DESIGN AND FABRICATION OF SOLAR POWERED

OIL SKIMMER ROBOT

A PROJECT REPORT

Submitted to
MAHATMA GANDHI UNIVERSITY
By
VISHNU RAJAN
In partial fulfillment for the award of the Degree
Of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

MAR ATHANASIUS COLLEGE OF ENGINEERING

KOTHAMANGALAM 686666,

KERALA, INDIA

March 2017

1
 CERTIFICATE

This is to certify that the project report entitled “DESIGN & FABRICATION OF
SOLAR POWERED OIL SKIMMER ROBOT” submitted by VISHNU
RAJAN to the Mahatma Gandhi University Kottayam, Kerala in partial fulfillment
for the award of Degree of Bachelor of Technology in Mechanical Engineering is a
bonafide record of the project work carried out by him under my supervision during
the year 2016-2017.

Dr. Deviprasad Varma P.R [Project guide]

Professor and Head Korah T Sunny
Department of Mechanical Engineering Assistant Professor
Mechanical
Engineering

MAR ATHANASIUS COLLEGE OF ENGINEERING

KOTHAMANGALAM 686666
KERALA, INDIA

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 ACKNOWLEDGEMENT

First and foremost, I sincerely thank the ‘God Almighty’ for his grace for the
successful and timely completion of this project.
I express my sincere gratitude and thanks to Dr. Soosan George T, our principal
and Dr. Deviprasad Varma, Head of the Department, Mechanical Engineering for
providing the facilities and all the encouragement and support

Acknowledgement to guide and to all others

Finally, I would like to acknowledge the heartfelt efforts, comments,

criticisms, co-operation and tremendous support given to us by our Project guide
Assistant professor Kora T Sunny Department of Mechanical Engineering and dear
friends during the preparation of the project and also during the presentation without
whose support this work would have been all the more difficult to accomplish

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 ABSTRACT

DESIGN AND FABRICATION OF SOLAR POWERED OIL

SKIMMER ROBOT

Keywords: oil spill, environmental pollution, solar power, oil skimmer, nano belt,
remote control, gear, motor, propeller

Oil Skimmer Robot is a device which can be used for ocean purification by
removing the oil from water surface. The system uses a photovoltaic powered conveyor
belt to propel itself and collect oil. The flexible conveyor belt softly rolls over the
ocean’s surface, absorbing oil while deflecting water because of its hydrophobic
properties. The photovoltaic cells generate enough electricity to keep the fleet moving
for several weeks and provide the energy to propel the vehicles forward. As the head
moves through the water the conveyor belt constantly rotates and sucks up pollution.
The belt is then compressed to remove the oil. As the clean part of the belt comes out
of the head it immediately begins absorbing oil, making the collection process seamless
and efficient. This process is more streamlined than current ocean-skimming
technologies because the robots can operate autonomously and don’t need to return to
the shore for constant maintenance.

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 CONTENTS

CHAPTER 1 INTRODUCTION
CHAPTER 2 LITERATURE REVIEW
CHAPTER 3 OBJECTIVES
CHAPTER 4 METHODOLOGY
4.1 COMPONENTS AND DESCRIPTIONS
4.1.1 DC MOTOR
4.1.2 SOLAR CELL
4.1.3 SPUR GEAR
4.1.4 RF MODULE
4.1.5 FM TRANSMITTER
4.1.6 FM RECIEVER
4.1.7 CONVEYOR ARRANGEMENT
4.1.8 GEAR WHEEL ARRANGEMENT
4.1.9 BEARING WITH BEARIBG CAP
4.1.10 BATTERY
4.2 COMPONENTS SPECIFICATIONS
4.2.1 SOLAR PANEL
4.2.2 BATTERY
4.2.3 PMDC MOTOR
4.2.4 MOTOR FOR PROPELLER
4.2.5 BEARING USED
4.3 CALCULATIONS
4.3.1 DESIGN OF BELT
4.3.2 VELOCITY OF BELT
4.3.3 DESIGN OF SHAFT
4.4 DESIGN PROCEDURE – CAD
4.4.1 MODELLING
4.4.2 CREO
4.4.3 ENGINEERING DESIGN
4.5 MANUFACTURING
4.5.1 METAL CUTTING

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 4.5.2 SAWING
4.5.3 WELDING
4.5.4 DRILLING
4.5.5 INSPECTION
4.5.6 SEQUENCE OF OPERATION IN WORKSHOP
4.6 WORKING PRINCIPLE
4.7 TESTING
4.8 ADVANDAGES, DISADVANTAGES, APPLICATIONS
4.8.1 ADVANTAGES
4.8.2 DISADVANTAGES
4.8.3 APPLICATIONS
CHAPTER 5 MATERIAL IIST AND COST
CHAPTER 6 CONCLUSION
REFRENCES

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 LIST OF TABLES

Table 4.1 Thin film and polycrystalline solar cell systems with ami solar energy
conversion efficiencies in excess of 5 percentage

Table 4.2 Single crystal solar cell systems with ami solar energy conversion

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 LIST OF FIGURES

Fig 4.1 movement of conductor

Fig 4.2 DC motor assembly

Fig 4.4 Commutator

Fig 4.5 Solar cell arrangement

Fig 4.6 Silicon photovoltaic cell

Fig 4.7 Solar cell circuit

Fig 4.8 Schematic of FM Transmitter

Fig 4.9 Circuit of receiver

Fig 4.10 Lead acid battery

Fig 4.11(a) CAD Model of Oil skimmer

Fig 4.11(b) CAD Model of Oil skimmer

Fig 4.11(c) CAD Model of Oil skimmer

Fig 4.11(d) CAD Model of Oil skimmer

Fig 4.12(a) Initial stage of fabrication

Fig 4.12(b) Electronic circuit

Fig 4.12(c) Remote controller

Fig 4.12(d) Final assembly

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 CHAPTER 1

INTRODUCTION

Each Sea swarm robot is comprised of a head, which is covered by a

layer of photovoltaic cells, and a nano wire covered conveyor belt. The photovoltaic
cells generate enough electricity to keep the fleet moving for several weeks and provide
the energy to propel the vehicles forward. As the head moves through the water the
conveyor belt constantly rotates and sucks up pollution. The nano wire-covered belt is
then compressed to remove the oil. As the clean part of the belt comes out of the head
it immediately begins absorbing oil, making the collection process seamless and
efficient.
This process is more streamlined than current ocean-skimming technologies
because the robots can operate autonomously and don’t need to return to the shore for
constant maintenance. As the vehicles work in unison they can cover large areas and
by communicating with each other and researchers on land, they can coordinate their
collection efforts. Measuring just 16 feet long by seven feet wide, the fleet can access
hard to reach places like coastlines and estuaries.

