ACKNOWLEDGEMENT

FIRST OF ALL, WE WOULD LIKE TO GIVE OUR DEEPEST GRATITUDE TO

ETHIOPIAN ROAD CONSTRUCTION CORPORATION NEKEMTE ROAD
MAINTENANCE PROJECT FOR ALLOWING US TO TRAIN IN THE
COMPANY BY FACILITATING SUITABLE WORKING CONDITIONS.

MOREOVER, WE WOULD LIKE TO ACKNOWLEDGE OUR MENTOR

MR. YONANNIS MITIKU, FOR HIS SUPPORT, ADVICE AND MOTIVATION
THROUGHOUT THE INTERNSHIP PERIOD.

LAST BUT NOT LEAST, WE WOULD LIKE TO ACKNOWLEDGE MR. BEKA

DAHINE FOR HIS RELENTLESS HELP DURING THE INTERNSHIP.

EXECUTIVE SUMMARY
THIS REPORT INCORPORATES THE BACKGROUND, OVERALL STRUCTURE
AND DESCRIPTION OF DIFFERENT SECTIONS IN ERCC NEKEMTE ROAD
MAINTENANCE PROJECT.

THEN TRIES TO DISCUSS ABOUT THE FOUR MONTH GENERAL INTERNSHIP

EXPERIENCE IN THE SECTION OF THE COMPANY WE HAVE BEEN WORKING
WITH THE MAIN ACTIVITIES CARRIED OUT IN EACH SECTIONS.

WE ALSO TRIED TO EXPLAIN THE OVERALL BENEFIT GAINED FROM THE

INTERNSHIP.

LASTLY, PROBLEM IDENTIFICATION AND APPROPRIATE DESIGN SOLUTION

ISSUED IS DISCUSSED.

ERCC NEKEMTE ROAD MAINTENANCE PROJECT

BRIEF HISTORY OF THE COMPANY:

LOCATED IN EAST WOLLEGA ,NEKEMTE, KEBELE 03, AROUND

WOLLEGA UNIVERSITY.

ERCC IS A NEW GOVERNMENTAL ORGANIZATION ESTABLISHED ON

JULY 08/ 2011.

ERCC IS SPECIALIZED IN THE CONSTRUCTION OF ROADS AND BRIDGES.

ERCC HAS MANY EQUIPMENT MAINTENANCE PROJECT BRANCHES TO
MAINTAIN CONSTRUCTION EQUIPMENT
MAINTENANCE PROJECT IS ONE OF THEM.

AND

NEKEMTE

ROAD

VISION
TO BE GLOBALLY COMPETITIVE CONSTRUCTION COMPANY AND TO TAKE
THE LEADING POSITION IN AFRICA.

MISSION
TO SATISFY THE CUSTOMERS AND STAKEHOLDERS OF THE CORPORATION
BY DELIVERING,

ROADS AND BRIDGES CONSTRUCTION, REHABILITATION, UPGRADING

AND MAINTENANCE,

CONSTRUCTION EQUIPMENT AND MACHINERIES MAINTENANCE.

CONSTRUCTION MATERIALS PRODUCTION AND SALES,

ORGANIZATIONAL STRUCTURE

OVERALL INTERNSHIP EXPERIENCE

Our company has five workshops,
1. Engine maintenance shop
2. Body repair shop
3. Machine shop
4. Welding shop and
5. Electrical Installation shop
Among the five shops, we are assigned to work in the engine
maintenance and machine shop.

OVERALL WORK FLOW

PROCESS FLOW OF REPAIRING VEHICLES

ENGINES
1.
2.
3.
4.
5.
6.
7.
8.

DISASSEMBLE ENGINES INTO COMPONENTS AND PARTS.

WASHING OF PARTS OF ENGINES

CONDITION INSPECTION OF PARTS

MAINTENANCE OF PARTS
ASSEMBLY OF ENGINES

COMPLETING OF ENGINES WITH PARTS

TESTING OF ENGINES AND TROUBLE SHOOTING
FINAL COMPLETING OF ENGINES WITH PARTS

DESIGN OF ENGINE BUILD STAND

WHAT IS AN ENGINE BUILD STAND?
AN ENGINE BUILD STAND IS AN APPARATUS THAT IS USED TO HOLD AN
ENGINE AFTER IT IS EXTRACTED FROM A VEHICLE OR PRIOR TO
INSTALLATION.
IT IS PRIMARILY USED TO SAFELY HOLD THE BLOCK IN PLACE WHILE A
MECHANIC OR ENGINE BUILDER BREAKS DOWN, REPAIRS, OR REBUILDS
AN ENGINE.

