Design of Automatic Wall Plastering Machine
Design of Automatic Wall Plastering Machine
Design of Automatic Wall Plastering Machine
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IJESRT
INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH
TECHNOLOGY
DESIGN OF AUTOMATIC WALL PLASTERING MACHINE
Ankush N. Askar*, Laukik P. Raut
*
Student, M. Tech CAD/CAM, GHRCE Nagpur, India
Department of Mechanical Engineering, GHRCE Nagpur, India
DOI: 10.5281/zenodo.439237
ABSTRACT
Due to manual process of wall plastering on construction site, there is a huge scale requirement of labor and hence
the labor cost is responsible for increasing the price of construction or project work. The quality of work is mostly
depending on the skill of the labor work in manual plastering process.
The solution of these problems is just to automate the process, so that there will be a saving of period and cost
and getting good plaster finishing to the walls. The plastering machine can plaster the walls automatically and
very smoothly. Due to which the process will fast and there will be saving of cost and time this will helps to reduce
the total cost, total time which ultimately responsible for the growth and hence the progress rate of a country is
going to increase.
KEYWORDS: Plastering, Plasterboard, AC/DC motor, gears, wire ropes, labor cost etc.
INTRODUCTION
Construction sector is responsible for a progress of any country, because most of the growth of the nation is
depending upon industrialization, civilization, transportation etc which compulsorily has their initial stage of
building construction or simply construction. It is a biggest economic sector because of it the development trade
in most countries amounts to 10-20% of the total national product, still due to labor demand and most of the work
is repetitive it is a slow manual process [2]. So for improving the economic growth of the country and indirectly
developing the lifestyle of the country’s people there must be need of improving the techniques of working.
Construction sector is unique sector which required more time and money, having very slow and stepwise process.
Presently in construction sector near about all the processes are manual which required more time for their
completion. Due to which the cost of the project is maximum, hence it must be necessary to automate the processes
in the construction work and improve the efficiency of it. Wall plastering is the main procedure among the
processes followed in the building construction, which is used for plaster the walls of the construction to get
smooth and finished wall surfaces. Plastering is also essential to give specified strength to the walls; it protects
the walls from moisture from both the sides. Wall plastering also gives good look to the walls and ultimately
creates best residential condition in the particular room. But in present days wall plastering is being done manually
in most of the part of world i.e. the procedure of wall plastering is being done with the assist of labors. Due to
which the process is lengthy. So this is an initiative towards the automation in plastering technique.
This process takes long time and consumes additional human power. So due to this slow process the labor cost
has also been increase as the labors are working on daily basis. If the labor is not a skilled person then there have
been a low quality work and there have been wastage of material. Ultimately the manual plastering technique
have some downsides like high cost, more time, material wastage and low quality work due to unskilled labors.
PROBLEM IDENTIFICATION
In the manual plastering technique, the crucial factor is skilled labor because of which plastering has been done
on the walls, but presently there is lack of skilled labors due to which it is very inconvenient to complete this
process. The labor requires more time to finish the process which increases their wages and hence the total
plastering or labor cost increases.
Objectives
From the above discussion about old plastering techniques, problems in old plastering techniques, their downsides,
background of the plastering method and the decided aim to be achieve following are some objective have been
decided.
1. This Machine will reduce the human work.
2. It will be straight forward in construction and simple to control.
3. Higher excellence of the plaster can acquire.
4. It will be move horizontally from to other place. So that it will be portable.
5. It will assist to save labor cost.
6. It will avoid wastages of the mortar, thus to save the cost.
7. Machine cost will be less than existing machines.
8. It can be control with the help of remote controller.
LITERATURE REVIEW
For the modification of the plastering technique lots of work had been done in the past by many people, but due
to some problems or deficiencies in that some machines has not been that much in working condition. For getting
an idea about the work done in the record on plastering technique it is necessary to do the literature survey and
review. According to that following are some vital points which have been taken from the recoded literature and
are very much important for designing new Automatic plastering machine.
Israe is the country in which ‘TAMIR’ had been developed. But these innovations have not been capable to give
a step ahead in the plastering industry. Thus even today, the plastering machines developed in the sixties are still
considered to be up to date.
Trowel Technique
Mahesha P.K, etal [2] Experimented the trowel operation procedure which is a customary plastering method. The
exact plastering procedure is dependent on how the trowel is being used and apply coat of mortar on wall.
