DESIGN AND ANALYSIS OF MULTI-PURPOSE ELECTRICAL AUTOMATED BAKEING INJERA

MACHINE
2021

Department of Mechanical Engineering

Second Progress Report

DESIGN AND ANALYSIS OF MULTI-PURPOSE

ELECTRICAL AUTOMATED BAKEING INJERA MACHINE
Prepared by ID
1.Abrham Hagos……………………………………………… Tech /0132/08
2. Sofoniyas Wendimenehi……………..……………………….Tech/ 1651/08
3. Biruk Tadiyos………………………………………………. Tech/1737 /08

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Submitted to: Mr. HALEFOM K.

Submission date: May 26/2021

Chapter One
Introduction
1.1 Background of the study
Injera is pancake-like thin bread a fermented “teff” flour mixed with water. It is a major staple
food of Ethiopians and Eritreans for millennia. Averagely one Injera weighs around 310g and it
is 52cm in diameter.
It has been a national dish served with “Wot” across the country. Traditionally Injera is baked by
spreading or pouring batter of fermented teff in a small cup; moving your hand in a helical
fashion to spread batter in a cup to make circular Injera. Most of the people living in Ethiopia
bake Injera using biomass fuel as a primary energy source (Adem & Ambie, 2017).
Mostly Injera baking is performed by women and it is labor and time-consuming work. In our
country Injera baking process is done by hand and some of the processes like pouring is
physically challenging and it may lead to anatomical disorder (Ali A., 2018).
In the previous Injera baking machine, one Injera is baked at a time and small cups have been
used to spread the batter manually. Recently the economic growth, the number of universities,
hotels, individual users and bachelors is increasing exponentially across Ethiopian cities calls for
the need of mass production of Injera. Current Injera baking process is unsuitable and tedious for
mass production. In the future the market prospect of Injera will be higher since the
technological advancement of the country will push the manufacturing section to be more
advanced and production way to be more automated. Standardizing the production process of
Injera could also increase marketability of injera.
1.1.1 Problem Statement and Justification
Baking Injera traditionally with wood and biogas is not acceptable with regard to consequent
problems of deforestation, global warming and household air pollution. To avoid these problems
many Ethiopians and Institutions tried to advance the ways of Injera making process in different
ways, some of these are mentioned in literature review of this paper. Traditional electrical stoves
and bio gas stoves has been marketed locally but they are unable to penetrate the mass Injera
production market. Even though various mass Injera production design patents have been issued
for numerous innovators, there is still a big room for improvement
1.2 Objectives
1.2.1 General objectives
This project is aimed to provide the designing and analysis of the batter supplying mechanism,

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the batter spreading mechanism and the polishing mechanism. It provides a design of automated
Injera baking machine for mass production of Injera.
1.2.2 Specific objectives
The specific objectives of this paper are:
 To review the existing Injera baking technologies and traditional way of making
Injera.
 To the main components of Electrical Automated Baking injera
 To modify the technologies by adding additional features
 To study the economic feasibility
1.3 Scope of the Project
The scope of this final year paper consists of the design modification of the spreading
mechanism of Chinese made machined named “HY-910S-C Automatic Continuous Injera
Making Machine”. This machine is used as a basis for the design proposed in this paper.
This project also assesses the traditional way of making Injera by using observation and
questioning experienced Injera makers since the best quality of Injera can be gained though
replicating the method being applied for millennia.
The project will focus on a complete 3D –modeling of a continuous Injera baking machine and
complete design of the spreading and polishing mechanism. Sensing the real needs of the
customers by direct interview of users. Analysis of the needs of customers is to be performed in
order to find best solution for the problems that the current working prototypes are facing. Based
on the customer’s need, Each and every design consideration will have a contribution and impact
on final design of the machine. The project extends to detail analysis of each parts of the
spreading and polishing mechanism accompanied with simulation which depicts basic work I
mechanism of the machine. Finally, this paper will forward suggestions for further improvement.

Chapter Two
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Literature Review
2.1 Historical Background
Traditionally, Injera” is made with just two ingredients – Eragrostistef, also known as “teff”, an
ancient grain from the highlands of Ethiopia, and water. There is little written or known about
“teff's” origin and while there is no scholarly consensus, some believe that the production of
“teff” dates back as far as 4000 BC.
2.2 Steps of Injera Making
Injera” is very useful for people who is suffering with Celiac disease as it is gluten free. What
makes Injera” is “teff”, and “teff” is 100% gluten free. So, using “teff” you can do breads, cakes
or any recipe you can think of. We hope this step of how to do Injera” may give you a good
knowledge about “teff” and how it is changed to a product (Terefe, n.d.).
Step 1: Ingredient
 “Teff” flour
 Baking yeast
 Warm water
 Race seeds (“Gomenzer”)
Step 2: first we need to choose which type of “teff” is used to make Injera is white or brown. But
we need to be sure that the “teff” we bought is should be grinded to flour. The amount of “teff”
flour depend on how much Injera is needed to make.
Step 3: medium sized bowl is perfect to mix all the ingredients. Now our flour is ready to mix
with water (the water should be warm, don’t use hot water) and the amount of water we are
going to add is depend on the size of flour. We need to the mixing until we see a change to slurry
paste look like.
Step 4: we need to add a new ingredient (baker’s yeast it is fermented dough) to slurry paste,
which enables Injera to have a good flavor and take off carbon dioxide during baking.
Step 5: Now, we have reached on a step we will leave our slurry alone in our bowl. The time we
will wait may differ based on how many Injera we are going to make and based on our place.
Ethiopia and Eritrea are the best place to find the real test of Injera, but the day they will leave
their slurry may take up to four days. if anyone is going to make a small amount of Injera leave it
covered for 12 hours in a warm spot covered with dish towel. Don’t ever stir it or try to open it,
leave it until 12 hours.
Step 6: After 12 hours of waiting, we will find two layers at the bottom which is slightly solid
and at the top the liquid part. At these stages, we need to separate the liquid part from the slightly
solid part, and we will use the method called Decantation i.e., pouring out the liquid part and
remain with the solid portion. Then have another bowl with water, and add the dough to the
water. This make the dough to be thin. We need to make the dough thin to make Injera.

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Step 7: Once again, we need another bowl with a boiled water. Then take some portion of dough
from the bowl we have in step 6 and add it on the bowl with the boiled water. Mix the dough
with the boiled water and this mixture is called “absit”. The boiled “absit” will be mixed with the
rest mass of dough, to make it thin and ready for baking Injera.
Step 8: Give power to the baking pan (electricity powered pan or wood fuel powered pan in the
country side). Now, you will apply a Race seeds(“Gomenzer”) on your pan. The Race seeds are
not that much important but if you are going to apply them on your pan; it will make the baking
of Injera very smooth and when you finally pull out your baked Injera it will make it not to be
sticky to the pan.
Step 9: Finally, pitch the liquid dough and round it through the pan in a circular fashion. Then
cover the pan with the lid or anything that will make you able to cover the pan, and wait for 2
minutes averagely. But make sure your cover must hold the moisture inside the pan otherwise
our Injera will crack and the result will be deformed Injera.
Step 10: After 2 minutes open the lid or cover, don’t get your face too much close to the pan
because the steam that will get out of the pan when it is open is very hot so it may hurt your face.
So, our suggestion is open the pan and give it from 1-2 minutes until it cools down.
Step 11: At this point, pull out the baked Injera by using utensil from your pan. Be careful when
you pull out it because Injera is very thin and smooth you may break it and lose the circle shape.
Step 12: Finally, enjoy eating your Injera. We recommended eating Injera with Ethiopian food
and foods like Spaghetti or Macaroni but if you find any other food that is compatible, please
share it on the comment page.
2.3 Injera Baking Stoves
2.3.1 Traditional Injera Baking Stoves
Biomass Fuel Stoves
As already we tried to say that Injera is the staple bread item in Ethiopia, is known for intensive
energy consuming cooking. Baking this food item in the traditional three stone stoves, with an
efficiency of 5-15%, consumes huge amounts of firewood and causes consequent problems like
deforestation, global warming and household air pollution. To avoid these problems many
Ethiopians and Institutions are to advanced stoves.
These stoves are made by help of Energy sector, by recognizing emission of greenhouse and
consumption of wood. These firewood saving stoves are mostly made from cement and local
clay soils. To improve these stoves not only the governmental sectors are involved but also non-
governmental institutions are also involved. Some of these improved stoves which faces the
market are Gonzie, Mirt, Awuramba fixed …etc. (MiftahFekadu, 2019)

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Figure 1: Mirt stove

However, these stoves have limitations some are using high labor, low production rate, not
suitable for commercial, still have emission problems since it is working with biomass fuel,
energy loss human satisfaction.
Electric Stoves
Electric Injera stoves (mitads) are a sound alternative in Ethiopia because of relatively wide
availability of electricity (hydropower). However, these electrical mitad have designs dating
back to the 1960’s and are highly inefficient as well and are over loading the electricity grid.
(Diehl, may, 2017).
Electric Injera baking stoves can be a solution to overcome problems which cause environmental
hazards. Electric Injera baking stoves are more likely environmentally friendly than biomass fuel
stoves. since, the stoves are using electric as a power source. However, these stoves are limited
for urban areas as a result of power shortage.
Current electric stoves (mitads) are stationary and use a traditional clay baking plate, but with
grooves cut in the underside, in which the heating element is embedded. As heating element, a
coil-shaped resistance wire in a lay-out consisting of concentric rings is used. But some stoves
placed this embedded by a glass sheet for better result of energy saving potential and reduction
of baking time. Magic Mitad which is developed by a Dutch start-up (Magic Ventures) is best to
show this. They can achieve to reduce heating time by 3 minutes from clay embedded one.
However, there were problems with the quality of Injera baked on Magic Mitad, slight
differences were formed on eyes (holes) on injera’s surface. This was due to a non-uniform
distribution of heat throughout the baking pan.