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 CHAPTER 2

LITERATURE REVIEW

The growths of oil and gas exploration and production activities have increased
environmental problems, such as oil spillage and the resulting pollution. The study of
the methods for cleaning up oil spills is a critical issue to protect the environment.
Various techniques are available to contain oil spills, but they are typically time
consuming, energy inefficient and create secondary pollution

Nikolas M.P Kakkalas (2007) studied about the robotic swarm concept for oil
spill confrontation and found that this method is efficient than existing systems.(Journal
of hazardous materials, October 2007) [1]

A sustainable approach to controll oil spills were done by Abdul Aziz Al-Majed
and suggested use of palm fibre for oil skimming (Journal of environment management
2012) [2]

A review of polymer nanofibres by electrospinning and their application in oil

water separation for cleaning up marine oil spills was done by Rosalam
Sarbatly(Marine bulletin 2016) [3]

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 CHAPTER 3

OBJECTIVES

 To design a miniature model of oil skimmer robot

 To fabricate the miniature model of oil skimmer robot

 To equip the system to run with solar energy

 Testing of the oil skimmer robot

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 CHAPTER 4

METHODOLOGY

4.1 COMPONENTS AND DESCRIPTION

This project consists of the following components to fulfill the requirements of

complete operation of the machine.

 D.c motor
 Solar cell
 Spur gear
 Fm transmitter and receiver
 Conveyor arrangement
 Bearing with bearing cap
 Battery

4.1.1 D.C Motor

An electric motor is a machine which converts electrical energy to mechanical

energy. Its action is based on the principle that when a current-carrying conductor is
placed in a magnetic field, it experiences a magnetic force whose direction is given by
Fleming’s left hand rule.

When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound or
series wound or compound wound motors.

Fleming’s Left Hand Rule:

Keep the force finger, middle finger and thumb of the left hand mutually
perpendicular to one another. If the fore finger indicates the direction of magnetic field
and middle finger indicates direction of current in the conductor, then the thumb
indicates the direction of the motion of conductor.

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Principle of Operation of DC Motor:

Figure I show a uniform magnetic field in which a straight conductor carrying no

current is placed. The conductor is perpendicular to the direction of the magnetic field.

In figure II the conductor is shown as carrying a current away from the viewer,
but the field due to the N and S poles has been removed. There is no movement of the
conductor during the above two conditions. In figure III the current carrying conductor
is placed in the magnetic field. The field due to the current in the conductor supports
the main field above the conductor, but opposes the main field below the conductor.

Movement of Conductor

N S

Magnetic flux current carrying

Conductor
Fig 4.1 movement of conductor

The result is to increase the flux density in to the region directly above the
conductor and to reduce the flux density in the region directly below the conductor. It
is found that a force acts on the conductor, trying to push the conductor downwards as

5
shown by the arrow. If the current in the conductor is reversed, the strengthening of
flux lines occurs below the conductor, and the conductor will be pushed upwards
(figure-IV).

Now consider a single turn coil carrying a current as shown in the above figure.
In view of the reasons given above, the coil side A will be forced to move downwards,
whereas the coil side B will be forced to move upwards. The forces acting on the coil
sides A and B will be of same magnitude. But their direction is opposite to one another.
As the coil is wound on the armature core which is supported by the bearings, the
armature will now rotate. The commutator periodically reverses the direction of current
flow through the armature. Therefore the armature will have a continuous rotation.

A simplified model of such a motor is shown in figure VI. The conductors are
wound over a soft iron core. DC supply is given to the field poles for producing flux.
The conductors are connected to the DC supply through brushes let’s start by looking
at the overall plan of a simple 2-pole DC electric motor. A simple motor has 6 parts, as
shown in the diagram below.

 An armature or rotor

 A commutator

 Brushes

 An axle

 A field magnet

 A DC power supply of some sort

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 Fig 4.2 DC motor assembly

An electric motor is all about magnets and magnetism: a motor uses magnets to create
motion. If you have ever played with magnets you know about the fundamental law of
all magnets: Opposites attract and likes repel.

So if you have 2 bar magnets with their ends marked north and south, then the North
end of one magnet will attract the South end of the other. On the other hand, the North
end of one magnet will repel the North end of the other (and similarly south will repel
south). Inside an electric motor these attracting and repelling forces create rotational
motion.

In the diagram above and below you can see two magnets in the motor, the armature
(or rotor) is an electromagnet, while the field magnet is a permanent magnet (the field
magnet could be an electromagnet as well, but in most small motors it is not to save
power).

Electromagnets and Motors:

To understand how an electric motor works, the key is to understand how the
electromagnet works. An electromagnet is the basis of an electric motor. You can
understand how things work in the motor by imagining the following scenario. Say that
you created a simple electromagnet by wrapping 100 loops of wire around a nail and
connecting it to a battery. The nail would become a magnet and have a North and South
Pole while the battery is connected.

7
Now say that you take your nail electromagnet, run an axle through the middle of it,
and you suspended it in the middle of a horseshoe magnet as shown in the figure below.
If you were to attach a battery to the electromagnet so that the North end of the nail
appeared as shown, the basic law of magnetism tells you what would happen: The North
end of the electromagnet would be repelled from the north end of the horseshoe magnet
and attracted to the south end of the horseshoe magnet.

The South end of the electromagnet would be repelled in a similar way. The nail would
move about half a turn and then stop in the position shown.

You can see that this half-turn of motion is simple and obvious because of the way
magnets naturally attract and repel one another. The key to an electric motor is to then
go one step further so that, at the moment that this half-turn of motion completes, the
field of the electromagnet flips. The flip causes the electromagnet to complete another
half-turn of motion.

You flip the magnetic field simply by changing the direction of the electrons flowing
in the wire (you do that by flipping the battery over). If the field of the electromagnet
flipped at just the right moment at the end of each half-turn of motion, the electric motor
would spin freely.

8
The Armature:

Fig 4.3 Armature

The armature takes the place of the nail in an electric motor. The armature is an
electromagnet made by coiling thin wire around two or more poles of a metal core. The
armature has an axle, and the commutator is attached to the axle. In the diagram above
you can see three different views of the same armature: front, side and end-on. In the
end-on view the winding is eliminated to make the commutator more obvious. You can
see that the commutator is simply a pair of plates attached to the axle. These plates
provide the two connections for the coil of the electromagnet.

The Commutator and brushes:

Fig 4.4 Commutator

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The "flipping the electric field" part of an electric motor is accomplished by two parts:
the commutator and the brushes. The diagram at the right shows how the commutator
and brushes work together to let current flow to the electromagnet, and also to flip the
direction that the electrons are flowing at just the right moment. The contacts of the
commutator are attached to the axle of the electromagnet, so they spin with the magnet.
The brushes are just two pieces of springy metal or carbon that make contact with the
contacts of the commutator.