PROBLEM STATEMENT AND JUSTIFICATION

IN THE ENGINE MAINTENANCE SHOP
THERE IS A PROBLEM OF HOISTING AN
ENGINE FOR INSPECTION, ASSEMBLY,
DISASSEMBLY AND MAINTENANCE.
THEY PUT THE ENGINE ON AN OPEN
GROUND, PLY WOOD OR TIRE DO
WHAT EVER REPAIR THE ENGINE NEEDS
TO HAVE.

OBJECTIVES OF THE PROJECT

TO PROVIDE EFFICIENT AND EFFECTIVE WAY OF MOUNTING AN ENGINE
FOR INSPECTION.

TO INCREASE PRODUCTION RATE BY DECREASING TIME REQUIRED FOR

INSPECTION, ASSEMBLY, DISASSEMBLY AND MAINTENANCE OF AN
ENGINE.

TO REDUCE LABOR FORCE REQUIRED

CONSTRAINTS AND DESIGN TARGETS

THE ENGINE STAND MUST BE,

LESS THAN THE AVERAGE HUMAN HEIGHT.

STRONG ENOUGH TO SUPPORT WEIGHT OF 250KG.
360 DEGREE ROTATING WITH SELF LOCKING PROPERTY.
PRODUCED EASILY AND WITH FEW PARTS AS POSSIBLE.
EASILY OPERATED BY ONE PERSON.
SAFE FOR OPERATION.
EASILY PORTABLE (MOBILE) IN THE ENGINE MAINTENANCE SHOP.

OPERATING PRINCIPLES OF THE ENGINE

BUILD STAND
THE WORM GEARBOX IS ROTATED BY
THE TORQUE APPLIED THROUGH THE
HANDLE AND THE WORM GEARBOX
AGAIN ROTATES THE SHAFT WELDED
TO THE HEAD PLATE THERE BY
ROTATING THE ENGINE MOUNTED ON
THE HEAD PLATE.

DESIGN OF ADAPTIVE CONNECTOR

THE

POINT WHERE THE ADAPTIVE

ENGINE IS CONNECTED TO THE
HEAD PLATE IS FULLY CONSTRAINED
IN ALL DIRECTIONS.

THE

LOAD ACTS ON THE SURFACE

WHERE THE ENGINE IS MOUNTED
ON
THE
ADAPTIVE
ENGINE
CONNECTOR.

ITERATION 1

NOW LET US SIMULATE THE RESULT

TO SEE IF IT WORKS.

FROM

THE RESULT OF THE

ANALYSIS, WE SEE THAT THE ADAPTIVE
ENGINE
CONNECTOR
HAS
A
MAXIMUM VON MISES STRESS OF
1037MPA WHICH IS UNACCEPTABLE.

THE

ANALYSIS SHOWED THAT THE

SMALL WIDTH BEING USED WERE NOT
ADEQUATE FOR THE DESIGN LOADING
NECESSARY. THE NEXT ROUND OF
DESIGNS INCORPORATED A WIDTH OF
20MM.

ITERATION 2

FROM

THE ANALYSIS, WE SEE

THAT THE ADAPTIVE ENGINE
CONNECTOR HAS A MAXIMUM VON
MISES STRESS OF 847.6MPA, WHICH
HAS DECREASED A LITTLE BIT THAN
THE PREVIOUS, BUT IT IS STILL
UNACCEPTABLE. SO WE HAVE TO
MAKE A DESIGN CHANGE.

THE ANALYSIS SHOWED THAT THE

SMALL THICKNESS BEING USED

WERE NOT ADEQUATE FOR THE
DESIGN LOADING NECESSARY. THE
NEXT
ROUND
OF
DESIGN
INCORPORATED A THICKNESS OF
15MM.

ITERATION 3
FROM THE ANALYSIS, WE SEE
THAT THE ADAPTIVE ENGINE
CONNECTOR HAS A MAXIMUM
VON MISES STRESS OF 100.8MPA,
WHICH IS LESS THAN THE YIELD
STRENGTH, 207MPA OF MILD
STEEL. THEREFORE THE DESIGN IS
ACCEPTABLE AND SAFE FROM THE
STAND POINT OF STRESS.

CHECK FOR FACTOR OF SAFETY

FROM THE ANALYSIS WE SEE THAT THE

MINIMUM SAFETY FACTOR FOR THE ADAPTIVE
ENGINE CONNECTOR IS, N = 2.05. IN ANOTHER
WORDS, THE YIELD STRENGTH OF THE MATERIAL
WE ARE USING IS 2.05 TIMES THE HIGHEST
STRESS IN OUR MODEL.
A GIVEN PART IS SAID TO BE,

OVER DESIGNED - IF > 3,

STRONG ENOUGH IF 1 < 3
UNDER DESIGNED IF < 1
HERE IN THIS CASE, IT IS STRONG ENOUGH
WHICH IS EXACTLY WHAT WE ARE LOOKING
FOR.
THEREFORE, THE DESIGN IS SAFE AND
ACCEPTABLE FROM THE STANDPOINT OF
SAFETY FACTOR.