Figure 2: Electric Mitad with clay plate (left) and Electric Mitad with magic Mitad plate
(right)

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Automated Electric Stoves

As compared to other baking foods Injera is difficult to automate because of its characteristics.
Because of some reasons:
 Too expensive and unaffordable (affordability by small Injera baking institutions)
 Thickness of Injera (attempts by Chinese manufacturers): Not suitable for commercial
purpose (Profit)
 Weren’t able to reduce the number of operators of the machine (brushing up surface of
oven and control)
 Non-Ethiopian solution for Ethiopian problems
But we have many reasons to automate these processes:
 Injera is the staple food of Ethiopia and Eritrea, this ensures wide market.
 Market in and outside of the country for many years to come.
 Bread production in Addis Ababa (80,000 bread per hour).
 Bread is consumed on breakfast, but Injera is consumed on lunch and dinner.
 Automation of Injera is technology driven (People does not bake Injera in big cities).
 Trend of living style in Addis Ababa encourages consumers to buy.
 Mass production helps reduce unit cost (Profit).
 Institutions are in need of mass production of Injera (Hotel, Universities, Military
Camps).by many Ethiopians and by other non-Ethiopians tried to automate injera.
However, most of them could not penetrate the market here are some of the reasons:
 Too expensive and unaffordable (affordability by small Injera baking institutions)
 Thickness of Injera (attempts by Chinese manufacturers): Not suitable for commercial
purpose (Profit)
 Weren’t able to reduce the number of operators of the machine (brushing up surface of
oven and control)
 Non-Ethiopian solution for Ethiopian problems.
Because of the above reasons some of automated stoves are became non-functional and non-
feasible. Some of these works have been presented below.
A person named Abdella Y. Ali has suggested design and development of semi-automatic Injera
baking machine for family household in Ethiopia. In his work consists batter delivery, polishing
and batter dispensing mechanism. The connecting rod pushes the cover downward direction, as a
result the rotating plate inside the cover polishes the pan. When the cover further pushes the pan,
the spring under the pan stores energy and when released, the spring creates vibration. So that
the batter delivered over the pan will be dispensed. The bottle which is located over the cover
uses gravity to deliver the batter through solenoid valve which is located the cover. Unlike others
this design uses indirect method to spread the batter over the pan rather than using direct contact
method like rotating plate over the pan and tried to achieve difficulties comes from size and cost
(Ali A. , 2018).

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Figure 3: Solid model of semi-automatic Injera machine

The other inventor named Yoseph Temesgen who got a patent from us in 2005. Key to the
invention’s operation are the polishing assembly, the batter application assembly, and the
reciprocating collection assembly. The polishing assembly comprises a polishing pad which may
be positioned over the cooking surface when the cooking surface is not in use. When engaged,
the polishing assembly utilizes a novel drive mechanism to apply the rotating polishing pad to
the cooking surface so as to clean it prior to the application of the bread batter to the cooking
surface. The batter application assembly is also position-able over the cooking surface, and it
comprises a drive to rotate a batter supply line reciprocating nozzle carrier so that the batter is
poured onto the cooking surface along a spiral path so as to generate a uniform circular pour of
batter. Finally, a reciprocating collection assembly utilizes a reciprocating conveyor equipped
with a spatula, pick up belt, and coordinated conveyor rollers so as to remove the cooked bread
wafer from the cooking surface at cook completion time for cooling while simultaneously
discharging a previously cooled wafer generated by this fully automated, this process is cyclic
(United State of America Patent No. US 7.421,943 B1, 2005).

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Figure 4: Automatic Injera baking machine by Yoseph Temesgen

The inventor named Girma Mulat Bekele also tried to automate injera. Generally, in this
invention there are two steps. The first step is the batter delivery step done by the batter-
spreading embodiment. The second step is the cooking step, a “start” switch to the controller will
start those two steps. On step one, after receiving the start switch, the batter-spreading
embodiment moves to station one and starts the process of delivering the batter to the griddle/hot
surface.The inventor named Girma Mulat Bekele also tried to automate injera. Generally, in this
invention there are two steps. The first step is the batter delivery step done by the batter-
spreading embodiment. The second step is the cooking step, a “start” switch to the controller will
start those two steps. On step one, after receiving the start switch, the batter-spreading
embodiment moves to station one and starts the process of delivering the batter to the griddle/hot
surface. Once completed, it will continue to the second station. After finishing at the second
station, it will move on to the third and fourth station. After finishing delivering the batter in a
thin and uniform manner over all the griddle/hot surfaces, it will return to its ready position and
the second step will be starting. On this step the XYZ and rotational moving robot hand will
move the covers to put on top of the griddles and a cooking timer will be initiated by the
controller. When the present cooking timer is expired, the robot hand will move back and pick
all the covers back to the shelf it brought them before. Once this process is completed, it will be
waiting for the operator to remove the Injera and restart the whole process by pushing the start
“switch” again. (United State of America Patent No. US10092011B1, 2016)

Figure 5: Semi-Automatic Injera Making Machine by Girma M. Bekele

The other person who is also patented with other two inventors from US are called Mengistu
Kindie with Robert Sweeney and Jim Aitken are also provide an apparatus which is used for
producing bread from a batter mixture. The apparatus including: flat cooking surface, a heating
element below the cooking surface to generate heat, a batter dispenser arranged to dispense
batter directly to the cooking surface and transfer mechanism arranged to transfer the cooked
batter from cooking surface to cooling area. This arrangement enables continuous automated
production of flat leavened bread, including Injera and the like, with repeated used of the same
cooking surface. According to the inventor cooking time is a couple of minutes. (United States
of America Patent No. US20030143309A1, 2002)
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Figure 6: Continuous Bread making machine by Mengistu Kindie

The other Ethiopian who is also patented from US called Emru Desalegn suggested an
automated process for making Ethiopian bread comprises discharge of Ethiopian bread batter at
spaced apart intervals along a continuously moving conveyor. The batter is spread into a
predetermined configuration and then transported by the continuously moving conveyor through
an oven where in the bread is baked. Following baking the bread is transported through a cooling
zone by the continuously moving conveyor, after which the bread is packed and distributed.
(United State of America Patent No. US20050208183A1, 2005)

Figure 7: Automated Bread machine by Emru Desalegn

The other Ethiopian whose name is Dr. Wudneh Admassu introduced zelalem Injera machine in
Dallas and Washington, D.C., makes its daily bread. The company makes Injera using a
conveyor belt and a patented automated system. The machine can turn out 1000 pieces of Injera
an hour with only two employees stationed at the end of the process to package them, and then a
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few more load them onto a truck and ship them out daily, seven days a week. Wudneh applied
for a patent for his invention in 2002 and officially received it on June 20, 2006. (America, n.d.)

Figure 8: Zelalem Injera machine

Wassie Mulugeta, who owns the successful Wass Ethiopian restaurant in Hamilton, Ontario, has
been working the fundamental development change in the way we cook in Ethiopia. In 2007 he
invented a mitad for making Injera at home the old-fashioned way, one piece at a time. His
rotary baking system and method for making Injera received a patent in 2011, but so far he
hasn’t built one to produce mass produce injera. (America, n.d.)

Figure 9: Wassie Mullugeta’s Injera machine

Sisay Shimeles, who has degrees in structural engineering and international finance, was born in
Addis Ababa, educated in France, Germany and Russia, and now lives in state college, pa.,
where he’s worked with Pennsylvanian state university’s learning factory in the school of
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engineering to make an Injera machine for use in Ethiopia. After nearly five year of work, and
with the help of California-based designer Micheal Ma, Sisay’s Injera machine, patented in
2012.

Figure 10: Sisay Shimelis’ Injera machine

The U.S. Patent Office has awarded patents to a few other Injera machines, but as far as we can
tell, they haven’t yet been built and aren’t producing Injera except the so called Zelalem Injera
Machine.
The other type of machine, which is made by Chinese company (HY-910S-C Automatic
continuous Injera maker machine). Now a day, this is the best achieved machine in Injera baking
process. The machine has six sets (plates). Each baking plate is with a separate temperature
controller, control temperature accurately. The mold is made by high thermal conductivity of
material, rapid and uniform heating and saving cost. The whole machine is made by stainless
steel, and has adjustable baking speed and excellent thermal conductivity waffle iron produces
waffle quickly, evenly and uniformly. According to the company the maximum capacity of the
machine is producing ninety Injeras per hour and the machine can be used for making American
Waffles, Liege Waffles, Stroop waffles, Ice cream cone cookies, Tart cookies, etc…
(MACHINE,2018)

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Figure 11: HY-910S-C Automatic continuous Injera maker machine

The block diagram of HY-910S-C Automatic continuous Injera maker machine is showed is as
follow:

Figure 12: Block diagram for HY-910S-C Automatic Continuous Injera Maker Machine
Dosing pump
It is a type of positive displacement pump who’s characterized by a forced liquid for maximum
precise flow control. Draws with a fixed volume of fluid. Driven by an air actuator or an electric
motor. Dosing pumps are typically small. Dosing pump has several components which
contribute to proper functioning:
 Reservoir (container): the tanker is used to hold a material to be dosed.
 Dosing pump: the pump has an inlet, a dosing line and suction line. depending on its
application it is made from rubber, plastic and stainless steel.
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 Injector: it is a non-return type valve designed to inject the fluid into the flow. And
designed to avoid pump pressure and unequal dosing.
 Foot valve: as its named implies that it is one way or non-return type valve which is
attached to the suction line.
 Control system: to ensure for better and appropriate functioning of pump.
Types of dosing pumps
There are various types of dosing pumps (www.cannonwater.com, n.d.):
1. Diaphragm dosing pump: used a diaphragm mechanism. There are two types of
diaphragm pump (constant injection and pulse injection). Constant injection pumps have
a valve and piston in the inlet and outlet. Diaphragm pulse injection pumps are attached
to solenoid coils. Which is injects the fluid in pulse. These types of pumps have simple
design and are inexpensive.
2. Lobe pump: these pump features are meshing gear impellers. These pumps are more
suited for fluids which have high viscosity than fluid having low viscosity. They are not
designed for low flow rate.
Peristaltic pumps: nowadays, these pumps are more accurate than pumps mentioned above. They
feature a flexible bent tube, which allows the fluid to pass. A roller in the pump helps to control
the flow.
Dynamic seal
Are types seals used to produce a barrier between stationary or moving surface in linear,
oscillating and rotary motion application. These seals are used to separate or retain fluid,
pressure and removing contaminants. And also used prevent leakage post parts which are in
relative motion. Generally, there are two type dynamic seal (www.sspseals.com, n.d.):
1) Clearance seal: these positive clearance seals help inhibit contact between the mating
surfaces.
2) Contact seal: these seals create sealed interface by applying pressure to the surface.
Types of dynamic seal
There are various types of dynamic seal:
1) Hydraulic and pneumatic seals: used in reciprocating, rotary and oscillating motion
devices.
2) Oil and grease seals: used to prevent the lubricant leakage and intrusion of harmful
contaminants.
3) Exclusion seals: used to scrubbing retracting rod off dust, ice or other particles.
4) X-rings: these seals are also known as quad rings. Used for long stroke applications.
5) O-rings: designed to be bi-directional and are easy to install.
6) Piston rings: used to seal cylinders.