Putting It All Together:

When you put all of these parts together, what you have is a complete electric motor:

In this figure, the armature winding has been left out so that it is easier to see the
commutator in action. The key thing to notice is that as the armature passes through the
horizontal position, the poles of the electromagnet flip. Because of the flip, the North
Pole of the electromagnet is always above the axle so it can repel the field magnet's
North Pole and attract the field magnet's South Pole. If you ever take apart an electric
motor you will find that it contains the same pieces described above: two small
permanent magnets, a commutator, two brushes and an electromagnet made by winding
wire around a piece of metal. Almost always, however, the rotor will have three poles
rather than the two poles as shown in this article. There are two good reasons for a
motor to have three poles:

10
 It causes the motor to have better dynamics. In a two-pole motor, if the
electromagnet is at the balance point, perfectly horizontal between the two poles
of the field magnet when the motor starts; you can imagine the armature getting
"stuck" there. That never happens in a three-pole motor.

Each time the commutator hits the point where it flips the field in a two-pole
motor, the commutator shorts out the battery (directly connects the positive and
negative terminals) for a moment. This shorting wastes energy and drains the
battery needlessly. A three-pole motor solves this problem as well.

It is possible to have any number of poles, depending on the size of the motor and the
specific application it is being used in.

4.1.2 Solar cell

A solar cell works on the principle of photo-voltaic principle, the photo-voltaic solar
energy conversion is one of the most attractive non-conventional energy sources of
proven reliability from the micro to the Megawatt level.

Its advantages are:

(1) Direct room temperature conversion of light to electricity through a

simple solid state device.

(2) Absence of moving parts,

(3) Ability to function unattended for long periods as evidence,

(4) Modular nature in which desired currents, voltages and power levels
can be achieved by mere integration,

(5) Maintenance cost is low as they are easy to operate,

(6) They do not create pollution,

(7) They have a long effective life, and

(8) They are highly reliable.

Disadvantages are:

(1) Distributed nature of solar energy,

(2) Absence of energy storage,

11
 (3) Relatively high capital cost.

While the first disadvantage can be party overcome by concentration, the second is an
inherent disadvantage overcome in PV systems by the use of conventional storage
batteries. Efforts are being made worldwide to reduce costs per watt through various
technological innovations.

Solar Cell Modules

In actual usage, solar cells are interconnected in a certain series and parallel
combinations to from modules. These modules are hermetically sealed for production
against corrosion, moisture, pollution and weathering combination of suitable modules
constitutes on array. One square meter of fixed array kept facing south yields nearly
0.5 kWh of electrical energy on a normal sunny day if the orientation of the array is
adjusted to face the sun’s rays a any time, the output can increase by 30% solar PV
system can produce on output only if sunlight is present. If it is required to be used
during non-sunshine hours suitable system of storage batteries will be required.

There may be tracking arrays or modules or fixed arrays. A tracking array is defined
as one, which is always kept mechanically perpendicular to the sun array line so that all
times it intercepts the maximum insulation. Such arrays must be physically movable
by a suitable prime mover and are generally, considerably more complex than fixed
arrays. So we use a fixed arrays which is usually oriented east west and tilled up angle
approximately equal to the latitude of the site (tilt ß = Ø, latitude angle). We kept that
11º south facing latitude angle fixed arrays are mechanically simpler than tracking
arrays. Thus array designs fall into two board classes and thus use design as that of flat
plat arrays.

Flat Plate Arrays:

Where in solar cells are attached with a suitable adhesive to some kind to of substrate
structure usually semi rigid to prevent cells being cracked.

This technology springs from the space related photo-voltaic technology, and, many
such arrays have been built in various power sizes.

Constructing Arrays:

Where in suitable optics example frasnel lenses, parabolic mirrors, compound parabolic
concentrators (CPC), and others are combined with photo voltaic cells in an array

12
fusion. This technology is relatively new to photo voltaic in terms of hardware
development, and comparatively fewer such Arrays have actually been built.

Solar Cell Connecting Arrangements

Cells may be connected in parallel to achieve the desired voltage. The optimum
operating voltage of a photo voltaic cell is generally about 0.45 volts at normal
temperatures, and the current in full sunlight may be taken 0.270 amperes / sq. mm.

Fig 4.5 Solar cell arrangement

If the exposed area of the cell is 40 square cm (6.2sq.in) or 40*10^-4 sq. m, the current
and power are decreased or increased proportionately. By combining number of solar
cells in series that is in a string, the voltage is increased but the current is unchanged.
In this case, if one cell get damaged then the whole string would become inoperative,
similarly by combining number of solar cells in parallel, the current is increased but the
voltage is unchanged, in this change one cell get damaged than it does not affect the
other cell in the string.

To get a voltage of 0 to 36 V we require 72 cells to be connected in series so that we

connected 72 cells in series to a required voltage, this connecting module is shown in
fig.

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Construction

The construction of the photo-voltaic cell is also known as the barrier layer or rectified
cell as shown in figure. It consists of a base plate made of either steel or aluminum and
carries a layer of metallic selenium, which is light sensitive. An electrically conducting
layer of cadmium oxide is applied by sputtering over the selenium l

Fig4.6 Silicon photovoltaic cell

The layer is sufficiently thin to allow light to reach the selenium and is electrically
continuous as it acts as the negative pole. The negative contact is formed of a strip of
woods metal sprayed on to the edge of the top surface. The base plate forms the positive
contact. A transparent varnish protects the front surface of the cell.

When light falls on the upper surface of the selenium, electrons are released from the
surface, which maintained a flow of current through the external circuit connected
between the positive and negative contacts.

In the current output of a photocell should be proportional to the illumination, which is

achieved by keeping the external resistance at a low value. Also if greater accuracy is
required then illumination should not be allowed to exceed 25 lumens/feet². The
smaller the size of the cell, of course compatible with obtaining sufficient current to be
properly measured, the better a linear relation is obtained between current and
illumination. This is because, for such a cell, the resistance of the electrically

14
conducting film is at minimum. Also, since the current is small, the voltage drop due
to the circuit resistance will be kept low.

Limitation of the photocell is that if the light is incident at the angels of 60º or above,
the lacquer tends to reflect a significant an amount of light which, therefore, does not
reach the selenium layer.

Thus the current is less than what it should be according to cosine law of illumination.
Using a Matt lacquer can make some compensation for this. A better method is to omit
the lacquer and cover the cell with a hemispherical dome of transparent plastic. The
equivalent circuit of a photo-voltaic cell is shown in figure.

Here E is a perfect photo-voltaic generator, which produces a current proportional to

the illumination.

Rs = Series resistance,

C = the effective capacitance,

R = the equivalent of the barrier layer resistance and

RL = the resistance of external circuit

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 Rs

E C R RL

Fig 4.7 Solar cell circuit

Types of Solar Cells

Apart from the differences in the nature of the semiconductor used, the following
different cell configurations have been used:
(1) p-n homo junction

(2) p-n hetro junction

(3) Scotty barrier

(4) Homo junction hetro structure

(5) MIS (metal insulator-semiconductor cell)

(6) SIS (semi-conductor-insulator semi-conductor cell).

