one most essential issues is bore pipe cut from original way line in the pipe lifting process
due to way line in the pipe lifting process due of the presence of tree root, small rock and wear and tear
of the pipe material. So we require lifting instruments for additionally lifting process. The lifting
apparatus name is SPR hook. Modeling, analyzing and fabrication is shown in this present examination.
The detailed description about the pipe, bore and hook is been done in this present examination.

Mayur N. Adhude et al [4] explained that bore well drilling required numbers of segments to lift the water. The
components required might be bore well casing pipe, submersible water pump, water lifting channels, electric
cables, starter and any more. One of these components i.e. Bore well motor pump has an extraordinary significance
and installation in the bore well after drilling is a major task. There are some major steps that to be taken after
while introducing the bore well motor pump. For this installation procedure we required specially designed
mechanism and machines.
S. Gowri Shankar et al [5] decribed that the conventionally the bore well pipe and pump are lifted out of the bore
well using rope and pulley block mechanism driven by robust vehicles and the initial setup and installation is done
manually. Especially the pipe lifting takes more time as it is very long. A new, compact and low cost borewell pipe
lifting machine is mainly developed to overcome the problem. This machine is developed using the rollers and belt
drive mechanism coupled to AC motor which is mainly used to reduce human effort, time and cost.

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Chapter :- 3

3] Machine Components And Specifications:-

Sr. Components Material no. of Specifications

No. quantity
1 Gear hss 1 Teeth = 80
2 Ac motor - 1 Power=0.25 HP
Rpm = 1200
3 Square Mild steel As per 4 × 4 cm
frame requirment
4 Shaft Mild steel As per Shaft diameter = 50
requirment mm
5 Belt rubber 2 v-belt
length = 60 mm
6 Pulley Mild 1 V type,1 slot
Steel 1)Dia=400mm
2)Dia=50mm

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Chapter :- 4

4] THEORY OF DESIGN AND FEA

4.1] Modelling:-

Mechanical modeling is the process of turning 2D drawings, sketches, or

conceptions into actual 3D models.

4.2] Software Available For Modelling:-

1] SolidWorks:-

SolidWorks is the perfect 3D modeling software for engineers and 3D designers.

SolidWorks is a powerful and complete tool that will help designers and engineers to build
innovative mechanical models. This 3D software has a user friendly interface and can be used
for design, or to create machinery parts, for example. It will perfectly fit engineering students
looking for a great tool to make mechanical drawings!

2] Catia:-

Catia is a professional software tool developed by Dassault Systèmes. Mostly

used for aerospace projects, this program is particularly useful for complex and detailed
designs. With this program, you can actually work on any product. If you are an engineer, it
will perfectly meet your expectations to create your 3D CAD models, and it is really perfect
for mechanical engineering projects.

4.3] Software Used For Modelling:-

As we have basic knowledge of the solidwork software, so that we decided

to design all the machine components on the solidwork software.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

4.4] Torque Calculation:-

1. Torque of AC motor used:-

𝟐𝝅 𝑵 𝑻
𝒑=
𝟔𝟎

𝟐𝝅 𝑵 𝑷
𝑻=
𝟔𝟎

But

𝒑 = 𝟎. 𝟐𝟓 𝑯𝑷 = 𝟏𝟖𝟔. 𝟒𝟐𝟓 𝑾 .......................................... [1 HP = 745.7 W]

N = 1200 RPM

𝟐𝝅 ∗ 𝟏𝟐𝟎𝟎 ∗ 𝟏𝟖𝟔. 𝟒𝟐𝟓

𝑻=
𝟔𝟎

𝑻 = 𝟏. 𝟒𝟖 𝑵 − 𝒎

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

4.5] FEA :-

Finite element analysis (FEA) is the use of calculations, models and simulations to
predict and understand how an object might behave under various physical conditions. Finite
element analysis (FEA) is the modeling of products and systems in a virtual environment, for
the purpose of finding and solving potential (or existing) structural or performance issues.
Finite Element Analysis (FEA) is a computer-aided engineering (CAE) tool used to analyze
how a design reacts under real-world conditions. Useful in structural, vibration, and thermal
analysis, FEA has been widely implemented by automotive companies.

4.6] Meshing :-

Meshing is often used in software-based simulation for Finite Element

Analysis (FEA) and Computational Fluid Dynamics (CFD). It can significantly impact the
accuracy of the simulation and the resources required to perform the simulation.

The meaning of meshing–or mesh generation–is: defining continuous

geometric shapes (such as 3D models) using 1D, 2D, and 3D shapes (mesh faces). The finer
the mesh, the more accurately the 3D model will be defined. Though meshes can be created
manually, most meshing today is performed using software, with minimal human input.

