TABLE OF CONTENTS
CANDIDATE’S DECLARATION II
ABSTRAK V
ABSTRACT VI
TABLE OF CONTENTS VII
LIST OF FIGURES XI
LIST OF TABLES XIV
LIST OF SYMBOLS XV
CHAPTER 1 1
INTRODUCTION 1
1.0 INTRODUCTION
1 1.1
BACKGROUND 2
1.2 PROBLEM STATEMENTS
4 1.3
OBJECTIVES 5
1.4 SCOPES
6
CHAPTER 2 7
LITERATURE REVIEW 7
2.0 INTRODUCTION
7 2.1
BACKGROUND 8
2.1.1 Palm Oil Industry in Malaysia
8 2.1.2
Oil Palm Mechanization 10
2.2 INTRODUCTION TO THE OIL PALM
12
2.2.1 Historical Background
12
2.3 CHARACTERISTICS OF OIL PALM
13
2.3.1 Canopy
14
2.3.2 Fruit and Bunches
15 2.3.3
Stem 16
2.3.4 Root System
17
2.4 HARVESTING
19
2.4.1 The Technology
19
CHAPTER 3 21
METHODOLOGY 21
3.0 INTRODUCTION
21 3.1
EXPANSION OF PROBLEM STATEMENT 22
3.2 FLOWCHART
24
3.3.1 Flow chart
25
3.4 PROCESS FLOW EXPLANATIONS
26
3.4.1 Identify problem statement
26 3.4.2
Literature review 26
3.4.3 Idea development
28 3.4.4
Concept Generation 29
3.5 DATA COLLECTION
29
3.5.1 Product Comparison
30 3.5.2
Study on Previous Research 30
3.5.3 Survey
31
3.6 HOUSE OF QUALITY
31
3.6.1 Voice of Customers
33 3.6.2
Technical Requirement 33
3.6.3 Planning Matrix
34 3.6.4
Interrelation Matrix 34
3.6.5 Technical Correlation Matrix
35
3.7 PRODUCTION DESIGN SPECIFICATION PDS
37 3.8
MOPHOLOGICAL CHART 38
3.8.1 Exterior Shape Design
39 3.8.2
Impeller 39
3.8.3 Disc Holder
39 3.8.4
Cutting Disc 39
3.8.5 Pressurized Air Distributor
39
3.9 CONCEPT GENERATION
40 3.10
DESIGN LIMITATION FACTORS 41
3.11 OBJECTIVE TREE
42 3.12
SCORING METHOD 43
3.13 FINAL CONCEPT
44
CHAPTER 4 45
PROTOTYPING 45
4.0 INTRODUCTION
45 4.1
PROTOTYPE DEVELOPMENT PROCESS 46
4.2 DETAIL DESIGN
47
4.2.1 Lower Casing
47 4.2.2
Upper Casing 48
4.2.3 Axial Impeller
50 4.2.3
Air Distributor 50
4.2.4 Impeller Sub
50
4.3 FUSED DEPOSITION MODELLING
51
4.3.1 Processes
53 4.3.2
Technical Details 53
4.4 SILICONE MOLDS
54
4.4.1 Procedure Steps
55 4.4.1.1
The Inspection of Master Pattern 55
4.4.1.2 Box Construction
56 4.4.2
Making the male mold 59
4.4.2.1 The Silicone Mixing Process
59 4.4.2.2
Inhibition of cure 61
4.4.3 Typical Properties
61 4.4.4
Making the female mold 61
4.4.4.1 Sprue Setting
62
4.5 PART CASTING
63
4.5.1 The Polyurethane Mixture
63 4.5.2
Solidify Forming 64
4.6 LATHE MACHINING
65 4.7
MAKING SCREW HOLES USING DRILL PRESS 68
4.8 CUTTING THE MATERIAL USING BANDSAW
69 4.9
ASSEMBLY PROCESS 71
4.10 FINISHING
74
4.10.1 Spraying
74
CHAPTER 5 75
ANALYSIS AND DISCUSSION 75
5.0 INTRODUCTION