Table 4.1 Thin film and polycrystalline solar cell systems with ami solar energy
conversion efficiencies in excess of 5 percentage

Type of cell Semi-conductor Highest

constituents efficiency
%(AMI)
Polycrystalline Homo-junction Silicon ~8
Thin-film hetro-junction
p-CuαS/n-Cds ~9
Thin-film hetro-junction

16
 p-Cu₂Te₂/n-CdTe ~6
Thin-film hetro-junction p-Cu In Se₂/n-Cds
~6
Thin-film amorphous
semiconductor, schotty barrier Silicon ~6

Table 4.2 Single crystal solar cell systems with ami solar energy conversion

Type of cell Semi-conductor constituents Higher

eficiencites

η (%)

Homo junction Silicon 18

Homo junction Gallium arsenide 18

Homo junction Indium phosphide 6

Hetro junction p-Cu₂s/n-Si 5

Hetro junction p-Inp/n-Cds 14

Hetro junction p-Cu InSe₂/n-Cds 12

Homo junction Hetro structure Alα Ga₁-α As, Ga As 18

MISª Silicon 12

MISª Gallium arsenide 15

SIS^b Indium Tin oxide/silicon 12

SIS^b Tin oxide/silicon 12

Hetro junction p-Cd Te/n-Cds 8

MIS = Metal Insulation Semi-conductor cell

MIS^b = [High Conductivity – Transparent] Semiconductor-Insulation Semi-conductor cell.

17
Above 17 distinctly different types of solar systems having AMI solar energy
conversion efficiencies in excess of 5 percentages have been reported in ATABLE 1
and 2. Of these, nine have efficiencies in excess of 10 percentages. Three semi-
conductor, silicon, gallium arsenide and cadmium sulphide are constituents of 15 of
these cells of the remaining three cells, two contain cadmium telluride as principle
constituents, and the other contains indium phosphate.

Over 95% of cells in commercial production are silicon p-n junction while consumer
items are now using amorphous Si-pn cells. While the former has been used in space
ventures and in terrestrial PV arrays generating 1MW, a-Si cells are used under low
illuminating intensities since they deteriorate under high intensities. Their low-cost
advantage is yet to be realized.

In these varieties of cells, we use “MONOCRYSTALLINE CELL” for getting the

power and its production is been explained below.

4.1.3 Spur Gear

The spur gears, which are designed to transmit motion and power between parallel
shafts, are the most economical gears in the power transmission industry.

Internal Spur Gear

The internal gears are spur gears turned "inside out." In other words, the teeth are cut
into the inside diameter while the outside diameter is kept smooth. This design allows
for the driving pinion to rotate internal to the gear, which, in turn, allows for clean
operation. Intended for light duty applications, these gears are available only in brass.
When choosing a mating spur gear, always remember that the difference in the number
of teeth between the internal gear and pinion should not be less than 15 or 12.

External Spur Gear

Perhaps the most often used and simplest gear system, external spur gears are
cylindrical gears with straight teeth parallel to the axis. They are used to transmit rotary
motion between parallel shafts and the shafts rotate in opposite directions.

They tend to be noisy at high speed as the two gear surfaces come into contact at once.
Internal spur gears: The internal spur gear works similarly to the external spur gears
except that the pinion is inside the spur gear. They are used to transmit rotary motion
between parallel shafts but the shafts rotate in the same direction with this arrangement.

18
Applications

 Light duty applications

 Timing

 Positioning

 Rollers

 Indexing

 Material handling

 Feed drives

 Machine tools

 Conveyors

 Marine hoists

4.1.4 RF Module
An RF module (radio frequency module) is a (usually) small electronic circuit used
to transmit and/or receive radio signals on one of a number of carrier frequencies. RF
modules are widely used in electronic design owing to the difficulty of designing radio
circuitry. Good electronic radio design is notoriously complex because of the sensitivity
of radio circuits and the accuracy of components and layouts required to achieve
operation on a specific frequency. Design engineers will design a circuit for an
application which requires radio communication and then "drop in" a radio module
rather than attempt a discrete design, saving time and money on development.

Types of RF modules

The term RF module can be applied to many different types, shapes and sizes of small
electronic sub assembly circuit board. It can also be applied to modules across a huge
variation of functionality and capability. Most standard, well known types are covered
here:

 Transmitter module

 Receiver module

RF Transmitter module:

19
Whenever the high output pulse is given to base of the transistor BF 494, the transistor
is conducting so tank circuit is oscillated. The tank circuit is consists of L2 and C4
generating 433 MHz carrier signal. Then the modulated signal is given LC filter section.
After the filtration the RF modulated signal is transmitted through antenna.

Transmitter Code Generation

Operation

When a button on the keyboard is pressed two tones corresponding to that key
is generated. The tones corresponding to that key is generated. The tones generated
are fed to IC UM9121 5B which is an encoder, it converts the messages into electrical
signals and feeds them to the FM transmitter. The FM transmitter thereafter transmits
the signal with atmosphere as the medium (or) channel, via a telescopic antenna which
provides point to point links. The range of operation of the circuit depends on the range
of operation of the FM transmitter employed in the circuit.

Thus the signal is transmitted from the keyboard corresponding to the relay to
be triggered. Therefore transmission can be done in an efficient manner using this
circuit.

4.1.5 FM Transmitter

Fig 4.8 Schematic of FM Transmitter

FM transmission can be done by two methods

20
 1) Where frequency modulated waves can be directly produced by varying the
master oscillator frequency, in this case L-C oscillator is used (drift in
frequency).

2) Where a crystal oscillator is used which phase is modulated by the audio signals
(drift free frequency).

In this project, FM transmission is done such that the signal transmitted falls between
the desired bandwidth limits. In this case the frequency deviation is produced in
proportion to the amplitude of the signal received. The resulting FM wave is than
passed through a number of frequency multiplier stages. These sagesnot only raise the
center frequency of the signal but the frequency deviation is multiplied by the same
factor as well. The modulated wave is then amplified by the class C power amplifier
and then transmitted.

A part of frequency multiplier stage is fed to the AFC circuit in order to make
correction in case of any drift in the center frequency due to changes in the circuit
parameters. Thus change in center frequency can be correct and transmission by the
FM transmitter can be made accurate.

4.1.6 FM Reciever

Fig 4.9 Circuit of reciever

21
 The RF receiver receives the signal from the RF transmitter. It has 3
terminals- left, right, and forward. Two separate circuits are used to run the impellers.
When the signal reaches the left terminal of the receiver, it passes to the R1 resistor and
reaches the opto coupler. Opto coupler is an electronic device used for the isolation of
electrical signals. It consists of an IR diode and photo transistor. When the signal passes
through the IR diode it emits infrared light beam. When the infrared rays fall on the
base of the photo transistor it comes to conducting state and current is passed through
the relay. The relay switch is closed and the impeller starts to rotate. The green LED is
used to indicate whether the relay is in on or off state and diode D2 is provided to
produce voltage drop across the delay.