DESIGN OF SOME BASIC COMPONENTS

AVAILABLE DATA,
SELF-LOCKING

SPEED OF WORM GEAR (NW) = 40RPM

< 50%
MATERIAL SELECTION
SINGLE THREADED WORM
HARDENED STEEL WORM
VELOCITY RATIO (V.R) > 36, TAKE 50 PHOSPHOR BRONZE WORM GEAR
PRESSURE ANGLE () = 14.5O
RIGHT ANGLE SHAFTS

DESIGN WORM GEARBOX

DESIGN OF WORM
MODULE, = 4

AXIAL PITCH, = 12.566

CENTER DISTANCE, = 133.5
PITCH CIRCLE DIAMETER OF WORM,
= 67
LENGTH OF WORM, = 85
DEPTH OF TOOTH, = 8.62
ADDENDUM, = 4

OUTSIDE DIAMETER OF WORM,

= 75

DESIGN OF WORM GEAR

NUMBER OF TEETH, = 50 DIAMETER,

DG = 200
FACE WIDTH, = 37

OUTSIDE DIAMETER, = 212.73

DESIGN CHECK
CHECK FOR TANGENTIAL LOADING
TANGENTIAL LOAD ACTING ON THE GEAR, 596.83
THE DESIGNED TANGENTIAL LOADING, 4287.6
SINCE THE DESIGNED TANGENTIAL LOADING IS MUCH MORE THAN THE TANGENTIAL
LOAD ACTING ON THE GEAR THE DESIGN IS SAFE FROM THE STAND POINT OF
TANGENTIAL LOADING.

CHECK FOR DYNAMIC LOADING,

TANGENTIAL LOAD ACTING ON THE GEAR, 596.83
THE DESIGNED DYNAMIC LOADING, 4296
SINCE THE DESIGNED DYNAMIC LOADING MUCH GREATER THAN THE
TANGENTIAL LOAD ACTING ON THE GEAR, THEREFORE THE DESIGN IS SAFE FROM
THE STAND POINT OF DYNAMIC LOADING.

CHECK FOR STATIC LOAD,

TANGENTIAL LOAD ACTING ON THE GEAR, 596.83
THE DESIGNED STATIC LOADING, 8592.4

EFFICIENCY OF THE WORM GEARBOX

EFFICIENCY, = 28.8%

SINCE THE EFFICIENCY OF WORM GEARING IS LESS THAN 50%, THEN

THE WORM GEARING IS SAID TO BE SELF-LOCKING, I.E. IT CANNOT BE
DRIVEN BY APPLYING A TORQUE TO THE WHEEL. THIS PROPERTY OF
SELF-LOCKING IS DESIRABLE IN THIS CASE.

DESIGN OF WORM SHAFT

MATERIAL SELECTED, MILD STEEL
DIAMETER, = 32
SAFETY FACTOR, F. S = 2

DESIGN OF WORM GEAR SHAFT

MATERIAL SELECTED, MILD STEEL
DIAMETER, = 32

SAFETY FACTOR, F. S = 2

CAN THE GEARBOX PRODUCE ENOUGH TORQUE TO

ROTATE A MASS OF 250KG?
THE TORQUE PRODUCED BY THE WORM GEAR MUST EXCEED THE TORQUE
THAT WEIGHT OF AN ENGINE PRODUCES TO ROTATE THE ENGINE.

TORQUE PRODUCED BY THE MASS OF AN ENGINE, =750.32NM

TORQUE PRODUCED THE WORM GEAR, = 859.43
SINCE > THEREFORE, WE CAN CONCLUDE THAT OUR GEARBOX HAS THE
CAPACITY TO ROTATE THE GIVEN WEIGHT.

DESIGN OF KEY
WORM KEY
MATERIAL SELECTION, MILD STEEL
TYPE OF KEY, RECTANGULAR SUNK
KEY
WIDTH OF KEY, = 12

HEIGHT OF KEY, = 8
LENGTH OF KEY, = 1.5 = 48

WORM GEAR KEY

MATERIAL SELECTION, MILD STEEL
TYPE OF KEY, RECTANGULAR SUNK
KEY
WIDTH OF KEY, = 16

HEIGHT OF KEY, = 10
LENGTH OF KEY, = 50

BEARING SELECTION
FOR WORM SHAFT

FOR WORM GEAR SHAFT

TYPE OF BEARING, SINGLE ROW

ANGULAR CONTACT BALL

TYPE OF BEARING, SINGLE ROW

ANGULAR CONTACT BALL

BORE = 30MM,
OUTSIDE DIAMETER = 72MM

BORE = 50MM,
OUTSIDE DIAMETER = 110MM

AND

WIDTH = 12MM IS CHOSEN.