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7) U-cups: also known as a lipped seal. These seals provide stability in dry, reciprocating
and long stroke applications.
The materials used to construction a dynamic seal are metals and polymer or rubber depending
on its application.

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Chapter three
Material and Methodology
To achieve the objectives, we used both primary and secondary sources.
 The Primary sources
Among the primary sources we use:
 Visual observation
 Interview to local manufacturers
 The secondary sources
Among the secondary sources we use:
 Referring books
 Discussion with advisor
 Previous experience
 Referring different internet links.
We used the primary sources like interviews and visual observations to identify and analyze the
existing problems that should have to be solved.
The secondary sources like reference books, discussion with advisor, referring different internet
links are used for better designing, analyzing and manufacturing the machine.
Designing process phases:
 Phase I: conceptual design- it is an early stage in designing process, it’s important to
come up with a general concept before proceeding. Conceptual design is the process by
which the design is initiated, carried to the point of creating a number of possible
solutions, and narrowed down to a single best concept. It is sometimes called the
feasibility study. Conceptual design is the phase that requires the greatest creativity,
involves Research, Adaptation, Brainstorming, and Experience. This phase includes
collecting experimental data on several concepts that determine the characteristics and
feasibility of each of the concepts. The five steps of conceptual design are a follow .
1. Who am I designing for?
2. Competitor research.
3. Be inspired.
4. Sketch ideas.
5. Concept development.

 Phase II: Embodiment design- structured development of the design concept occurs in
this engineering design phase. This phase includes specific experiments on the design
concept selected. In this phase we will obtain experimental results that will determine the
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overall structure of the selected dispensing devices and polishing devices.

 Phase III: Detail design- in this phase the design is brought to the stage of a complete
engineering description of a tested and producible product. In this phase an appropriate
arrangement of the pattern is selected along with mechanism by which the desired
movement are achieved. After identifying movement mechanisms, the next step is to
design the mechanical components that bring it to life. this components design will
include gear system, linkages, shafts, control systems and more. The next step will
include simulating the system either using SOLID WORK simulation.

 Phase IV: Planning for Manufacture- A great deal of detailed planning must be done to
provide for the production of the design. A method of manufacturing must be established
for each component in the system. This phase includes manufacturing of a model that
represents the finished design.

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Chapter Four
Design and Analysis of Batter supply and Spreading mechanism
In this chapter, the design and analysis of the proposed solution is presented. The main
components of the Automatic Injera baking machine are introduced and discussed briefly. It has
four main subsystems. These sub-systems are motion creating components, the batter pouring
mechanism and polishing mechanism and the stove. Design of the batter pouring mechanism is
carried out along with the detail design of the polishing mechanism. The geometry analysis ofthe
motion creating components are determined.
The design of each mechanism is carried out by utilizing the basic design process. These
includes concept generation followed by concept selection in which various criteria are
considered. After a concept is selected, geometric analysis, force analysis and motor selection
are conducted to obtain the final solution which can be a basis for further improvements.
4.1 Design of Batter Supply Mechanism
The batter supply mechanism is the system which supplies the batter to the spreading
mechanism. It consists of various components including:
 Reservoir
 Hoses and pipes
 Pump
 Control Mechanism
 Valves
4.1.1 Reservoir
He reservoir to store the batter is positioned near the spreading assembly so as to make batter
delivery easy and available as required.
The batter is fed to the reservoir by various methods as the customers’ requirement. It could be a
continuous feeding or batch feed system. After the batter is filled in the reservoir it then metered
and drained from the reservoir.
The batter in the reservoir has various densities over the length of the reservoir (Demisse, 2020).
The density at the top of the reservoir is light since the amount of the solid part of the mixture is
less but the amount increases as we go down the height of the reservoir and becomes thick at the
bottom of the reservoir. This has a great effect on the pouring process because the amount of
solid part of the mixture varies during the cooking process which creates a problem of having a
variable thickness of Injera.
Numerous methods can be developed to avoid this type of problems. Two of them are discussed
below.
 Employing an agitator in the reservoir which mixes and creates a homogenous solution
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which ensures that the thickness of Injera gained after cooking is the same.
 Tapping the batter around half the height of the reservoir and feeding the reservoir with
batter at constant rate and maintaining the same level ensures that the amount of batter
supplied to the dispenser is approximately equal.
Depending on the need of the customer, either of the two solutions can be implemented. In our
case, it is vital to minimize the cost so, the best possible solution is the second one since it
ensures it can make the continuous production possible.
Features of the reservoir
 The reservoir is filled continuously making it possible to minimize the size of the
reservoir. The reservoir can be made with various shape but for manufacturing ease it can
be made with a shape of rectangular prism and frustum.
 At the bottom of the reservoir, there is a hole used for drainage since it is required during
cleaning and start up process.
 The outlet of the reservoir is placed at 35% of the height.
Reservoir sizing
Even though, in the above section, parameters which require attention are discussed, the first
parameter to be determined is the size of the reservoir. A rule of thumb for sizing a hydraulic
reservoir recommends that the volume of the reservoir shall be equal to three times the rated
output of the system's fixed-displacement pump or mean flow rate of its variable-displacement
pump. (Fundamentals of Hydraulic Reservoirs, 2012).
Traditionally it is determined that 16 liters of batter can be used to produce 25 Injera. Twenty-
five Injera means the cycle has passed 3 times during the cooking operation.
Calculating the average amount of batter volume to produce a single Injera is calculated as:
V_batter= (16 liters)⁄(25 injera)
V_batter= 0.64 liters⁄injera
To produce an Injera, it is required to supply a batter volume of 0.64 liters.
From an observation of the traditional Injera making process, it is observed that provided that
uninterrupted power is supplied, an Injera can be produced with 2.2 minutes (132 seconds).
Based on this data the time it takes for the machine to produce is specified and the hourly
capacity is determined. The hourly capacity for the machine is determined to be around 130
Injeras per hour.
This computation enables us to compute the amount of batter required to supply constantly to the
machine.
Amount of batter (in liters) required for an hour is calculated as:
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V_total=V_batter*130 Injeras⁄hour
V_total=0.64 liters⁄injera*130 Injeras⁄hour
V_total=83.2 liters⁄hour
Taking an assumption that the tank is refilled every 15 minutes. The required volume becomes
20.8 liters.
Taking the rule of thumb to determine the volume of the batter,
V_required=V*3=20.8 liters*3
V_required=62.4 liters
The reservoir should contain additional space equal to at least 10% of its fluid capacity. This
allows for thermal expansion of the fluid and gravity drain-back during shutdown, yet still
provides a free fluid surface for deaeration. In any event, NFPA/T3.16.2 requires that maximum
fluid capacity of the reservoir be marked permanently on its top plate. (Fundamentals of
Hydraulic Reservoirs, 2012)
Taking a design consideration factor of 1.15 for the air volume above the batter, the total volume
of the reservoir 72 liters.
The best way to prevent aerated fluid from being drawn into the pump is to prevent aeration of
fluid in the first place by paying careful attention to fluid flow paths, velocities, and pressures
when designing the hydraulic system.

Figure 13. Batter Reservoir

4.1.2 Dosing pump

The Dosing pump is the drive that transports the batter from the batter reservoir to the dispensing

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box which is attached to a vertical pipe. The dimensions and the overall size of the dosing pump
and piping system must be determined since it defines the flow time and flow property.
Piping systems have their own code and procedure of design when its application is for heavy
industries which have complicated systems and require complicated piping. For this project the
piping system is fairly simple and requires simple design aimed at sizing the pump power
required to push it.
The teff batter fluid is a shear thickening non-Newtonian fluid so its analysis must be based on
semi-empirical formulas and experimental data. But due to the shortage of studies that are done
on the flow of a batter fluid and the shortage of necessary appliances and platform for us to do
the analysis ourselves, the analysis performed on this paper is based on previously worked on
thesis documents of the school.
Volume of the batter needed to bake a single Injera was determined to be 6.4*10-4 m3. The
batter is stored in a reservoir and a hose connection is tapped at a certain point on the reservoir
and a control valve is used to control the flow of batter from the reservoir. After this control
valve a dosing pump is placed. This pumps out the batter from the reservoir passing through a
hose and control valve to a chamber which delivers the batter to a vertical pipe.
The time it takes for the batter delivery shall be synchronized with the time it takes for the batter
spreading system since the batter pumped by the dosing pump is spread after a time gap on the
cooking surface. From the Chinese HY-910-C Automatic Continuous Injera Making Machine, it
can be observed that the time to spread the batter is approximately 8 seconds.
Selection criteria
1. Flow rate
2. Pump head
3. Pressure
4. Horse power
5. Operating temperature
6. Accuracy
7. Cost
Pipe selection
Pipe material
In food and beverage industries, numerous machineries of the plant that are in direct contact with
food or food ingredients are made of materials that are compatible to the particular food type or
doesn’t have any harmful side effect. Food safe plastics and nun-corrosive metals are widely
used.
The other requirement is most if not all of the parts that are in contact with the food are supposed
to be made from the same materials in order to avoid corrosion and food contamination that is

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created when different materials are in contact and rub together.