When we press the knob of the remote towards left, the right impeller is in
on state and the left impeller is stationary. Therefor the entire system moves toward
left. When we press the knob of the remote towards right the reverse process take place
and the entire system move toward right.

The forward terminal of the receiver is connected to both the circuits. When
forward signal is given to the receiver, both the impeller will start to rotate and the
system moves in forward direction.

4.1.7 Conveyor arrangement

This is made up of M.S. Conveyor belt and roller mechanism is used to transfer the
work piece from one place to the other place. The roller having two end bearings with
bearing cap. It is made up of mild steel.

4.1.8 Gear wheel arrangement:

The spur gear arrangement is used to move the conveyor in forward and direction

a. Spur Gear Arrangement - Forward and Reverse Application

4.1.9 Bearing with bearing cap:

A bearing is a machine element that constrains relative motion between moving parts
to only the desired motion.

The design of the bearing may, for example, provide for free linear movement
of the moving part or for free rotation around a fixed axis or, it may prevent a motion
by controlling the vectors of normal forces that bear on the moving parts. Many
bearings also facilitate the desired motion as much as possible, such as by minimizing

22
friction. Bearings are classified broadly according to the type of operation, the motions
allowed, or to the directions of the loads (forces) applied to the parts.

The term "bearing" is derived from the verb "to bear" a bearing being a machine element
that allows one part to bear (i.e., to support) another. The simplest bearings are bearing
surfaces, cut or formed into a part, with varying degrees of control over the form, size,
roughness and location of the surface. Other bearings are separate devices installed into
a machine or machine part. The most sophisticated bearings for the most demanding
applications are very precise devices; their manufacture requires some of the highest
standards of current technology.

The bearings are pressed smoothly to fit into the shafts because if hammered the bearing
may develop cracks. Bearing is made up of steel material and bearing cap is mild steel.

Construction and Types of Ball Bearings

A ball bearing usually consists of four parts: an inner ring, an outer ring, the balls and
the cage or separator.

To increase the contact area and permit larger loads to be carried, the balls run in
curvilinear grooves in the rings. The radius of the groove is slightly larger than the
radius of the ball, and a very slight amount of radial play must be provided. The bearing
is thus permitted to adjust itself to small amounts of angular misalignment between the
assembled shaft and mounting. The separator keeps the balls evenly spaced and
prevents them from touching each other on the sides where their relative velocities are
the greatest. Ball bearings are made in a wide variety of types and sizes. Single-row
radial bearings are made in four series, extra light, light, medium, and heavy, for each
bore, as illustrated in Fig. 1-3(a), (b), and (c).

100 Series 200 Series 300 Series Axial Thrust Angular Contact Self-
aligning Bearing Fig. 1-3 Types of Ball Bearings

23
The heavy series of bearings is designated by 400. Most, but not all, manufacturers use
a numbering system so devised that if the last two digits are multiplied by 5, the result
will be the bore in millimeters. The digit in the third place from the right indicates the
series number. Thus, bearing 307 signifies a medium-series bearing of 35-mm
bore. For additional digits, which may be present in the catalog number of a bearing,
refer to manufacturer’s details.

Some makers list deep groove bearings and bearings with two rows of
balls. For bearing designations of Quality Bearings & Components (QBC), see special
pages devoted to this purpose. The radial bearing is able to carry a considerable amount
of axial thrust.

4.1.10 Battery

In isolated systems away from the grid, batteries are used for storage of excess solar
energy converted into electrical energy. The only exceptions are isolated sunshine load
such as irrigation pumps or drinking water supplies for storage. In fact for small units
with output less than one kilowatt. Batteries seem to be the only technically and
economically available storage means. Since both the photo-voltaic system and
batteries are high in capital costs. It is necessary that the overall system be optimized
with respect to available energy and local demand pattern. To be economically
attractive the storage of solar electricity requires a battery with a particular combination
of properties:

(1) Low cost

(2) Long life
(3) High reliability
(4) High overall efficiency
(5) Low discharge
(6) Minimum maintenance
(A) Ampere hour efficiency
(B) Watt hour efficiency

Lead-acid wet cell

24
Where high values of load current are necessary, the lead-acid cell is the type most
commonly used. The electrolyte is a dilute solution of sulfuric acid (H₂SO₄). In the
application of battery power to start the engine in an auto mobile, for example, the load
current to the starter motor is typically 200 to 400A. One cell has a nominal output of
2.1V, but lead-acid cells are often used in a series combination of three for a 6-V battery
and six for a 12-V battery.

The lead acid cell type is a secondary cell or storage cell, which can be recharged. The
charge and discharge cycle can be repeated many times to restore the output voltage, as
long as the cell is in good physical condition. However, heat with excessive charge and
discharge currents shortends the useful life to about 3 to 5 years for an automobile
battery. Of the different types of secondary cells, the lead-acid type has the highest
output voltage, which allows fewer cells for a specified battery voltage.

Fig 4.9 Lead acid battery

Construction:

Inside a lead-acid battery, the positive and negative electrodes consist of a group of
plates welded to a connecting strap. The plates are immersed in the electrolyte,
consisting of 8 parts of water to 3 parts of concentrated sulfuric acid. Each plate is a
grid or framework, made of a lead-antimony alloy. This construction enables the active
material, which is lead oxide, to be pasted into the grid. In manufacture of the cell, a
forming charge produces the positive and negative electrodes. In the forming process,

25
the active material in the positive plate is changed to lead peroxide (pbo₂). The negative
electrode is spongy lead (Pb).

Automobile batteries are usually shipped dry from the manufacturer. The electrolyte is
put in at the time of installation, and then the battery is charged to from the plates. With
maintenance-free batteries, little or no water need be added in normal service. Some
types are sealed, except for a pressure vent, without provision for adding water.

Chemical action

Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell discharges,
lead peroxide from the positive electrode combines with hydrogen ions to form water
and with sulfate ions to form lead sulfate. Combining lead on the negative plate with
sulfate ions also produces he sulfate. Therefore, the net result of discharge is to produce
more water, which dilutes the electrolyte, and to form lead sulfate on the plates.

As the discharge continues, the sulfate fills the pores of the grids, retarding circulation
of acid in the active material. Lead sulfate is the powder often seen on the outside
terminals of old batteries. When the combination of weak electrolyte and sulfating on
the plate lowers the output of the battery, charging is necessary.

On charge, the external D.C. source reverses the current in the battery. The reversed
direction of ions flows in the electrolyte result in a reversal of the chemical reactions.
Now the lead sulfates on the positive plate reactive with the water and sulfate ions to
produce lead peroxide and sulfuric acid. This action re-forms the positive plates and
makes the electrolyte stronger by adding sulfuric acid.