Importance of the Meshing:-

Meshing is one of the most important aspects of getting accurate results from FEA/FEM and
CFD simulations. Usually, results become more accurate as the mesh becomes smaller and
denser. However, a trade-off of that is that simulations become larger and solve times become
longer. The major importance of meshing in CFD or FEA lies in the ability to solve the
governing partial differential equations in the allocated cell Ansys meshing capabilities help
reduce the amount of time and effort spent to get to accurate results. Since meshing typically
consumes a significant portion of the time it takes to get simulation results, Ansys helps by
making better and more automated meshing tools.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

4.7 Types Of Analysis Available:-

I. Structural Analysis:-

Structural analysis provides an interactive, analytical environment for user

to examine an enterprise from multiple perspectives but for analyzing the qualitative or
structural aspects of the enterprise.

II. Thermal Analysis:-

Thermal analysis is a general term defining a technique used to analyze

the time and temperature at which physical changes occur when a substance is heated or
cooled. Each technique is defined according to the types of physical changes being analyzed.

III. Electromagnetic Analysis:-

Electromagnetic analysis establishes the basic principle of electrical and

electronic circuits over the entire frequency spectrum from dc to optics.

IV. Buckling Analysis:-

Buckling Analysis is an FEA routine that can solve all the difficult buckling
problems that cannot be solved by hand calculations.

4.8 Type Of Analysis Used:-

We have used structural analysis as it is important as it provides a basis
for structural design and also it evaluates whether a specific structural design will be able to
withstand external and internal stresses and forces.

4.9 Type Of Software Used:-

To analyze the components of the machine such as gear, shaft, supporting plate and
frame we used the latest version of the ANSYS (i.e. ANSYS 2022 R1).

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 Design And Analysis Of Compact Bore Well Motor Lifting Machine

Chapter :- 5

5] Modelling And Analysis:-

5.1 Modelling of machine components:-

5.1.1 Modelling of gear:-

First and most important component of the gear assembly is spur gear. Spur gears are
the most easily visualized common gears that transmit motion between two parallel shafts. Because of
their shape, they are classified as a type of cylindrical gears.

Fig. Modelling Of Gear

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.1.2 Modelling of shaft:

The another component we designed is shaft. Shaft is a rotating machine element which is
used to transmit power from one place to another.

Fig. Modelling Of Shaft

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.1.3 Modelling of plate:-

Supporting plate is also designed to support the rope during working of machine.

Fig. Modelling Of Plate

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.1.4 Modelling of Gear Assembly:-

A gear assembly is a simple, rotating machine which usually has teeth when they connect to another
gear, they transmit torque, which is like a twisting force. Gear assembly is used to transfer motion and
torque between machine components in mechanical devices. Depending on the design and construction
of the gear pair employed, gears can change the direction of movement and/or increase the output speed
or torque.

Fig. Modelling Of Gear Assembly

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.1.5 Modelling of Frame:-

A frame or a machine is an engineering structure that that contains at least one member that
is not atwo-force member. A frame is a rigid structure.
After considering all the factors such as metarial selection, design purpose and need of design,
finallywe designed the frame by using Solidworks.

.
Fig. Modelling Of Frame

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.1.6 Modelling of Machine:-

We followed all the steps required during design of any component and successfully completed the
designof the components i.e. design of gear, shaft, supporting plate and frame. After designing of all the
parts of the machine, we assembled that all components to complete our design of machine.

Fig. Modelling Of Machine

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.2 Meshing Of Machine components:-

5.2.1 Meshing Of Gear Assembly:-

The main purpose behind frame is to support the gear the gear assembly. This is why one end of
gear assembly is mounted on one side of the frame and another mounted on other side of the frame, a
processreferred to as Frame meshing. Compared to the shaft’s core region, the shaft’s mesh region is
more flexible. Hence, accounting for the stiffness of the frame mesh is important when trying to
accurately capture the dynamics and vibrations in the system. This method allows the Frame to maintain
contact inthe central region of the rod and creates an avoidance of edge contact. Crowning should not be
larger than necessary, as it will reduce the shaft contact area, thus weakening the shafts’ strength.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Fig. Meshing Of Gear Assembly

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.2.2 Meshing Of Machine:-

The main purpose behind machine is to minimize the human work. So that machine meshing is
important. Compared to the shaft’s core region, the Machine mesh region is more flexible. Hence,
accounting for the stiffness of the frame mesh is important when trying to accurately capture the dynamics
and vibrations in the system. This method allows the machine to maintain contact in the central region of
the ground andcreates an avoidance of edge contact. Crowning should not be larger than necessary, as it
will reduce theshaft contact area, thus weakening the shafts’ strength.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Fig. Meshing Of Machine

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.3 Analysis Of Machine components:-

5.3.1 Work flow for solving problem:-

A. Preprocessing:-
- Building Geomerty and FEM model.
- Define element properties.
- Apply load and constraints.
- Contact and other setup condition.