Receiving a good finish is the grouping of compact force combined with the right angle of trowel, how distant the
foremost edge is with the wall. The foremost edge will be approximately 10-15 mm away apart from the wall.
Arunkumar Biradar, etal [3] Demonstrated the trowel technique. The right layer technique is essential with
exclusively the trowel getting used to use and end the skim coat. Achieving a well-mannered finish is that the
grouping of compact pressure and the correct angle of trowel. So front position of the trowel is an absolute
approach from the wall. With the resultant stroke, the plaster is simply spread with the help of trowel on the wall
surface.
Fig.2 describes the trowel operation technique in early covering technique. The right layering method is vital with
exclusively the trowel used to and finished the skim coat. Achieving a well-mannered end is that the combination
of compact pressure and the correct angle of trowel (how so much the front position is from the wall). Layering
technique for applying plaster is initiated by trowel burdened with plaster, the front position of trowel need to
move step by step addicted to the wall. With resultant hit of trowel used for layering the plaster as only applied.
There'll be no plaster on trowel and it'll be quite flat the forefronts are more or less ten-fifteen millimeter unit
detached from the wall.
Pre-plastering requirements
Mahesha P.K, etal [2] Stated that the brick structure should be developed in proper manner, with the
manufacturer’s condition and suggested installation procedure. All pre-requirement must be fulfilled, otherwise
failing to permit the condition to fully cure can result in excess contraction and cracking on the pointing lines after
the walls plastering. 3 mm deviation in surface alignment is allowable over 1200 mm radius.
Ali Al-Hamad, etal [1] explained that, the components need to be fabricated for the machine are ceiling bean, steel
tube, upper adjustable touch, conveyor belt, plastering board, resist board, supporting bar, lower adjustable touch,
hydraulic base, hydraulic handle, hydraulic pedal, oil window, driving shaft, rollers, driveshaft, gears, pulleys etc.
G. Pritschow, etal [4] Shows that due to small working envelop the controller for mobility of robot should be
accurate, which can be a microcontroller. Thus the movable podium should be able to go up and go down the
staircase. Compact dimensions will allow the robot to pass through doorways and to work in small rooms. A low-
cost PC depends run system will be used for motion control, sensor signal processing and human machine
interface.
Mechanical Concept
Arivazhagan.B [5], explained the mechanical design of the plastering machine which consists of the motor pump
to push the cement mix, Funnel to load the cement mix, flexible pipe to bear the cement blend to the hopper,
horizontal bar guide to move the plastering unit horizontally, horizontal top to grasp the vertical bar guide and
move beside the horizontal direction, vertical rail guide to move the hopper vertically, vertical head to grasp the
hopper and move beside vertically, cement mix inlet to the hopper, the hopper to hold cement mix provisionally,
cylinder slot to discharges the cement consistently with the pressure from the pump present in hopper, metal sheet
G. Pritschow, etal [4] Stated that the robotic manipulator must have some degrees of autonomy these are, two
degrees of autonomy for plaster application in a plane for a single robot working position. A further degree of
autonomy is required to compensate for tilting of the movable machine and thus enable parallel motion of the
plastering tool with respect to the wall or ceiling.
The plaster is poured into the hopper, with the help of lead screw the machine is raised up and will be lock at
some instance. The exciting force is given by the rope and machine mechanism. In that way the plastering is done
automatically to the wall by automatic plastering machine.
Mahesha P.K, etal [2], demonstrated that the machine has to be located near the wall which has going to plaster.
The machine should be perfectly leveled. Then the mortar is poured into the hopper of the tray. The lifting force
is transferred to tray through power screw, which driven by AC motor.
Ali Al-Hamad, etal [1], explained that, the machine works with conventional cement mortar, it can plaster the
wall mechanically by stirring up and down in straight up direction. It has two rails for rising and moving
automatically, therefore can be used for different height and width of the wall.
6. A Construction Johan Forsberg, Roger The time used for plastering the wall is
Robot for Aarenstrup, expected to be less than 50% of that required
Autonomous (Robotics and by manual work.
Plastering of Walls Automation, Lulea The reason for developing the robot is mainly
and Ceilings. University of Technology, ergonomic. They also discuss about
Sweden) Mechanical error sources, Navigation errors &
Control errors.