For the vertical pipe and horizontal batter spreader, a metal is more preferable since rigidity is
required for effective dispensing action. Corrosive materials are excluded from this choice since
it comes in contact with the batter. Out of all metals, Stainless steels are widely used in food and
beverage manufacturing and processing industries for manufacture, bulk storage and
transportation, preparation and presentation applications (Moerman & Partington, 2014
Pipe dimensions
Stainless steel pipes come in different sizes i.e. Inner diameter Di, Outer diameter Do and
thickness. From [ANSI/ASME 36.19M - Stainless Steel Pipe] standard table a stainless steel of
the following dimensions is selected.
The selected stainless-steel pipe has the following dimensions:
OD (Outer Diameter): 13.7mm
WT (Wall Thickness): 1.65mm
ID (Inner Diameter): 10.4mm
Mass(weight/length)0.49 kg⁄m

Calculating the flow rate through the vertical pipe:

Volume of batter for a single Injera(V): 6.4*10-4 m3
Spreading time (t): 8 Seconds
3
volume (m )
Volumetric flow rate¿ …………........ equation 4.1
Time (s)
−4 3
6.4∗10 m −5 3
Volumetric flow rate¿ =8∗10 m /sec
8 sec

Area of the pipe is calculated to be by using inner diameter (ID):

2
A=π r ……………………………… equation 4.2
A = π(5.2mm)2 = 8.495*10−5 mm2

The flow rate is calculated to be 8 ∗10−5 m3 /sec . Based on this computing the velocity of the
batter in the vertical pipe,

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3
m
volume flow rate( )
Velocity(v) sec …………......... equation 4.3
¿
Area of pipe
3
m
−5
8∗10
Velocity(v) sec
¿ −5 2
=9.42 m/s
8.495∗10 m
Using the above calculated velocity value, it is possible to determine the characteristics of the
flow by computing the Reynolds number
ρvD
Re = …………………….. Equation 4.4
μ
Kg
ρ=1080.244 3 substituting the values in the above equation yield:
m
kg m
1080.244 ∗9.42 ∗10.4 mm
μ=1.4 Pa. s m
3
s
Re =
1.4 Pas
m
V =9.42 Re =75.59
s
D=10.4 mm
The Reynolds number is 75.59, since the number is much less than 2000 (75.59 << 2000), shows
that the flow is laminar.
Applying basic fluid principles on the batter flow
1. Conservation of mass: The mass of batter entering the vertical pipe is the same as the
mass of batter flowing in the horizontal batter spreader (A= 169mm2).
ṁ1 = ṁ2
ρ1 v 1 A 1=ρ2 v 2 A 2…………………. equation 4. 5

Since the flow is assumed to be incompressible, ρ1 is equal to ρ2 and the equation reduces to;
v 1 A1=v 2 A 2…………….... equation 4. 6

From this expression, it is possible to determine the flow velocity in the horizontal batter
spreader,
m −5 2 −5 2
9.42 ∗8.495∗10 mm =v2∗16.9∗10 mm
s

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m
V 2=4.74
s
The horizontal batter spreader has holes in the lower side to dispense the batter onto the cooking
surface. These holes are nine in number and varying diameter. Their diameter varies with their
radius since the cooking area to be covered by the holes vary as we go from the center to the
edge of the cooking surface.
The relation of the radial position of the holes and the radius of the holes are to be determined
using the circumference of the radial position. From these known parameters, the radius of the
holes is to be computed.
The radius of the cooking surface is 26cm. Considering a relief of 1cm on either side (center and
the edge of the horizontal batter spreader; leaving 24cm to be divided to nine holes. This makes
the distance between each hole to be 3cm. Considering the ratio between the circumference of
the radial position and the area of the dispensing holes is given by:
2 πR
2
=Constant
πr
The above relation can be reduced to: Where:
R
2
=Constant R = radial position
r
r = radius of the holes
Assuming the largest radius to be 10mm, and constructing the table of the radius of the holes and
using the above relation and present as:
Hole no. 1 2 3 4 5 6 7 8 9
Radial 1 4 7 10 13 16 19 22 25
position(cm)
Hole 2 4 5.3 6.3 7.2 8 8.7 9.38 10
Diameter(mm
)
Available tool 2 4 5.5 6.5 7 8 9 9.5 10
Diameter
(mm)

2. Conservation of Energy (Bernoulli’s equation)

The Bernoulli formula gives the energy per unit mass carried by the flow. It’s the summation of
2
p v
3 forms of energy i.e., the flow energy ( ), kinetic energy ( ) and potential energy(z).
ρg 2g

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2 2
p1 v1 p2 v2
+ + z 1 +h p −h¿ = + + z 2………………………equation 4.7
ρg 2 g ρg 2 g
Where:
ℎp = Dosing pump head
ℎlt = Head loss in pipe
P1 = P2 = 0, because the gauge pressure is measured, only atmospheric pressure is exerted on
the top of the reservoir at P1 and the batter fluid enters the dispenser chamber as a free jet at P2.
V1 = 0, because the batter movement (velocity) in the mini reservoir is almost zero or negligible
compared to the velocity in the pipe V2.
Z2 = 0, because the datum (the reference line) is at the end of the pipe point 2.
These known zero values reduces the equation to:
2
v2
z 1+ h p−h¿= ………………………………. equation 4.8
2g
z1 is the height of the batter in the reservoir. It can be calculated as the (80-35) % of the
maximum height.
Z1 = (80 − 35) % ∗ hmax
Z1 = (80 − 35) % ∗ 60cm
Z1 = 0.27m
Determining the total head loss
The total head loss in several serial connected pipes is algebraic sum of all the head losses due to
pipes in the network.
Major head loss: due to friction in pipes and ducts.
2
L V
h L =f ……………………………..equation 4.9
D 2g
For laminar flow, the head loss is proportional to velocity rather than velocity squared, thus the
friction factor is inversely proportional to velocity.
64
Circular pipes: f¿ ℜ and Re =75.59

64
f= =0.847
75.59

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Substituting the known values into the equation

2
m
0.847∗1.5 m∗(9.42 )
s
h L= 2
2 m
10.4 mm ∗9.81
s
h L =1.1m

Minor head loss: Due to bends, valves and fitting loss.

a. Valve loss (Gate valve)
A standard gate valve is used to control the Volumetric flow rate. The minor loss coefficient K is
selected from Table where K = 2. Using the equation to calculate the minor head loss.
2
v
hlm 1=k =2∗¿ ¿
2g
hlm 1=2.29 m

b. Fitting loss (Standard 900 threaded elbow)

A Flanged regular 900 elbow is fitted at the bend of pipe 2. The minor loss coefficient K is
selected from Table, where K = 0.3. Using the equation below to calculate the minor head.
2
m
2 0.3∗(4.74 )
v s
hlm 1=k =
2g 2∗9.81
hlm 1=0.34 m

The total head loss is calculated as:

htl = 1.1m + 2.9m + 0.34m = 4.34m
Substituting the values into reduced Bernoulli equation:
2
m
(4.74
)
s
0.27+ h p−4.34=
2∗9.81
hp = 5.215m

The head of the dosing pump required is calculated by assuming a factor of 1.15.
hdp = 1.15 ∗ 5.215m

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hdp = 6m
4.1.3 Dynamic seal
Selection criteria
The selection of dynamic seals basis on the following considerations:
 Type of application
 Environmental serviceability
 Ease of installation
 Reliability
 Resistance to extrusion between matting parts.
 Tolerance to the sealing medium
 Sealing orientation
 Dimensions
 Materials used to construct
 Operating temperature
 Maximum operated speed
 Maximum operated pressure
Parameters need to be determined
The following parameter needs to be determined for the proper functioning of dynamic seals:
 Internal diameter
 Outer diameter
 Axial cross-section
 Radial cross-section
4.2 Design of batter pouring mechanism
The batter pouring mechanism is the major component of the machine which dispenses the batter
on the “mitad” surface to be cooked.
Various concepts were developed and adopted from different sources to find a solution for this
function. From these concepts, the one that qualifies the design criteria is selected and passed on
to detail design process.
4.2.1 Concept generation of batter spreading mechanism
The main function of the batter spreading mechanism is to dispense the batter on the “mitad”
surface and distribute it evenly. Five concepts are developed and these concepts are discussed
below.
Concept 1: Pneumatic spreader
In this mechanism, the batter is measured and poured directly on central surface of the stove.
The flow control valve allows only specified amount of batter to pass through it. This amount of
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batter is set by the operator according to the thickness requirement of the customer.
The main air supplies 6 is used to deliver the air required for the spreading. Along with it the
batter is delivered to the vertical pipe through main batter hose 5. The vertical pipe 11 has two
concentrically arranged pipes in which the inner part delivers the batter on the surface of the
stove and the peripheral pipe section delivers the air.
The pneumatic spreader has air holes 10 which are arranged in a way that it is capable of
spreading the batter in the tangential and radial direction. The air holes are to be arranged on an
RHS which is bent with a certain angle from radial direction. This arrangement to spread the
batter in both tangential and radial directions which is achieved by spreading the poured batter
on the center and pushing it towards the periphery of the stove due to the rotation motion of the
assembly.

Figure 14. Pneumatic spreader.

Concept 2: L- shaped spreader with holes of different diameter
Specific amount of batter is supplied from the batter tank and delivered to the surface thought
the holes of horizontal pipe section 3. The flow rates of each spreading holes 2 are controlled by
the nozzle diameter.
The batter reaches the main batter pipe 1 which delivers the batter to be spread and it is
distributed to each of the holes. Since the holes have different diameter, the flow rate will be
different. Even distribution of the batter across the pan can be gained by examining and tuning
the diameter and space between the holes. The circular motion of the horizontal section is
created by stepper motor which rotates 3600. Since the shaft and the batter way rotate, they must
be supported by a cantilever bearing housing 5 from above.

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Figure 15. L-Shaped spreading with holes of different diameter.

Concept 3: Spiral rotating nozzle
Traditionally the even distribution and desired thickness of injera is achieved by rotating the cup
to pour the batter starting from the edge and reach the center after several rounds which is
achieved by rotating hand in a helical path. The frame is fixed on the base and a DC motor 4 is
mounted on it with its shaft connected to a rotating arm 5.
On the rotating arm, a small stepper motor 6 which drives a linear translating nut 7 on a screw 8
in which a flexible batter hose 9 is mounted. During pouring process, the nozzle 10 at the end of
the hose starts draining at the center and the whole arm starts to rotate and simultaneously
the DC motor is rotated so as to change the position of the nozzle radially. The rotation of the
two motors is synchronized to yield a spiral path.
This mechanism required using two electric motors (Stepper and DC motors) to create the
helical motion the same as the traditional way. The DC motor is used to rotate the horizontal arm
which holds the components holding the nozzle which delivers the batter to the surface of the
stove. The components on the arm are used to create the radially inward motion of the nozzle.
These two motions occur simultaneously thus creating the desired the helical motion.

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Figure 16. Spiral rotating nozzle.