AND

WIDTH = 27MM IS CHOSEN.

Angular contact bearing permits the bearing to carry a

relatively large axial load in one direction while also carrying
a relatively large radial load.

DESIGN OF CRANK LEVER

LENGTH OF HANDLE, = 120

LENGTH OF LEVER ARM, = 250
OVERHANG OF THE JOURNAL, = 40

A MEAN FORCE THAT A MAN CAN APPLY ON

THE WORKING HANDLE OF A CRANK LEVER,
OFF AND ON FOR A FULL WORKING DAY IS
100N.

DIAMETER OF HANDLE, = 14
WIDTH OF LEVER ARM, = 20
THICKNESS OF THE LEVER ARM, = 10
DIAMETER OF THE JOURNAL, = 16

CASTER WHEEL SELECTION

LOAD PER CASTER WHEEL,
+
=
= 128.6

ENVIRONMENTAL CONDITIONS,
FLOOR CONDITIONS,
TAKING INTO CONSIDERATION THE
ABOVE INFORMATION A CASTER
WITH THE FOLLOWING
SPECIFICATION HAS BEEN CHOSEN
FROM A CATALOG.

WHEEL DIAMETER,
WHEEL WIDTH,
WHEEL COMPOSITION,
BEARING TYPE,
LOAD CAPACITY,
BEARING BORE,/
HUB LENGTH,
PART NUMBER,

DESIGN CONCLUSION
NO ENGINE SHOP OR GARAGE IS COMPLETE WITHOUT AN ENGINE STAND TO BUILD
NEW ENGINES ON. ROTATING ENGINE STANDS GIVE YOU A STABLE AND SAFE WAY TO
BUILD AN ENGINE. ROTATING ENGINE STANDS GIVE YOU 360 DEGREE ACCESS TO THE
ENGINE BLOCK. QUALITY ENGINE STANDS WILL LOCK IN PLACE TO KEEP FROM
ROTATING WHEN YOU'RE INSTALLING THE CRANK, PISTONS OR OTHER ENGINE
COMPONENTS. BECAUSE THE ENGINE BLOCK IS STABLE, YOU GET A BETTER ENGINE
BUILD. YOU CAN TAKE YOUR TIME FITTING RINGS AND INSTALLING PISTONS WITH FULL
VIEW OF YOUR WORK.

CONCLUSION
THIS INTERNSHIP PROGRAM BRIDGES THE GAP BETWEEN THE STUDENTS
THEORETICAL KNOWLEDGE AND PRACTICAL SKILL. GENERALLY THE
INTERNSHIP BOOSTED OUR KNOWLEDGE IN MANY AREAS LIKE:-

THE SPIRIT OF WORKING TOGETHER AND COOPERATIVENESS

COMMUNICATION & INTERACTION WITH COLLEAGUE
GAVE US THE CHANCE TO CHANGE THEORETICAL KNOWLEDGE TO PRACTICAL
OR REAL KNOWLEDGE

THE ABILITY OF MAKING DECISIONS AND TAKING RESPONSIBILITY

THE SKILL OF GIVING A SOLUTION FOR SPECIFIC PROBLEMS
DEVELOP OUR SELF-CONFIDENCE AND PROFESSIONALISM
THE DESIGNED PROJECT HAS A FULL CAPACITY TO SAVE THE EXISTING
PROBLEM AS IT HAS MANY ADVANTAGE AND MULTI-USE.

RECOMMENDATION
WE RECOMMENDED ERCC NEKEMTE ROAD MAINTENANCE PROJECT THE
FOLLOWING POINTS,

IN ORDER TO INCREASE ACCURACY AND DURABILITY OF MAINTAINED

COMPONENTS, THE COMPANY SHOULD IMPLEMENT THE USE OF CAD

SOFTWARES LIKE SOLIDWORKS AND CATIA.

IN ORDER TO DECREASE TIME CONSUMPTION ON MOUNTING AN

ENGINE FOR TEST AFTER INSPECTION AND MAINTENANCE, THE
COMPANY SHOULD INVEST ON BUYING AN ENGINE TEST STAND.

USING

OLDER MACHINES DOESNT MAKE COMPETENT, SO THE

COMPANY HAS TO USE LATEST MACHINES SUCH AS CNC MACHINES
TO BECOME SUCCESSFUL COMPANY REGARDLESS OF TIME
MANAGEMENT AND UPGRADING ITS PRODUCTION CAPACITY.

FINALLY, OUR DESIGN OF A GEAR DRIVEN ENGINE STAND HAS TO BE

IMPLEMENTED TO SOLVE PROBLEM THAT THE COMPANY FACING AND
INCREASE PRODUCTIVITY BY REDUCING LABOR.

THANK YOU !