At the same time, charging enables the lead sulfate on the negative plate to react with
hydrogen ions; this also forms sulfuric acid while reforming lead on the negative plate
to react with hydrogen ions; this also forms currents can restore the cell to full output,
with lead peroxide on the positive plates, spongy lead on the negative plate, and the
required concentration of sulfuric acid in the electrolyte.

The chemical equation for the lead-acid cell is

26
 Charge

Pb + pbO₂ + 2H₂SO₄ 2pbSO₄ + 2H₂O

Discharge

On discharge, the Pb and pbo₂ combine with the SO₄ ions at the left side of the equation
to form lead sulfate (pbSO₄) and water (H₂O) at the right side of the equation. One
battery consists of 6 cell, each have an output voltage of 2.1V, which are connected in
series to get a voltage of 12V and the same 12V battery is connected in series, to get a
24 V battery. They are placed in the water proof iron casing box.

4.2 COMPONENTS SPECIFICATIONS

4.2.1 Solar panel

Array Size : 12 x 6

Size : 16 x 14”

Output Voltage : 12V (Normal Condition)

Output Voltage : 22V (peak Hours)

Type : D.C Voltage

Material : Silicon

Watts : 10W

4.2.2 Battery

Material : Lead-Acid Battery

Output Voltage : 12 V

Output Power : 7 Ampere -Hour

4.2.3 P.M.D.C Motor

Power : 90 Watts

Voltage : 12 Volt
27
 Output Speed : 60 RPM

Speed in rotor : 2800 RPM

Type : Permanent Magnet Type

4.2.4 Motor for propeller

Power : 90 Watts

Voltage : 10 Volts

Speed : 3500 rpm

Type : Permanent Magnet type

4.3.5. Bearing used

Bearing number : SKF 6202(deep groove ball bearing)

Inner race bore : 15mm

Outside diameter : 35mm

Width : 11mm

4.3 CALCULATIONS

4.3.1 Design of belt

Length of belt L = Π (r₁ + r₂ ) +2 l + ( r₁ - r₂ )² (4.3.1)

radius of rollers r₂ = r₁ = 1.25 cm

l = Distance between two pulley

= 55 cm

∴ L = Π (2.5)/2 + 2 x (55) = 114 cm

Maximum tension in belt T = f x b x t (4.3.2)

ultimate stress f = 2 N/mm²

breadth b = 0.1 m
28
 thickness t = 1.2 mm

So tension T = 2 x 0.1 x 1.2 x 10³ N

= 240 N

4.3.2. Velocity of belt

d = Diameter of the drive pulley in mm

n = Speed of the drive pulley in rpm.

V = Velocity of the belt in m/sec

= Πdn (4.3.3)
60
= Π x 2.5 x51

60x1000

= 0.066 m/sec

Maximum power = force*velocity = T*V (4.3.4)

= 240*0.066

= 14.4 watts

4.4.3. Design of shaft

T τ
= (4.3.5)
J R

𝜋𝑑 4
Moment of inertia J =
32

𝑑
Radius R =
2

29
T = F*R (4.3.6)

We take 𝜏 = 125 𝑀𝑝𝑎

So we get d = 2 mm is safe

We take d = 15 mm

4.4 DESIGN PROCEDURE – CAD

Computer aided design or CAD has very broad meaning and can be defined as the use
of computers in creation, modification, analysis and optimization of a design. CAE
(Computer Aided Engineering) is referred to computers in Engineering analysis like
stress/strain, heat transfer, flow analysis. CAD/CAE is said to have more potential to
radically increase productivity than any development since electricity. CAD/CAE
builds quality form concept to final product. Instead of bringing in quality control
during the final inspection it helps to develop a process in which quality is there through
the life cycle of the product. CAD/CAE can eliminate the need for prototypes. But it
required prototypes can be used to confirm rather predict performance and other
characteristics. CAD/CAE is employed in numerous industries like manufacturing,
automotive, aerospace, casting, mould making, plastic, electronics and other general-
purpose industries. CAD/CAE systems can be broadly divided into low end, mid end
and high-end systems.

Low-end systems are those systems which do only 2D modeling and with only
little 3D modeling capabilities. According to industry static’s 70-80% of all mechanical
designers still uses 2D CAD applications. This may be mainly due to

the high cost of high-end systems and a lack of expertise Mid-end systems are actually
similar high-end systems with all their design capabilities with the difference that they
are offered at much lower prices. 3D sold modeling on the PC is burgeoning because
of many reasons like affordable and powerful hardware, strong sound software that
offers windows case of use shortened design and production cycles and smooth
integration with downstream application. More and more designers and engineers are
shifting to mid end system.

High-end CAD/CAE software’s are for the complete modeling, analysis and
manufacturing of products. High-end systems can be visualized as the brain of

30
concurrent engineering. The design and development of products, which took years in
the past to complete, is now made in days with the help of high-end CAD/CAE systems
and concurrent engineering.

4.4.1. Modeling

Model is a Representation of an object, a system, or an idea in some form other than

that of the entity itself. Modeling is the process of producing a model; a model is a
representation of the construction and working of some system of interest. A model is
similar to but simpler than the system it represents. One purpose of a model is to enable
the analyst to predict the effect of changes to the system. On the one hand, a model
should be a close approximation to the real system and incorporate most of its salient
features. On the other hand, it should not be so complex that it is impossible to
understand and experiment with it. A good model is a judicious trade off between
realism and simplicity. Simulation practitioners recommend increasing the complexity
of a model iteratively. An important issue in modeling is model validity. Model
validation techniques include simulating the model under known input conditions and
comparing model output with system output. Generally, a model intended for a
simulation study is a mathematical model developed with the help of simulation
software.

Software for modeling:

 Solid works

 Creo

 CATIA

 Unigraphics, etc

31
4.4.2. Creo

Creo Elements/Pro (formerly Pro/ENGINEER), PTC's parametric, integrated 3D

CAD/CAM/CAE solution, is used by discrete manufacturers for mechanical
engineering, design and manufacturing. Created by Dr. Samuel P. Geisberg in the mid-
1980s, Pro/ENGINEER was the industry's first successful rule-based constraint
(sometimes called "parametric" or "variational") 3D CAD modeling system.
The parametric modelling approach uses parameters, dimensions, features, and
relationships to capture intended product behaviour and create a recipe which enables
design automation and the optimization of design and product development processes.
This design approach is used by companies whose product strategy is family-based or
platform-driven, where a prescriptive design strategy is fundamental to the success of
the design process by embedding engineering constraints and relationships to quickly
optimize the design, or where the resulting geometry may be complex or based upon
equations. Creo Elements/Pro provides a complete set of design, analysis and
manufacturing capabilities on one, integral, scalable platform. These required
capabilities include Solid Modeling, Surfacing, Rendering, Data Interoperability,
Routed Systems Design, Simulation, Tolerance Analysis, and NC and Tooling Design.
Like any software it is continually being developed to include new functionality. The
details below aim to outline the scope of capabilities to give an overview rather than
giving specific details on the individual functionality of the product.