Concept 4: Four rotating pipes with holes at different radius
Four pipes 3 are attached to the rotating vertical pipe which delivers the batter to the system.
Since there are four pipes directed radially outwards, there are four batter holes 5 positioned
various diameter to pour the batter on the stove. The whole assembly is rotated about 3600 or
full rotation to achieve complete spreading. The rotation is achieved by rotating the vertical pipe
4 which the delivers the batter to the stove 6.
Considering the injera to be made from four sections which are varied with radius. At different
radius, the amount of batter required varies due to geometry of a circle. Stepper motor 7 is to be
used since the rotation of the assembly shall be precise in order to achieve good quality injera.

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Figure 17. Four rotating pipes with holes at different diameters

Concept 5: L-shaped spreader with numerous flow valves
Known amount of batter is supplied to the spreading pipe and distributed via nozzles 5. Several
holes which are arranged radially can be used.
Required amount of batter is supplied to the main vertical pipe 3 and distributed to several
number of branches which have a manual control valve 4 to tune the amount of flow in order to
achieve a desired thickness. The manual control valves are used to tune the amount of batter
which is delivered to the stove.
The main vertical pipe 3 is rotated along the pan to deliver radially and the time to complete a
complete revolution is synchronized with the flow rate of the batter.
The stepper motor 6 is enabled to create rotational motion and deliver power through pulleys 7
and belt 8 attached to it. Thus, definite amount of batter is delivered to the cooking surface of the
stove 9 or pan.

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Figure 18. L-Shaped spreader with numerous flow valves

4.2.2 Evaluation of batter pouring mechanism
Concept selection is the process of evaluating concept which are formed in the concept
generation process by considering the customers need and other critical criteria. The selected
concept will pass on to the next process of concept testing, meticulous analysis or further
development. Concept selection is often performed in two stages as way to manage the
complexity of evaluating dozens of product concept. The two stages are concept scoring and
concept screening. Both stages follow a six-step process. The steps are
1) Prepare the selection matrix
2) Rate the concepts
3) Rank the concepts
4) Combine and improve the concepts
5) Selection one or more concepts
6) Reflect on the results and the process
4.2.3 Weights of selection criteria
To obtain the weight of the selection criteria, the following table is constructed.
Criteria rating
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The concepts generated on the concept generation stage will be will be rated using the above
data.
Table 1: Criteria rating

manufacturability
Maintainability

Ease of use

development

value (%)
Weighted
Cost of the

Safety

sum
Reliability

Durability
solution
Cost of

Size
- 1 0 0 1 1 0 0 1 4 11
Maintainability
Ease of use 0 - 0 1 0 0 1 1 0 3 8

Manufacturabi 1 1 - 0 0 1 0 1 1 5 14
lity

Cost of 1 0 1 - 1 1 1 1 1 7 20
development

Cost of the 0 1 1 0 - 0 0 0 1 3 8
solution

Size 0 1 0 0 1 - 0 0 0 2 6

1 0 1 0 1 1 - 1 1 6 16
Reliability
1 0 0 0 1 1 0 - 1 4 11
Durability
0 1 0 0 0 1 0 0 - 2 6
Safety
Total 36 100

Criteria rating
The concepts generated on the concept generation stage will be rated using the above data.
Relative performance Rating
Much worse than reference 1
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Worsen than reference 2

Same as reference 3
Better than reference 4
Much better than reference 5
Concept scoring
The concepts will be rated and weighted with each criterion and the concept with the highest
score will be selected.
Table 3: concept scoring for concept 1,2,3
Concept

Concept1 Concept2 Concept

3
Selection criteria Weight Rating Weighted Rating Weighted Rating Weighted
(%) scored scored scored
Maintainability 11 4 0.44 4 0.44 1 0.11

Durability 11 3 0.3 4 0.44 2 0.22

Development 20 3 0.60 4 0.80 2 0.40
cost
Ease of use 8 3 0.24 4 0.24 2 0.16
Size 6 3 0.18 4 0.18 3 0.18
Reliability 16 4 0.64 4 0.64 3 0.48
Safety 6 4 0.24 4 0.24 4 0.24
Cost of solution 8 3 0.24 4 0.32 2 0.16
Manufacturability 14 3 0.42 4 0.56 1 0.14
Total 3.33 3.86 2.09
score
Rank 2 1 5
Continu No Yes No
e

Table 4. Concept scoring for Concepts 4 and 5

Concept

Concept 4 Concept 5
Selection criteria Weight Rating Weighted Rating Weighted
(%) scored scored
Maintainability 11 3 0.33 3 0.33
Durability 11 3 0.33 3 0.33
Development 20 3 0.60 4 0.80
cost
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Ease of use 8 3 0.24 3 0.24

Size 6 3 0.18 3 0.18
Reliability 16 4 0.64 3 0.48
Safety 6 4 0.24 3 0.24
Cost of solution 8 3 0.24 3 0.42
Manufacturability 14 3 0.42 3
Total 3.22 3.26
Rank 4 3
Continue No No
According to the above concept selection, concept 2 got the highest score and has been selected
for further development
4.3 Geometry Analysis of batter spreading mechanism
The geometry analysis of batter spreading mechanism can be performed based on the concept
selected from the concept selection stage.
The selected concept is L- shaped spreader with holes of different diameter and the geometric
analysis of this mechanism is performed by considering the dimensions of the “mitad” and the
opening lid angle. Since the mechanism is a moving part, careful consideration shall be taken in
order to avoid any obstacle to the motion of the moving parts.
4.3.1 Components of the mechanism
Horizontal pipe
The diameter of the “mitad” is 52cm excluding the edges supporting the cooking surface. There
should be a clearance between the “mitad” surface and the rotary parts. Determining the
clearance to be 20mm ensures the batter do not splash when poured and gives it an optimal
distance not to touch the surface if loaded.
Vertical Pipe
The vertical pipe which receives the batter from the hose connected to the reservoir in near
vicinity make a way for the batter to reach the horizontal pipe. The main function of the
horizontal pipe is to dispense the batter onto the surface. We do not need the vertical pipe to
store much of the batter since there shall not be excess batter being poured.
The length of the vertical pipe excluding the batter receiving holes should be less than 25mm
making it possible to avoid excess batter during pouring.
Frame
The standing frame shall have a horizontal clearance distance of 10cm to avoid any
entanglement with the moving parts.
The horizontal part of the frame shall consider this clearance and the radius of the cooking
surface since it only has to support the mechanism to the center of the cooking surface.

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Motor spacers
The batter spreading mechanism and the motor driving the mechanism is coupled with a
coupling since problems like vibration and shortened bearing life should be avoided. The driver
motor requires a position to be installed. Its position is directly above the vertical pipe.
According to the motor type chosen, the number of the spacers varies. It is possible to determine
the height and diameter of the spacers after motor selection.
4.3.2 Motor sizing for batter spreading mechanism
The spreading mechanism requires an actuator which actuates the rotation of the L-shaped
component which is a selected concept for spreading mechanism. There are various choices
available for this purpose. Some of these are:
 DC Motor
 Servo Motor
 Stepper Motor
Stepper motor is suitable for this application since they can offer precise position control with an
advantage of precise speed control making them an ideal choice for automation (Helen, 2019).
Selection of stepper motor for the spreading mechanism.
It is essential to properly determine the size of the stepper motor required for a specific
application since it has a vital part by ensuring the desired performance, function, reliability
along with a reasonable cost of the equipment.
Before carrying out the selection procedure, there are many factors to be considered.
1) Mass of the batter used for one Injera: It depends on the viscosity of the batter
and the thickness requirements.
2) Mass and dimension if each part: can be gained from geometric analysis of the
mechanism.
3) Operating speed and time for one cycle.
4) Stopping accuracy: The stopping accuracy of the equipment can be satisfied with
5) Position holding: Position holding is not required since the mass of the load is
negligible when compared to the mass of the equipment.
6) Power supply: A stepper motor requires a DC-power supply which is available
since there is 24/12 V power supply to be installed in the control panel.
Motor sizing calculations are conducted to determine the main parameters of the motor, some of
these parameters are:
 Moment of Inertia
 Torque
 Speed
There are seven steps which can be used to determine the size of the stepper motor to be used
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(Repanich, 2006).
Step 1: Develop the torque and inertia equations that model the batter spreading mechanism.
During the operation of applying the batter on the Injera cooking surface of the machine, it takes
an average of 8 seconds to completely perform the spreading. Taking the acceleration time for
the stepper motor to be 0.15.
From the above data, it is possible to determine the peak angular speed (ω) of the spreading arm.
θ
ω= ……………………..Equation 4.10
tt

Where θ: Number of revolutions

tt: Total time taken
Substituting 1 rev (2π rad) as θ and 8 seconds tt into equation 10.
2 πrad
ω=
(8−2∗0.15) sec
ω = 0.816 rad/sec
Step 2: Determine the load motion profile(s) and calculate peak values.
The motion profile can be determined from the values of velocity at various time values. A
simple trapezoidal velocity profile and can be used to represent the motion profile of the
mechanism.
The trapezoidal motion profile can be segmented into 3 steps,
Firstly, an acceleration to reach peak angular speed segment
Secondly, a constant velocity segment
Thirdly, a constant deceleration to reach a zero velocity

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Figure 19. Motion profile for the motor

Step 3: calculate the mass moment of inertia's of the load mechanics
Any mass which is rotated by the motor is included in this calculation. The components listed
below are driven by the stepper motor.
 Vertical batter pipe
 Horizontal batter spreader
Vertical batter pipe: is the component which delivers the batter to the horizontal spreader and
rotates since it is directly connected to the stepper motor.

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Figure 20. Vertical Batter Pipe

This component is composed of two parts welded together; these parts are the shaft and the pipe.
Moment of inertia can be calculated separately for the two parts:
For the shaft (Diameter of 15mm)
π 4
J= ρL D1 ……………………………. Equation 11 where
32
π g 4
J= ∗8 3 ∗10 cm∗(1.5) ρ =Density (8 g/cm2)
32 cm
2
J=39.76 gc m L=length (10)
D=Diameter (1.5cm)
For the pipe (Inner diameter of 18.03mm and outer diameter of 21.34mm):
π 4 4
J= ρL( D2 −D1 ) ……………………………. Equation 12
32
π g
J= ∗8 3 ∗25 cm¿
32 cm
2
J=1.997 gcm

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Horizontal Batter spreader: This component receives the batter to be spread from the vertical
pipe and delivers it to the pan surface evenly.

