Design And Development Of Smart Storage System For Clothes Drying.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Design and Development of
Smart Storage System
for Clothes Drying
Thesis submitted in accordance with the requirements of the
Universiti Teknikal Malaysia Melaka for the Bachelor Degree of
Manufacturing Engineering (Engineering Material)
By
Zamri Bin Ahmad
Faculty of Manufacturing Engineering
May 2008
APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as fulfillment of the
requirement for the Bachelor of Manufacturing Engineering (Engineering Material) with
Honours. The members of the supervisory committee are as follows:
……………………………………………….
Mr. Syahrul Azwan Bin Sundi @ Suandi
(PSM Supervisor)
Faculty of Manufacturing Engineering
3
DECLARATION
I hereby, declare this thesis entitled “DESIGN AND DEVELOPMENT OF
SMART STORAGE SYSTEM FOR CLOTHES DRYING” is the result of my
own research except as cited in the references.
Signature
:
……………………………….
Author’s Name
:
Zamri Bin Ahmad
Date
:
May 8th 2008
4
ABSTRACT
It is a routine for one to wash and dry their denim and clothes through out the year. As a
conventional method sun energy is using as a major source to dry clothes. Unfortunately,
nature will never be the same all the way. It is always sometimes raining and various
seasons. Besides, human now are really busy with their job and most of the family are
now working parent. Thus, a smart drying storage is proposed to encounter these
problems. To implement the development of this prototype, many steps have to perform.
Starts with project planning, information searching and then further with prototype
construction, there are been manage well until the recent progression that lead the way to
produce a final functional prototype of Smart Storage System. By analyze and study
about the previous researches, its help more to understand the concept and the application
to be use for this prototype. In addition to have a good result of this project, the
information about drying mechanism is also gathered from the published books, articles
and journals as guidelines. Through the literature review in the chapter 2, the idea of
design concept is contributed from the current product that available in the market place.
Some new idea also had been generate by the good example of the current used products.
Furthermore, the conceptual design presented for design development is selected by
according to the screening concept. Progression will continued for the next development
phase by referring to the methodology guidelines in the chapter 3 in this report. All of
additional information regarding to the result of Smart Storage System development is in
chapter 5 and 6.
i
ABSTRAK
Adalah menjadi rutin bagi seseorang itu mencuci dan mengeringkan pakaian mereka
sepanjang tahun. Kaedah konvensional menggunakan cahaya matahari sebagai sumber
utama bagi tujuan pengeringan pakaian. Namun begitu, cuaca tidak akan sama sepanjang
masa.. Hujan pada satu-satu masa dan musim yang pelbagai. Disamping itu kehidupan
manusia pada masa kini semakin sibuk dengan pekerjaan. Oleh yang demikian, sistem
penyimpanan pintar dicadangkan bagi mengatasi masalah ini. Bagi melaksanakan
pembangunan prototaip ini, banyak langkah perlu dilaksanakan. Bermula dengan
perancangan projek, pencarian maklumat dan kemudian terus kepada pembinaan
prototaip, dengan pengurusan yang baik sehingga kepada kemajuan mutakhir untuk
mengeluarkan sebuah prototaip system penyimpanan pintar. Analisis dan kajian
mengenai penyelidikan yang lalu, dapat membantu lagi bagi memahami konsep dan
aplikasi yang diperlukan dalam pembinaan prototaip. Tambahan pula untuk memiliki satu
keputusan yang baik bagi projek ini, maklumat tentang mekanisme pengeringan turut
dikumpul melalui buku rujukan, artikel mahupun jurnal sebagai rujukan tambahan.
Melalui kajian persuratan pada bab 2, idea untuk merekabentuk dijana melalui produk
yang sedia ada di dalam pasaran. Rekabentuk konsep yang dipilih bagi projek ini dipilih
melalui kaedah skrin. Perlaksanaan peringkat seterusnya adalah mengikut metodologi
pada bab 3 dan informasi berkenaan keputusan pembangunan prototaip SSS pada bab 5
dan 6.
ii
ACKNOWLEDGMENTS
First at all, Alhamdulillah and praise to Allah,
I manage to complete my Final Year Project – Projek Sarjana Muda.
I also would like to offer thanks and deepest gratitude from the bottom of my heart for all
the support, encouragement and inspirations I obtained through out the duration of this
project. The help rendered to me priceless, be it from the smallest of its kind to the
largest. They include;
My supervising lecturer, Mr Syahrul Azwan Suandi of which we had a good working
relationship, and who offered tremendous help and encouragement,
My family, who inspired me whether through the storm and carry on,
My friends and peers who are good companions in times of need.
Wassalam….