7. Mechanical Design Abd Alsalam Sh., Rosbi This paper the highlighting given the
of A Quadruped Mamat. (University mechanical structure of a quadruped machine
Robot for Horizontal Technology, Malaysia) able to walk on ground, go up on vertical walls
Ground to Vertical and perform the ground-wall movement
Wall Movement automatically.
It is electrically actuated one.
8. A Service Robot for Pablo Gonzalez De This explained the required features of the
Construction Santos, Joaquin robot manipulator developed for construction.
Industry Estremera, Also discussed main subsystem i.e. Frame,
E. Garcia. manipulator, Grasping device, controller &
(CSIC, Spain) guiding system.
9. Automatic Wall Dr. S. K. Rajesh Kanna. The movement of the poppet is controlled by a
Plastering and (Dept. of Mechanical high torque motor.
Repairing Robot Engg, Rajlakshmi The robots have been developed to apply the
using Artificial Institute of Technology, mortar on the vertical walls with pressure and
Intelligence India) having the capability of self adjusting the
A. D. Jaisaree. (Dept. of mortar thickness.
Computer science and The machine solves the issues like shortage of
Engg, Mahendra labor, raise in labor cost etc. and wastage of
Engineering College, mortar is reduced more than 60% thereby
India) reduces the raw substance requirement.
10. Advanced Dry Ir. Raymond Wan MEng, Good quality dry mix products are available in
Mortar Technology CEng, MIM, MICE, the market with improved performance.
for Construction MICT, MHKIE, RPE Although, dry mortars cannot totally solve all
Industry the construction problems,
On the contrary, advanced dry mortars are very
complicated powdery mixtures with
sophisticated chemical additives of newest
technology to provide wide range of superior
act to get together complex construction
requirements.
11. Finishing guide A Saint-Gobain Company This guide states the different methods of
For Thistle plaster finishing the wall surfaces by plastering,
and different accessories for plastering,
Gyproc plasterboard instruments, techniques etc.
12. Comparative Study Julia Friman This theory aims to match up to the most
on Mould Degree project for Master capable biocide anti fungal result when use as
Growth on Plaster of Science (One Year) in a covering on Plaster plates.
Boards Plant Ecology The method contained simple humid boxes,
treated with Biocides 30 hec together with a visual and an agar cultivation as
Department of Plant and assessment.
Environmental Science Dry grass was used as contamination. The
Göteborg University testing was designed to compare the biocides
with the reason of establishing relative mould
growth values.
13. Basic Concept and Reference:- WeiBert M., The introduction of plastering robots would
Enabling Leixner, Raddsatz. resemble the revolution in the plastering
Technologies using a industry in the sixties when plastering
mobile Robot for machines helped to improve overall
Internal Plastering. productivity by more than 30%.
The machine construction industry will also
have excellent chances at extending their
current markets.
14. A Novel Teng Long, En Li, Zaojun This research proposes a novel method of
Measurement and Fang, Weiqing Zhao and plastering machine measurement and control
Control Method for Zize Liang (Institute of method depends on laser triangulation.
Automatic Automation Chinese This method can’t solve some problems such
Plastering Machine. Academy of Sciences, as corner is unreached and the power of
Beijing 100190, China) vibration can’t be compensated.
METHODOLOGY
Methodology to be used is as follows for the designing of automatic plastering machine on the basis of literature
survey.