Figure 21. Horizontal Batter Spreader

From the solid works 3D drawing, it is possible to determine its moment of inertia at the center
of mass of the part.
Ic = 21009.6 g-cm2
To compute the value of the moment of inertia at the rod end, the term (M*L2) shall be added to
account for the shift of rotation axis from the center of mass to the axis of rotation of the shaft.
IC=IZ+ML2 where
c
I c =21,009.6 gcm +304.6 g∗¿M=Mass of the part
2
I c =68,603.35 gcm L=Distance between two axes

Step 4: Computing the total moment of inertia

The total moment of inertia driven by the stepper motor can be obtained by summing up the
above numbers.
2 2
J T =39.76 gcm +199.74 gcm
J T =68,841.81

Step 5: Selecting a stepper motor which qualifies the torque requirements of the load
Taking Nema 23 stepper motor, Jm = 0.070 kg·cm2 = 70 g·cm2
Step 6: Calculate the torque requirement of the mechanism

( )
0.816
T a=( 68,842.81+70 )∗ =0.004711 N . m
0.15 where:
2

The peak torque can be calculated by summing up Ta and Tf(0.05N.m) T peak =Peak torque
T Peak =T a +T f ……………. Equation 4. 12 T a=Inertial torque

T peak =0.00471 N . m+0.05 N . M =0.05471 Nm T f = Frictional torque

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The peak torque is calculated is 0.05471 N.m

Step 7: Calculate the torque margin and check if the motor is capable of supplying the torque
required by the mechanism
(T ¿ ¿ aveilable−T peak )
Torque marigm ( @ speed ) = ¿ ………………Equation 4.13
T peak

(0.26 N . m−0.0571 N . M )
Tourque marign (@ speed )=
0.05471 N . m
Torque marign(@speed) = 375%
The torque margin value of 375% indicates that the selected drive (Nema 23) works fine.
4.4 Force and Strength of batter spreading mechanism
Force analysis performed to determine the amount of the load on the frames which carries the
whole mechanism and used to feeding of determined amount of fluid.
Static analysis of the frame is to be performed

Figure 22: Force analysis of spreading mechanism support

To ease the strength analysis of the frame support, it is possible to concentrate the weight of
the components with a force and moment at the tip of the support.
The concentrated force at the tip of the frame is calculated Where
FT = WS+WSH+WH+4W WS=Weight of stepper motor

FT = (1.8kg+0.0296kg+0.1164kg+4*0.056kg) *9.81m/s2 Wsh =Weight of vertical shaft

FT=21.3N WH=weight of horizontal spreader

The moment at the tip is created by the horizontal spreader:
M =W H∗L
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M =0.116 Kg∗0.13 m
M =0.015 Nm
Stress Analysis on the supporting frame
Stress analysis is performed by ANSYS software by using static analysis

4.5 Design of polishing mechanism

4.5.1 Concept generation on Polishing mechanism
There is a five-step concept generation method. The method is used to break a complex problem
in sub problems. The following five steps are applied to develop and refine their own unique
problem-solving style.
1. Clarification of the problems
2. Searching externally
3. Searching internally
4. Exploring systematically
5. Reflect on the result and the process
Clarification of the problem
The main purpose of this step is to clarify the problem consists of developing a general
understanding and then breaking the problem down into sub-problem if necessary.

Energy
Motion Injera
Heat Fully automatic Injera Signal
baking machine
Material
Signal

Figure 23: Black box model of polishing mechanism

Functional decomposition is only one of several possible ways to divide a problem into simpler
sub-problems.
Decomposition by sequence of user actions: is often useful for product with very simple
technical function involving a lot of user interaction.

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Store/ Convert to
Energy rotational
accept

Apply Remove
“Gomenzer” Store Polishing polishin
gomenzer gomenze
g
r

Signal Sensing
trigger

Figure 24. Functional decomposition of the polishing system

4.5.2 Concepts on applying “gomenzer”
Concept 1. A spreading powered by a fan
In this concept an automated fan is used to blow the “gomenzer” to the plate (injera mitad) from
the “gomenzer” reservoir which has holes on its lower face to pass the “gomenzer”.
The fan (1) is placed on the wall of the “gomenzer”(2) reservoir.
As it visible on the drawing. The side of the reservoir is pierced for holes that is able to evenly
distribute the “gomenzer” evenly on the surface of the stove.

Figure 25. A Spreader Powered by a Fan

Concept 2. A mechanical spreader actuated by lowering of the pad
A cylindrical gomenzer reservoir is fixed on fixed frame. The reservoir has holes that can let the
“gomenzer” pass and the length span of the reservoir is made to span the radius of the “mitad”.
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There is an oscillating plate which allows to pass the “gomenzer” to the plate (injera mitad). The
oscillating movement is applied during the up and down movement of the polishing pad. The
assembly is fixed on the frame by using a protruding structure on one side (4) and the structure
(4) is attached to the fixed frame (5) and reservoir cylinder (1). Curved plate (2) is made to
oscillate by using an actuation method of lowering the pad which touches the lever (3) and opens
up the holes of the “gomenzer” reservoir and lets it be applied.

Figure 26. A Mechanical Spreader actuated by lowering of the Pad

4.5.3 Concept on lifting and lowering the pad
Concept 1. A motor coupled with a screw and nut
A screw (3) coupled to the stepper motor (3) which limits the up and down movement of the
polishing pad. The polishing pad is always attached to the screw with nut (5). The whole up and
down mechanism is guided by a rail in which the linear bearing (6) slides on. When the screw
rotates, the nut is restrained not to rotate making it possible to move up and down. The
mechanism is robust and reliable.

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Figure 27. A motor coupled with a Screw and Nut

Concept 2. Double acting rod less cylinder
A rod less pneumatic double acting cylinder which is attached to fixed frame it allows the up and
down movement of the polishing pad. The up and down movement of the piston and attached
objects (2) is obtained by varying the pressure of the two sides of the cylinder (1). The whole
mechanism is fixed on a fixed frame (3).

Figure 28. Double acting Rod-less Cylinder

4.5.4 Concept on polishing pad
Concept 1. Half-length polishing pad
The purpose of the pad is to polish the plate and make it smooth. which help us easily removing
of the baked injera. The pad has a 40mm thickness. The part in contact with the surfaced to be
polished is lined with gauze cushioned with a spongy material inside in order to avoid
unnecessary strain on the surface.

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Figure 29. Half-Length polishing Pad

Concept 2. Full-length polishing pad
A full-length polishing pad has a length of plate’s diameter. It needs half rotation compared to
that of half-length polishing pad to achieve the same performance, but has equal thickness.

Figure 30. Full-Length polishing Pad

4.5.5 Removing “gomenzer”

Concept 1. A brush operated by a motor
A purpose of the brush is to remove an applied “gomenzer”. A brush is attached to a fixed frame
drive by a motor to remove the gomenzer. This concept is adopted from the wiper mechanism
which is used to clean the wind shield of vehicles. The crank (5) is driven by a DC motor (7). In
turn the crank drives the connecting rod (4) which is attached to the wiper brush (2) wiping the
surface of the “mitad” (1). It is a four bar linkage mechanism with a rotating crank and
oscillating link.

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Figure 31. A Brush operated by a Motor

Concept 2. A pneumatic blower
In this concept a pneumatic blower used to blow an applied “gomenzer” to remove from the
plate (injera mitad). This requires air supplied from a compressor. Assuming the machine is to be
installed in an industrial setup, compressor is available and distributes air via hose (3) to an air
directing curved pipe (4) with holes. These holes enable air to reach the surface of the “mitad” in
order to remove the used “gomenzer”.

Figure 32. A Pneumatic Blower

Concept combination table
Concept combination table provides a way to consider combination of fragment systematically.
There are two guidelines that make the concept combination process easier. First, if a fragment
can be eliminated as being infeasible before combining with other fragments. Second
combination table should be concentrated on the sub-problems that are coupled.
Concept one
This combination is composed of “gomenzer” applier powered by a fan and uses full-length pad
operated up and down by screw and nut. Finally, it gets rid of the used “gomenzer” by wiper
brush operated by a motor.
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Lowering and Removing

Applying Polishing
Lifting the “Gomenzer”
“Gomenzer” pad
pad

Spreading
powered by Screw Brush
a fan and Nut Half-length pad operated by
motor

Mechanical Rod less

Full-Length Pneumatic
spreader pneumatic
pad Blower
Cylinder

Figure 33: Block diagram for combination 1

Figure 34: Combination 1

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Concept Two
This combination is composed of “gomenzer” applier actuated by up and down movement of the
polishing pad and uses half-length pad operated up and down by a double acting rod less
pneumatic cylinder. Finally, it gets rid of the used “gomenzer” by a pneumatic blower.

Lowering Removing
Applying Polishing
and Lifting “Gomenzer”
“Gomenzer” pad
the pad

Spreading Half-length Brush

Screw
powered by pad operated
and Nut
a fan

Rod less
Mechanical Full-Length Pneumatic
Pneumatic
spreader pad
Cvlinder Blower

Figure 35: Block diagram for combination 2

Figure 36: Combination 2

Concept Three
This combination is composed of “gomenzer” applier powered by a fan and uses half-length pad
operated up and down by double acting rod less pneumatic cylinder. Finally, it gets rid of the
used “gomenzer” by wiper brush operated by a pneumatic blower.
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Lowering Polishing
Applying Removing
and Lifting pad
“Gomenzer” “Gomenzer”
the pad

Screw and
Spreading Brush
Nut Half-length
powered by a operated by
pad
fan motor

Rod less
Pneumatic
Pneumatic
Mechanical Full-Length Blower
Cvlinder
spreader pad

Figure 37: Block diagram for Combination 3

Figure 38: Combination 3

Concept Evaluation
Concept selection is the process of evaluating concept which are formed in the concept
generation process by considering the customers need and other critical criteria. The selected
concept will pass on to the next process of concept testing, meticulous analysis or further
development

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Weights of selection criteria

To obtain the weight of the selection criteria, the following table is constructed.
Table 5 Weights of selection criteria

Reliability
developm
installatio

Weighted
Durabilit
Maintain

Cost of
Ease of

Manufact

Safety
urability

Cost of

Sum
ent
ability

Size

yy
the
Maintainability - 1 0 0 1 1 0 1 1 5 14

Ease of 0 - 0 1 0 0 1 1 0 3 8
installation
Manufacturabil 1 1 - 0 0 1 0 1 1 5 14
ity