Creo Elements/Pro is a software application within the CAD/CAM/CAE category,

along with other similar products currently on the market. Creo Elements/Pro is a
parametric, feature-based modeling architecture incorporated into a single database
philosophy with advanced rule-based design capabilities. It provides in-depth control
of complex geometry, as exemplified by the trajpar parameter. The capabilities of the
product can be split into the three main headings of Engineering Design, Analysis and
Manufacturing.

4.4.3 Engineering design

Creo Elements/Pro offers a range of tools to enable the generation of a complete digital
representation of the product being designed. In addition to the general geometry tools
there is also the ability to generate geometry of other integrated design disciplines such

32
as industrial and standard pipe work and complete wiring definitions. Tools are also
available to support collaborative development.

A number of concept design tools that provide up-front Industrial Design concepts can
then be used in the downstream process of engineering the product. These range from
conceptual Industrial design sketches, reverse engineering with point cloud data and
comprehensive free-form surface tools.

We created the model of Oil Skimmer Robot by using CREO software. The models are
shown below…

Fig 4.10(a) CAD Model of Oil skimmer

33
Fig 4.10(b) CAD Model of Oil skimmer

Fig 4.10(c) CAD Model of Oil skimmer

34
 Fig 4.10(d) CAD Model of Oil skimmer

4.5 MANUFACTURING

Manufacturing processes are the steps through which raw materials are transformed
into a final product. The manufacturing process begins with the creation of the materials
from which the design is made. These materials are then modified through
manufacturing processes to become the required part. Manufacturing processes can
include treating (such as heat treating or coating), machining, or reshaping the material.
The manufacturing process also includes tests and checks for quality assurance during
or after the manufacturing, and planning the production process prior to manufacturing

35
4.5.1 Metal cutting

Metal cutting or machining is the process of by removing unwanted material from a

block of metal in the form of chips. Cutting processes work by causing fracture of the
material that is processed. Usually, the portion that is fractured away is in small sized
pieces, called chips. Common cutting processes include sawing, shaping (or planning),
broaching, drilling, grinding, turning and milling. Although the actual machines, tools
and processes for cutting look very different from each other, the basic mechanism for
causing the fracture can be understood by just a simple model called for orthogonal
cutting.

In all machining processes, the work piece is a shape that can entirely cover the final
part shape. The objective is to cut away the excess material and obtain the final part.
This cutting usually requires to be completed in several steps – in each step, the part is
held in a fixture, and the exposed portion can be accessed by the tool to machine in that
portion. Common fixtures include vise, clamps, 3-jaw or 4-jaw chucks, etc. Each
position of holding the part is called a setup. One or more cutting operation may be
performed, using one or more cutting tools, in each setup. To switch from one setup to
the next, we must release the part from the previous fixture, change the fixture on the
machine, clamp the part in the new position on the new fixture, set the coordinates of
the machine tool with respect to the new location of the part, and finally start the
machining operations for this setup.

Therefore, setup changes are time-consuming and expensive, and so we should try to
do the entire cutting process in a minimum number of setups; the task of determining
the sequence of the individual operations, grouping them into (a minimum number of)
setups, and determination of the fixture used for each setup, is called process planning.

These notes will be organized in three sections:

(1) Introduction to the processes,

(2) The orthogonal cutting model and tool life optimization and

( 3) Process planning and machining planning for milling.

36
4.5.2 Sawing :

Cold saws are saws that make use of a circular saw blade to cut through various types
of metal, including sheet metal. The name of the saw has to do with the action that takes
place during the cutting process, which manages to keep both the metal and the blade
from becoming too hot. A cold saw is powered with electricity and is usually a
stationary type of saw machine rather than a portable type of saw.

The circular saw blades used with a cold saw are often constructed of high speed steel.
Steel blades of this type are resistant to wear even under daily usage. The end result is
that it is possible to complete a number of cutting projects before there is a need to
replace the blade. High speed steel blades are especially useful when the saws are used
for cutting through thicker sections of metal.

Along with the high speed steel blades, a cold saw may also be equipped with a blade
that is tipped with tungsten carbide. This type of blade construction also helps to resist
wear and tear. One major difference is that tungsten tipped blades can be re-sharpened
from time to time, extending the life of the blade. This type of blade is a good fit for
use with sheet metal and other metallic components that are relatively thin in design.

4.5.3 Welding:

Welding is a process for joining similar metals. Welding joins metals by melting and
fusing 1, the base metals being joined and 2, the filler metal applied. Welding employs
pinpointed, localized heat input. Most welding involves ferrous-based metals such as
steel and stainless steel.Weld joints are usually stronger than or as strong as the base
metals being joined.

Welding is used for making permanent joints. It is used in the manufacture of

automobile bodies, aircraft frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building.

Operation :

Several welding processes are based on heating with an electric arc, only a few are
considered here, starting with the oldest, simple arc welding, also known as shielded
metal arc welding (SMAW) or stick welding.
In this process an electrical machine (which may be DC or AC, but nowadays is usually
AC) supplies current to an electrode holder which carries an electrode which is

37
normally coated with a mixture of chemicals or flux. An earth cable connects the work
piece to the welding machine to provide a return path for the current. The weld is
initiated by tapping ('striking') the tip of the electrode against the work piece which
initiates an electric arc. The high temperature generated (about 6000oC) almost
instantly produces a molten pool and the end of the electrode continuously melts into
this pool and forms the joint.

The operator needs to control the gap between the electrode tip and the work piece
while moving the electrode along the joint.

In the shielded metal arc welding process (SMAW) the 'stick' electrode is covered with
an extruded coating of flux. The heat of the arc melts the flux which generates a gaseous
shield to keep air away from the molten pool and also flux ingredients react with
unwanted impurities such as surface oxides, creating a slag which floats to the surface
of the weld pool. This forms a crust which protects the weld while it is cooling. When
the weld is cold the slag is chipped off.

The SMAW process cannot be used on steel thinner than about 3mm and being a
discontinuous process it is only suitable for manual operation. It is very widely used in
jobbing shops and for onsite steel construction work. A wide range of electrode
materials and coatings are available enabling the process to be applied to most steels,
heat resisting alloys and many types of cast iron.

4.5.4 Drillng :

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-
section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit
is pressed against the workpiece and rotated at rates from hundreds to thousands
of revolutions per minute. This forces the cutting edge against the workpiece, cutting
off chips (swarf) from the hole as it is drilled.