B. Solution (FEA Solver):-

- Assembling the components and calculating the results using ANSYS.
- Calculating the required results.

C. Postprocessing:-

- Sorting and displaying the results

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.3.2 Analysis Of Gear Assembly:-

Structural analysis of components is an important task in design phase which ensures the success of the
design before stepping for product manufacturing. The material selected for a product to serve a particular function
needvalidation through certain analysis for the application desired. After successfully completion of analysis of
gear and shaft, we assembled all the components and various types of the boundary conditions are given to check
its strength and to calculate stress and strain produced in it. The materials considered for static structural analysis
to evaluate total deformation, strain energy, equivalent von mises stress and equivalent elastic strain by varying
the load on machine. The analysis results are further taken as input for multi criteria decision making to identify
the best and worst material options.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Fig. Analysis Of Gear Assembly (Total Deformation)

Fig. Analysis Of Gear Assembly (Equivalent Stress)

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

5.3.3 Analysis Of Machine:-

Structural analysis of components is an important task in design phase which ensures the success
of the design before stepping for product manufacturing. The material selected for a product to serve a
particular function need validation through certain analysis for the application desired. After successfully
completion of analysis of all the components of the machine, we assembled all the components and
various types of the boundary conditions are given to check its strength and to calculate stress and strain
produced in it. The materials considered for static structural analysis to evaluate total deformation, strain
energy, equivalent von mises stress and equivalent elastic strain by varying the load on machine. The
analysis results are further taken as input for multi criteria decision making to identify the best and worst
material options.

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Fig. Analysis Of Machine (Deformation)

Fig. Analysis Of Machine (Equivalent Stress)

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Application:-

This mechanism is mainly designed for the agricultural use. This mechanism is mainly used for the
installation and lifting the motor pump.

Future Scope:-
In the current design the machine is operated manually and only used to mount and dismount the
motor pump. Further it can be modified by operating automatically and make it to do various process
such as rescuing the child or any other objects that fall into the bore well. It can be modified with by
fitting a sensor it the machine to detect the object in hole, it will help the lifter not to dash in the object.
The machine is operated through a personal computer according to observations made by using the CCTV
camera, oxygen suppliers are also fixed and the machine is also capable performing operations according
to the user commands. As a whole if we produce this product in mass production, it can be very useful as
it can be used for both pipe removal and rescue operations

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Design And Analysis Of Compact Bore Well Motor Lifting Machine

Chapter :- 6

6] Conclusion:-
6.1 Results Calculated Using ANSYS:-

i. Results of the gear assembly:-

1] Strees And Strain:-

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2] Strees Vs Strain Graph:-

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ii. Results of the Machine:-

1] Stress And Strain:-

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2] Stress vs Strain graph:-

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 Depth at that where stress induced maximum cross-section should be more to

decrease the failure during loading.

 Curvature should be provided at the corners to reduce the stress concentration.

 Above graph shows that stress is directly proportional to strain and from that we
concludethat our design is safe

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REFERENCES

1. Prithiviraj, S., and Ravikumar, S. (2014). Modeling, Analyzing and Fabrication of

Lifting SPR hook for Bore well Pipe. International Journal of Engineering
Development and Research, 2(1), 343-346.

2. Ajeet Bergaley, Anshuman Purohit International Journal of Science and Modern

Engineering (IJISME) ISSN: 2319-6386, Volume-1, Issue-10, September 2013

3. Prithiviraj, S., and Ravikumar, S. (2014). IJISM ISSN-2319-6386, Volume-1 Issue-

10,September 2013 Structural analysis of crane hook using finite element method

4. Namde, S. M., Yadav, A. P., Kakade, C. M., & Kale, S. A. Design and Fabrication of
Submersible Pump Lifting Machine. Journal of Industrial Mechanics.

5. R. Shah Vrunda, Chirag S Dalal, & Rajeev Dubey (2015). Automated Machine for
Rescue Operation For Child. International Journal Of Research in Engineering and
Technology.
6. Design and Development of a Bore Well Rescue Robot | Niveditha Kalavakonda et.al | The
14th IFToMM World Congress, Taipei, Taiwan, October 25-30, 2015. DOI Number:
10.6567/IFToMM.14TH.WC.OS13.103
7. Bore Well Rescue Robot | V Venmathi et.al | International Journal of Computer Applications
(0975 – 8887) Volume 113 – No. 14, March 2015

8. Modeling, Analyzing and fabrication of lifting SPR book for bore well pipe 2014‖
IJDER | volume 2, issue 1| ISSN: 2321 -9939.

9. http;// en.wikipedia.org/wiki/bore well motor lifting machine in India.

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