Cost of 1 0 1 - 1 1 1 0 1 6 17
development

Cost of the 0 1 1 0 - 0 0 0 1 3 8
solution

Size 0 1 0 0 1 - 0 0 0 2 6

1 0 1 0 1 1 - 1 1 6 17
Reliability
0 0 0 1 1 1 0 - 1 4 10
Durability
0 1 0 0 0 1 0 0 - 2 6
Safety
Total 36 100

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Criteria rating
The concepts generated on the concept generation stage will be rated using the following scale.
Table 6: Criteria rating
Relative performance Rating
Much worse than reference 1
Worse than reference 2
Same as reference 3
Better than reference 4
Much better than reference 5

Concept scoring
The concepts will be rated and weighted with each criterion and the concept with the highest
score will be selected.
Table 7. concept selection for concepts 1,2 and 3

Concept
Concept 1 Concept 2 Concept
3
Selection criteria Weight (%) Rating Weighted Rating Weighted Rating Weighted
Scored scored scored

Maintainability 14 4 0.44 4 0.44 1 0.11

Ease of
installation
8 3 0.33 4 0.44 2 0.22
Manufacturability
14 3 0.60 4 0.80 2 0.40

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Cost of 17 3 0.24 3 0.24 2 0.16

development

Cost of the 8 3 0.18 3 0.18 3 0.18

solution
Size 6 4 0.64 4 0.64 3 0.48

Reliability 17 4 0.24 4 0.24 4 0.24

Durability 10 3 0.24 4 0.32 2 0.16

Safety 6 3 0.42 4 0.56 1 0.14

Total score 3.332 2.095
3.861
rank
Continue No Yes No

Concept 2 has been selected by using the above concept selection criteria. Concept 2 will pass
for further development.
Geometry Analysis of the polishing mechanism
Polishing pad
The selected concept combination consists of a half-length polishing pad, the pad shall be made
to polish approximately half of the “mitads” diameter. The average “mitad” diameter is
considered to be 52 cm thus making the radius 26cm up to the cooking edge.
A polishing pad is a tool that can be used to apply polish to a surface and process it in a
mechanical way. (Rooij, n.d.)
The selected concept combination consists of a half-length polishing pad, the pad shall be made
to polish approximately half of the “mitad s” diameter. The average “mitad” diameter is
considered to be 52 cm thus making the radius 26cm up to the cooking edge.
Clearance between the surface and the polishing pad shall be large enough to ensure that the
“mitad” edge do not touch the pad during the revolutionary movement of the eight stove and

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shall be small enough that the pad do not touch the lid. Assuming the clearance to be 30mm.

The clearance between “mitad” surface and the polishing pad determines the motion of the
pneumatic cylinder that lifts and lowers the whole mechanism.
The material to be used for the polishing pad has to have some properties. Some of these are:
 It shall have an intermediate smooth surface so that it does not scratch the surface.
 It shall have easily deformable so that it could fit the shape of the “mitad”.
 It shall have fair resistance to heat so that it does not heat up and burn during
contact with the “mitad” surface
Although all polishing pads are designed to process the polishing agent in a very controlled and
stable way, there are many different types of materials used for the polishing pad. Each material
has its own pros and cons. (Rooij, n.d.)
 Foam polishing pads
 Microfiber polishing pads
 Wool polishing pads
 PE fiber polishing pads
 Wet-sand pads
Based on the above criteria listed, wool polishing pads is the ideal choice to go with. It is fairly
smooth and naturally flame resistant and offers a greater level of safety than any other fibers
available. (IWTO, 2020
Since the polishing pad is required to be deformable, it is essential that it is reinforced by a foam
and wrapped with wool. The color of the polishing pad usually used for light polishing pads
(Rooij , n.d.).
Taking the width of the polishing pad to be 50mm and height of the foam to be 25mm and
attaching it to a plate which is connected with a shaft driven by a DC motor.
Motor sizing for polishing mechanism
The Polishing mechanism requires an actuator which actuates the rotation of the pad which is
attached to the shaft driven by an actuator. There are various choices available for this purpose.
Some of these are:
 DC Motor
 Servo Motor
 Stepper Motor
DC motor is suitable for this application since they can offer the required torque with low speed
and they are relatively cheaper than the other alternatives which are better choices if precision is
a necessity which is not in this case. Geared DC motor is an ideal actuator to use.

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Selection of DC motor for the spreading mechanism.

It is essential to properly determine the size of the stepper motor required for a specific
application since it has a vital part by ensuring the desired performance, function, reliability
along with a reasonable cost of the equipment.
Before carrying out the selection procedure, there are many factors to be considered.
1. Mass of the polishing pad used for one Injera along with the sheet metal holding the
2. Mass and dimension if each part: can be gained from geometric analysis of the
mechanism.
3. Operating speed and time for one cycle.
4. Stopping accuracy: The stopping accuracy of the equipment can be satisfied with
5. Position holding: Position holding is not required since the mass of the load is negligible
when compared to the mass of the equipment.
6. Power supply: A stepper motor requires a DC-power supply which is available since
there is 24/12 V power supply to be installed in the control panel.
Motor sizing calculations are conducted to determine the main parameters of the motor, some of
these parameters are:
 Moment of Inertia
 Torque
 Speed
There are seven steps which can be used to determine the size of the stepper motor to be used
(Repanich, 2006).
Step 1: Develop the torque and inertia equations that model the polishing mechanism. During the
operation of polishing action, there is process of adding the “gomenzer” while lowering the
polishing pad followed by the action of polishing with the pad. After the cooking surface is
polished and the polishing pad shall be raised and the “gomenzer” shall be removed by the
blowing action.
Taking an assumption that it takes two seconds each to lower down and lift up the polishing pad.
The primary action of the machine is to cook an Injera; therefore, it takes approximately 4sec to
perform the polishing action.
From the above data, it is possible to determine the peak angular speed (ω) of the spreading arm.
θ
ω= …………………………………. equation 4.16
tt

Where θ: Number of revolutions

tt: Total time taken
Substituting 1 rev (2π rad) as θ and 8 seconds tt into equation 1.

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2 πrad
ω=
(4−2∗0.15)sec
rad
ω=1.698
sec
Step 2: Determine the load motion profile(s) and calculate peak values.
The motion profile can be determined from the values of velocity at various time values. A
simple trapezoidal velocity profile and can be used to represent the motion profile of the
mechanism.
The trapezoidal motion profile can be segmented into 3 steps,
Firstly, an acceleration to reach peak angular speed segment
Secondly, a constant velocity segment
Thirdly, a constant deceleration to reach a zero velocity

Figure 39: Motion profile for the polishing pad

Step 3: calculate the mass moment of inertias of the load mechanics
Any mass which is rotated by the motor is included in this calculation. The components listed
below are driven by the DC motor.
 Vertically oriented shaft
 Polishing pad
Vertically oriented shaft: is the component which is coupled with the DC motor using coupling.
The shaft is connected with the polishing pad on the other end.

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Figure 40: Vertically oriented shaft

This component is composed of two parts welded together; these parts are the shaft and the
pad holding plate.
Moment of inertia can be calculated separately for the two parts: For the shaft (Diameter of
15mm)
π 4 π 4
J= ρ L1 D 1 + ρL D2 ……………….. Equation 4.17 Where:
32 32
π
∗8 g
32 ρ = Density (8g/cm3)
J= 2
¿
cm
2
J=10857.5 gc m L = Length (10cm)
D = Diameter (1.5 cm)
The pad and pad holding plate:

Figure 41: Pad and pad holding plat

Taking an assumption that the polishing pad has a negligible effect on the moment of inertia due
to lower density material (Polyurethane Foam Flexible) compared to the material pad holding
plate (AISI 1020 steel).

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ρpolyurethane <<ρAISI 1020 steel

Kg Kg
16 3
≪7930 3
m m
It is possible to calculate the rotational moment of inertia using the mass and dimensions
available and the relation of rotational moment of inertia for a prism.
2 2
m(a +c )
I= ……………………. equation 4.18
12
2 2
205 g (50 mm +260 mm )
I=
12
2
I =11975.41 gcm
To compute the value of the moment of inertia at the plate end, the term (M*L 2) is added to
account for the shift of rotation axis from the center of mass to the axis of rotation of the shaft.
2
I c =I Z + ML …………………….. equation 4.20 where:
2
I c =11975.41 gcm M = Mass of the past
2
I C =39099.89 gcm L = Distance between two axes

Step 4: Computing the total moment of inertia

The total moment of inertia driven by the DC motor can be obtained by summing up the above
numbers.
2 2
J T =10857.5 gcm +39099.89 gcm
2
J T =49957.39 gcm

Step 5: Selecting a stepper motor which qualifies the torque requirements of the load
Taking Nema 23 stepper motor, Jm = 0.070 kg·cm2 = 70 g·cm2
Step 6: Calculate the torque requirement of the mechanism

( )
1.698
T a=( 49957.39+70 )∗2 π∗ =0.007116 N . m
0.15
2

The peak torque can be calculated by summing up Ta and Tf(0.05N.m)

Tpeak = Ta + Tf………………………………equation 4.21
Tpeak = 0.007116N.m + 0.05N.m =0.0576N.m
where:

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DESIGN AND ANALYSIS OF MULTI-PURPOSE ELECTRICAL AUTOMATED BAKEING INJERA
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Tpeak = peak Torque

Ta = Inertial Torque
Tf = Frictional Torque
The peak torque is calculated is 0.0576N.m
Step 7: Calculate the torque margin and check if the motor is capable of supplying the torque
required by the mechanism

Torque HYPERLINK mailto:𝑀𝑎𝑟𝑖𝑔𝑛#@𝑠𝑝𝑒𝑒𝑑#=#(#𝑇#𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒#−#𝑇#𝑝𝑒𝑎𝑘#)##𝑇#𝑝𝑒𝑎𝑘##........................