6) Total distance of leading edge from the wall = plaster thickness + leading edge distance
= 12 mm + 10 mm
= 22 mm
Now,
1) In triangle AED,
By Pythagoras theorem,
AE2 = AD2 + DE2
3002 = AD2 + 102
AD = 299.83 mm
AD = 300 mm
2) In triangle DAE,
DC motor specification
Power of motor = 1 hp
= 750 watt
Torque = 240 kg-cm
= 23.54 * 103 N-mm
Fig. 4 DC motor
Frequency = 60 Hz
Now, Power = 2∏NT/60
750= 2 ∏*N*23.54/60
N = 304.40 rpm
Design of Shaft
Material for shaft – Fe 360
Yield Strength (Syt) = 220 N/mm2
Ultimate tensile strength (Sut) = 360 N/mm2
Now according to A.S.M.E (American Society of Mechanical Engineers)
Shear stress τ = 0.18 * Syt
= 0.18 * 220
= 39.6 N/mm2
τ = 0.3 * 360
= 0.3 *360
= 108 N/mm2
Total Load = 47.60 kg
= 48 kg
= 48 * 9.81
= 470 N
There are two different sides
So, load on single side = 470/2
= 235 N
RA = 235 N
RB = 235 N
Bending Moment M = RA * 30
=235*30 = 7050 N-mm
So, Twisting moment (Te) = √(Km * M) 2 + (Kt * T) 2
= √ (1.5 * 7050) 2 + (1 * 23.54 *10 3) 2
= 25806 N-mm
d = 14.91 mm
So, get standard diameter of the shaft i. e. 15 mm
For worm,
Dia. of worm = m * q
= 2 *10
= 20 mm
Axial pitch Pa = ∏ * m = 6.28 mm
Face width = 0.73 * dw = 14.6 mm
Centre distance = dw + D/2 = 40 mm
Addendum = 1m = 2 mm
Deddendum = 1.25m = 2.5 mm
Length of worm = Pa * Zw
= 31.4 mm
Ww = D * b * k
Where, D – pitch circle diameter of worm gear
b – face width of the worm gear
k – load stress factor = 0.345
So, Ww = 505.90 N
Design of Rope
Type of rope = 6 * 19
Material = Steel wire
Diameter = 3 mm
Minimum breaking stress = 1770 Mpa
Minimum load capacity = 588 kg
Area of wire rope = 0.38 * d2
= 3.42 mm2
Diameter of the pulley or drum = 30 * d
= 90 mm
Tensile strength = 540d 2 = 4860 N/mm 2
Factor of safety = 3.5 i.e. 3.5 * 2 = 7
Stresses in wire rope,
Direct stress 6d = W + w/ A
Where, W = load lifted
w = weight of the rope
A = C/S area of the rope
So, direct stress, 6d = 69.94 N/mm2
Bending stress when wire rope winds round the drum or pulley
6b = Er * dw/ D
= 84 * 103 *3/ 90
= 2800 N/mm2
Where, Er – Modulus of elasticity of wire rope = 84 * 10 3 N/mm2
Design of Bearings
Specification:-
Bore diameter d = 15 mm
Outside diameter D = 35 mm
Width B = 11 mm
Greece lubrication = 19000
Oil lubrication = 24000
Dynamic load C = 7800 N
Static load Co = 3550 N
Now, Radial and Axial load,
Radial load Fr = 235 N
Axial load Fa = 0 N
Equivalent dynamic load Fe = [ X * V * Fr + y * Fa] = [1 * 1 * 235 + 1
*0]
Fe = 235 N
Req. dynamic load capacity = L = (Cr/Fe) a
Ball bearing a = 3
So, L = 8000 hrs
8000 = (Cr/235) 3
Cr = 4700 N
Since, Cr < C, so selected bearing is suitable.
CONCLUSION
By studying all the above literatures and the work done following conclusions are obtained.
1. Automatic plastering machine is one type of unique machine will be used in construction industry.
2. It helps to save the time and money.
3. It works with cement mortar which is conventional one due to which no replacement of the material
required.
4. The machine is more productive than the conventional plastering technique.
5. Higher quality of a plaster can be obtained with this machine.
6. The thickness of the plaster will be constant over the wall which is generally varying 0.5 to 0.75 inches at
different conditions of the wall surface.
7. This machine needs to poured the mortar manually so, it has needed the work automation of loading
mortar.
8. It reduces the wastage of mortar up to 60% and hence required fewer raw materials.
9. Due to saving in time, labor cost, raw material, the overall cost of construction is less hence the machine
is economically efficient
than the conventional plastering technique.
RESULT
Table shows comparative result on different objectives, for a 10 feet*10 feet wall by both existing plastering
method as well as Automatic plastering machine as follows.
Sr. Objective Existing method Automatic
No. plastering
machine
1. No. of 2 to 3 1 or 2
labors
required
2. Time 6 to 7 (hours) 1 to 2 (hours)
required
(hours)
3. More material Less material
Material required required,
compared to compared to
plastering conventional
machine as there method as less
is more wastage material
of mortar. wastage is
there.
4. Comparatively Comparatively
Cost high cost. (As low cost. (As
number of labors no. of labors
and time required and time
is more) required is less)