38
Operation:

The geometry of the common twist drill tool (called drill bit) is complex; it has straight
cutting teeth at the bottom – these teeth do most of the metal cutting, and it has curved
cutting teeth along its cylindrical surface. The grooves created by the helical teeth are
called flutes, and are useful in pushing the chips out from the hole as it is being
machined. Clearly, the velocity of the tip of the drill is zero, and so this region of the
tool cannot do much cutting. Therefore it is common to machine a small hole in the
material, called a center-hole, before utilizing the drill. Center-holes are made by
special drills called center-drills; they also provide a good way for the drill bit to get
aligned with the location of the center of the hole. There are hundreds of different types
of drill shapes and sizes; here, we will only restrict ourselves to some general facts
about drills.

39
Common drill bit materials include hardened steel (High Speed Steel, Titanium Nitride
coated steel); for cutting harder materials, drills with hard inserts, e.g. carbide or CBN
inserts, are used;
In general, drills for cutting softer materials have smaller point angle, while those for
cutting hard and brittle materials have larger point angle;
If the Length/Diameter ratio of the hole to be machined is large, then we need a special
guiding support for the drill, which itself has to be very long; such operations are called
gun-drilling. This process is used for holes with diameter of few mm or more, and L/D
ratio up to 300. These are used for making barrels of guns;
Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), since the tool may
break and get stuck in the work piece; - Usually, the size of the hole made by a drill is
slightly larger than the measured diameter of the drill – this is mainly because of
vibration of the tool spindle as it rotates, possible misalignment of the drill with the
spindle axis, and some other factors;
For tight dimension control on hole diameter, we first drill a hole that is slightly smaller
than required size (e.g. 0.25 mm smaller), and then use a special type of drill called a
reamer. Reaming has very low material removal rate, low depth of cut, but gives good
dimension accuracy.

40
4.5.5 Inspection:

Critical appraisal involving examination, measurement, testing, gauging, and

comparison of materials or items. An inspection determines if the material or item is in
proper quantity and condition, and if it conforms to the applicable or specified
requirements. Inspection is generally divided into three categories: (1) Receiving
inspection, (2) In-process inspection, and (3) Final inspection. In quality control (which
is guided by the principle that "Quality cannot be inspected into a product") the role of
inspection is to verify and validate the variance data; it does not involve separating the
good from the bad.

4.5.6 Sequence of operations done at workshop

The hollow square section MS tubes were cut to desired length by sawing operation.
The cut tubes were welded to build the required frame work. Holes were drilled on the
tubes at the required places to facilitate clamping of different parts. An Aluminium plate
was fitted on top of the frame so as to provide a platform for placing the the solar panel
and the electronic circuit. The solar panel was mounted on top of the plate using a
clamp. Hollow PVC pipes with caps at the end were clamped on both sides of the frame.
This was done to provide the floating capacity to the entire frame work. Motor and
pulley was mounted on top of the Aluminium plate. Another pulley was mounted below
the frame to facilitate the dipping of the belt in water. The oil skimming belt was fitted

41
in between the two pulleys. Two impellers with separate motors were fitted at the
bottom portion of the frame. The electronic circuit was then made and was fitted above
the aluminium plate. A Lead acid battery was also mounted above the aluminium plate
and the required electric connections were made

4.6. WORKING PRINCIPLE

Each robot is comprised of a head, which is covered by a layer of photovoltaic

cells, and a oil absorbing fabric covered conveyor belt. The photovoltaic cells generate
enough electricity to keep the fleet moving for several weeks and provide the energy to
propel the vehicles forward.

As the head moves through the water the conveyor belt constantly rotates and
sucks up pollution. The fabric-covered belt is then compressed to remove the oil. As
the clean part of the belt comes out of the head it immediately begins absorbing oil,
making the collection process seamless and efficient.

This process is more streamlined than current ocean-skimming technologies

because the robots can operate autonomously and don’t need to return to the shore for
constant maintenance. As the vehicles work in unison they can cover large areas and
by communicating with each other and researchers on land. Measuring just 16 feet long
by seven feet wide, the fleet can access hard to reach places like coastlines and estuaries.

4.7 TESTING

Before deploying, the working of the motors and the electronic circuit was tested. The
battery was charged using solar power. The equipment was then deployed in a water
body and the forward and sideways motions were tested. The running of the oil
skimming belt and its oil skimming capability was also evaluated.

42
Fig 4.11(a) Initial stage of fabrication

Fig 4.11(b) Electronic circuit

43
Fig 4.11(c) Remote controller

Fig 4.11(d) Final assembly

44
4.8. ADVANTAGES, DISADVANTAGES AND APPLICATIONS

4.8.1. Advantages

 Small and compact

 Inexpensive

 Scalable

 Self-organizing

 Automation compatibility

 Corral, absorb and process

 Uses renewable source-solar energy

4.8.2. Disadvantages

 Initial cost is high

 Difficulty of Maintenance

4.8.3. Applications
 It can be very effectively used for skimming away oil spills from the surface of
oceans.
 The deep water horizon rig regions can use the Sea swarm in case of accidents.
 It can also be used in oil refineries near to oceans or any other industries which
dispose chemicals and other waste oils to the rivers nearby.

45
 CHAPTER 5

MATERIALS LIST AND COST

5.1. List of Materials with Cost

Sl no. Description Qty Type Amount(Rs)

1 D.C Motor 1 Gear 500

2 High Speed motor with propeller 2 P.M.D.C 2x300

3 Solar Panel 1 12v 10w 950

4 Bearing 4 6202 4x150

5 RF circuit board 1 Electronic 600

6 PVC pipe 3m 4 inch 500

7 PVC cap 8 4 inch 560

8 Battery 1 Lead Acid 900

9 Belt 150cm Nylon 600

10 Square steel tube 1 M.S 1500

11 Fevicol 1 100

TOTAL 7410

5.2 Labour Cost

Cost of drilling, welding, grinding, power hacksaw, gas cutting = Rs.1000

46
5.3. Other Cost

Other cost include transportation and accommodation costs = Rs 1000

5.4. Total Cost

Total cost = Materials cost + Labour cost + Other cost

= Rs 9410

47
 CHAPTER 6

CONCLUSION

We are proud that we have completed the work with the limited time successfully.
THE REMOTE CONTROLLED OIL SKIMMER ROBOT is working with satisfactory
conditions. We are able to understand the difficulties in maintaining the quality. We
have done to our ability and skill making maximum use of available facilities. A small,
compact, inexpensive and self organizing mechanism is suggested to collect and skim
away surface oil spills.

By using wi-fi or mobile technology, the entire mechanism can be automated.

The driving mechanism is based on solar energy so problems related to its fueling can
be completely omitted and is a renewable source.Use of nano fibre belts could improve
the efficiency of system.

48
 REFERENCES

Abdul Azeez Al Majeed (2011) The use of palm fibre in conveyer of oil
skimmers. Journal of environment management 2012.

Nikolas M.P Kakkalas (2007) Robotic swarm concept for oil spill
confrontation. Journal of hazardous materials, October 2007.

Rosalam Sarbatly (2016) A review of polymer nanofibres by electrospinning

and their application in oil water separation for cleaning up marine oil spills.
Marine bulletin 2016.

49