................................equation 4.22
( 0.26 N . m−0.0576 N . m )
Torque Marign ( @ speed ) =
0.0576 N . m
Torque Marign ( @ speed ) =351.4 %
The torque margin value of 351.4% indicates that the selected drive (Nema 23) works fine

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Chapter Five
Result and Discussion
5.1 Observation
An observation is a data collection method, by which you gather knowledge of the researched
phenomenon through making observations of the phenomena, as and when it occurs. So, we tried
to focused on how Injera” is made, starting from batter spreading to the retrieve process. To
understand full process, we have to observe Injera” bakery associations. So, we went to Mrs.
Etsegenet small restaurant which is around our college. First, we ask her willingness, after she let
us in. We observed a worker at the restaurant baking Injera” with two electric Injera” baking
machine.
During our observation, we noticed that the timing of each process is done by experience. The
worker keeps track of the time in her mind without looking at her watch.
Six steps which are involved in the process are presented below as follows:
1. Spreading the batter
2. Closing the lid
3. Open the lid
4. Retrieve the baked Injera”
5. Heat the pan
6. Polish the pan
These steps of the process are repeated as a cycle until we are done with baking.
The time that these data were taken was between 8:30 PM and 9:00 PM and on the other day
between 11:00 PM and 11:25 PM, because the power level at various time of the day fluctuates.
The number of Injera” produced per hour is approximately 30 Injera” per hour using two Injera”
baking machine. On the other day of observing we notice that the two pans are in different
capacity, one is slow while the other is fast than the other. So, we take data for each separately as
follow:
The following data is collected at 8:30- 9:00 pm local time.
Table 8: Data collected at 8:30-9:00
Data 1 Data 2 Data 3 Data 4 Average

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Time Fraction Time Fraction Time Fraction Time Fractio Average Average
n time fraction

Spreadi 17 s 0.071 20 s 0.079 21 s 0.089 19 s 0.079 19.25 s 0.079

Ng
Batter

Time to 60 s 0.253 75 s 0.297 70 s 0.299 68 s 0.285 68.25 s 0.283

close
the lid

Time to 90 s 0.379 86 s 0.341 87 s 0.371 87 s 0.365 87.5 s 0.364

open the
lid

Time to 58 s 0.244 55 s 0.218 45 s 0.192 52 s 0.218 52.5 s 0.218

retrieve

Time to 12 s 0.050 16 s 0.063 13 s 0.055 12 s 0.050 13.25 s 0.54

heat the
stove

Total 237 252 234 238 240.25

Time s s s s s

The following data is collected for slower pan at 11:00- 11:15 pm local time.
Table 9: Data collected at 11:00-11:15
Data Data Data Average
1 2 3

Time Fraction Time Fraction Time Fraction Average Average

time fraction

Time to 14 s 0.106 14 s 0.097 10 s 0.072 12.66 s 9.1

heat the
stove

Time to 22 s 0.167 22 s 0.153 40 s 0.289 28 s 20.2

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apply “
Gomenzer”
and polish
the stove

Time to 16 s 0.121 25 s 0.173 18 s 0.131 19.66 s 14.1

spreading
Batter

Time to 70 s 0.530 45 s 0.326 42 s 0.305 52.33 s 38.1

close the
lid

Time to 10 s 0.076 35 s 0.251 28 s 0.203 24.33 s 17.2

open the
lid

Total 132 s 145 s 138 s 138.33 100

s

The following data is collected for faster pan at 11:15- 11:25 pm local time.
Table 10: Data collected at 11:15-11:25
Data Data Data Average
1 2 3

Time fraction Time fraction Time Fraction Average Average

time fraction

Time to 25 s 0.190 25 s 0.203 21 s 0.168 23.66 s 0.187

heat the
stove

Time to 25 s 0.190 19 s 0.154 23 s 0.184 22.33 s 0.176

apply “
Gomenzer”
and polish
the stove

Time to 30 s 0.229 16 s 0.130 19 s 0.152 21.66 s 0.170

spreading

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batter

Time to 34 s 0.259 46 s 0.373 45 s 0.360 41.66 s 0.330

close the
lid

Time to 17 s 0.129 17 s 0.138 17 s 0.136 17 s 0.134

open the lid

Total time 131 s 123 s 125 s 126.33 s

Average time taken to retrieve an Injera can be calculated to be the average of eight
observations. Computing the average value yields an average baking time of 132 seconds.
5.2 Result
Major results on batter delivery and supply mechanism
 Volume of the reservoir is determined to be 72 liters with a shape of rectangular prism
connected with a frustum pyramid.
 The Volumetric flow rate of the dosing pump is determined to be 8 ∗ 10−5 m3⁄sec a
head of 6m.
 L-shaped spreader concept is selected among other mechanisms and
 The diameter of the holes of the horizontal spreader is determined and tabulated as
follows:
Table 11: Spreader hole dimension
Hole no. 1 2 3 4 5 6 7 8 9
Hole 2 4 5.3 6.3 7.2 8 8.7 9.38 10
Diameter(mm)
Available tool 2 4 5.5 6.5 7 8 9 9.5 10
Diameter
(mm)

 Motor selection was conducted for the spreading mechanism: Nema 23 is selected to
perform the operation of rotating the horizontal spreader.
 Frame support is analyzed with simulation software and checked for deformation and
stress. The result depicts that the material for frame is safe.

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Major results on polishing mechanism

 Concept combination is conducted on the various subsystems of the mechanism and a
half polishing pad, stepper motor driver, a mechanical “gomenzer” dispenser and
pneumatic remover.
 Nema 23 stepper motor drive is selected to perform the action of rotation

5.3 Cost Analysis

L-Shaped spreading with holes of different diameter of cost analysis

no Component type length diameter price

1 belt Flote 480 mm - 249
(NN450)
2 Steper motor hybrid - - 768
3 Main batter pipe Stainless 340 32 mm 2760
steel
4 Horizontal pipe Stainless 180 32 mm 460
steel
5 pulley Hybrid - 40 mm 454
plastic
6 Cantilever boaring steel - - 335
7 stand steel 440mm - 155
total 5181#

stove

no component type diameter length price

1 Roller plastic 50 mm - 175
2 Lid Aluminum - 98 mm 167.90
3 Stove Mitad 520 mm - 500
4 Stove cover Stainless steel 530 mm 1.23 sheet 460

Total 1300.90 #

The machine has 8 stove

 8*1300.90
10,407.20 #

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DESIGN AND ANALYSIS OF MULTI-PURPOSE ELECTRICAL AUTOMATED BAKEING INJERA
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Better Reservoir =72 litters

= hydrolic Reservoir (2012)
= Stainless steel sheet
= Thickness 2mm
Litters Type Thickness price
Batter reservoir 72 stainless 2mm 2300

Combination of the polishing mechanism

no component price
1 Spreading 611
2 Double acting red less cylinder 3,634
3 Half length polishing pad 286
4 Phinomatic blower 1,150
5 Steper motor 768
6 Stand 155
Total 6,604

The Total price is 25792.90 3#

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5.4 Conclusion and Recommendation

5.4.1 Conclusion
Traditionally Injera is cooked by using bio mass fuel which is starting to be replaced by an
electric heating source. Through time there is a change and development due to technological
advancement and the increased need of mass production of Injera is noticeable due to changing
lifestyle of users.
It is impossible to conduct mass Injera production with the current system of spreading and
polishing methods which calls for automation of the system. In order to achieve the mass
marketable quality of Injera, standardization is required. The study of flow analysis is quite
difficult since there is data shortage on the fluid properties of “teff” batter.
The batter spreading, batter delivery and polishing mechanisms designed can be used to achieve
the need for the automation of continuous mass Injera production.
The price of China machine also expensive more than our in machine. The material of china
machine used more stainless steel equipment all most fully.but In our machine less stainless
and aluminum plastic. And it is easy to buy the machine.
5.4.2 Recommendation
 Intensive research on the flow properties of “teff” batter shall be performed for further
advancement in this area.
 Further development in the automation of the whole mechanism shall be performed
thoroughly.
 An extensive experimental analysis should be done on spread ability of “teff” batter as
it’s dropped on a hot surface.
 The polishing mechanism of the system shall be further developed since there is not
much done and researched on polishing mechanism.

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DESIGN AND ANALYSIS OF MULTI-PURPOSE ELECTRICAL AUTOMATED BAKEING INJERA
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gaps. Energy for Sustainable Development, 1.
Ali, A. (2018). Design and Development of Semi-Automatic Injera Making Machine For Family
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Ali, A. (2018). Design and Development of Semi-Automatic Injera Making Machine for
Households in Ethiopia. International Research Journal of Engineering and Technology, 1-2.
America, E. F.-M. (n.d.). Ethiopian Food- Mesob Across America. Retrieved from
https://ethiopianfood.wordpress.com/2013/09/01/making-injera-the-new-fashioned- way/
Demisse, E. (2020, November 16). Batter distribution in the reservoir. (W. Yilma, & B. Haile,
Interviewers)
Desalegn, E. (2005). United State of America Patent No. US20050208183A1.
Diehl, R. J. (may, 2017). The Development of an Energy Efficient Electric Mitad for Baking
Injeras in Ethiopia.
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Girma, M. (2016). United State of America Patent No. US10092011B1.
Helen. (2019, March). Choosing the Right Motor for Your Project – DC vs Stepper vs Servo
Motors. Retrieved from Latest with seed
studio:https://www.seeedstudio.com/blog/2019/04/01/choosing-the-right-motor-for-your-
project-dc-vs-stepper-vs-servo-motors/
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HAWASSA UNIVERSITY IOT DEPARTMENT OF MECHANICAL ENGINNERING
DESIGN AND ANALYSIS OF MULTI-PURPOSE ELECTRICAL AUTOMATED BAKEING INJERA
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houses of Southern Ethiopia. pp. 1-2.

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Appendix
1. Moody curve

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DESIGN AND ANALYSIS OF MULTI-PURPOSE ELECTRICAL AUTOMATED BAKEING INJERA
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2. Minor head loss coefficient for common types of valve and fittings
Type of Component or Fitting Minor Loss Coefficient (K)
1 Flanged Tees, Line Flow 0.2
2 Threaded Tees, Line Flow 0.9
3 Flanged Tees, Branched Flow 1.0
4 Threaded Tees, Branch Flow 2.0
5 Flanged Regular 90o Elbows 0.3
6 Threaded Regular 90o Elbows 1.5
7 Threaded Regular 90o Elbows 0.4
8 Flanged Long Radius 90o Elbows 0.2
9 Threaded Long Radius 90o Elbows 0.7
10 Flanged Long Radius 90o Elbows 0.2
11 Flanged 180 o Return Bends 0.2

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12 Threaded 180 o Return Bends 1.5

13 Fully Open Globe Valve 10
14 Fully Open Angle Valve 2

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