Zamri Ahmad
iii
TABLE OF CONTENTS
Abstract
i
Abstrak
ii
Aknowledgements
iii
Table of Contents
iv
List of Figures
viii
List of Tables
x
List of Abbreviations, Symbols, Specialized Nomenclature
xi
CHAPTER 1: INTRODUCTION
1.1
Introduction
1
1.2
Problem Statements
2
1.3
Objectives
3
1.4
Scope of study
3
1.5
Conclusion
3
CHAPTER 2: LITERATURE REVIEW
2.2.
2.1
Introduction
4
2.2
Evaporation Process
4
2.2
Types of dryer
5
2.2.3 Traditional dryers
5
2.2.2 Spin dryers
5
2.2.3 Condensation dryers
6
2.2.4 Heat pump dryers
6
2.2.5 Mechanical steam compression dryers
7
2.3
8
Recently/Past studies
2.3.1
Heat Pump Assisted Clothes Dryer
2.3.1.1
8
8
Design
iv
2.3.1.2
2.3.2
Clothes dryer utilizing air conditioning waste heat
2.3.2.2
2.3.3
13
14
Disadvantages
Clothes Dryer Model: SDM-901
2.3.3.1
2.4
11
Disadvantages
15
16
Disadvantages
17
Conclusion
CHAPTER 3: METHODOLOGY
18
3.1
Introduction
18
3.2
Project Planning
18
3.3
Process Flow Chart
20
3.3.1
Define Problem
22
3.3.2
Literature Review
22
3.3.3
Detailed Function and Design Requirements
23
3.3.3.1
External Search
23
3.3.3.2
Internal Search
24
3.3.4
Conceptual Design
24
3.3.5
Best Design Selection
24
3.3.5.1
3.3.6
Pugh Method
25
Detailed Design
26
Specify Material, function, condition and
Manufacturing Process
3.3.7.1 Material for Storage
26
3.3.7.2
Main Frame
27
3.3.7.3
Drying Mechanism
27
3.3.7.4
Air Ducting
28
3.3.7.5
Electrical and Electronic Component
28
3.3.8
Prototype Testing
30
3.3.9
Actual Condition
30
3.3.10
Patent and Manufacture for Marketing
31
3.3.7
3.4
26
31
Conclusion
v
CHAPTER 4: DEVELOPMENT OF PROJECT
4.1 Introduction
32
4.2
33
Simulation
4.2.1 Programmable Logic Controller (PLC)
4.3
37
Conceptual Design
37
4.3.1 Design 1
4.3.1.1
Advantages
37
4.3.1.2
Disadvantages
38
38
4.3.2 Design 2
4.3.2.1 Advantages
39
4.3.2.2 Disadvantages
39
39
4.3.3 Design 3
4.3.3.1 Advantages
40
4.3.3.2 Disadvantages
40
42
4.4 Design and Development
4.4.1
4.4
33
Designing Phase
42
4.4.1.1 Sketching Process
42
4.4.1.2 Simulation Phase
43
4.4.1.3 Developing Processes
46
49
Conclusion
CHAPTER 5: RESULTS
5.1
Introduction
50
5.2
The Prototype
50
5.2.1 Simulation
50
5.2.2
Redesign
51
5.2.3
The SSS Prototype Views
52
5.2.3.1 Front View
52
5.2.3.2 Back View
52
5.2.4
The SSS Part and Accessories
53
5.2.4.1 The Doors and Windows
53
vi
5.2.4.2 Control Panel
53
5.2.4.3 Ducting
55
5.2.5
5.3
The SSS Bill of Material
56
59
Prototype Testing
5.3.1
Comparison Testing
59
5.3.2
Sensor Testing
60
5.3.2.1 Manually Testing
60
5.3.2.2 Automatically Testing
61
5.3.3
Night Testing
62
5.4 Conclusions
63
CHAPTER 6: DISCUSSION
6.1
Introduction
6.1.1
6.2
64
SSS Advantages
64
Drying Time
65
6.2.1
On Sunny Day
65
6.2.1
At Night
66
6.3
Ventilation System
68
6.4
Problems
69
6.4.1 Changing Design
69
6.4.2 Adding Motor
69
6.4.3 Corrosion Problems
70
6.5
6.6
Suggestion for Further Improvement
71
72
Conclusions
CHAPTER 7 CONCLUSIONS
73
REFERENCES
74
APPENDIX
vii
LIST OF FIGURES
Figure 1:
Figure 2:
Figure
Schematic Diagram of Heat Pump Assisted Clothes Dryer Main
Components (Ameen, A , 2004)
Schematic Diagram of Heat Pump Assisted Clothes
(Ameen, A , 2004).
Opened System ; Closed System (Ameen, A , 2004)
9
10
10
3(a), 3(b)
3D representation of the Cloth Dryer ; Prototype Cloth Dryer
(Ameen, A,2004)
11
12
Figure 7:
The different position of air conditioner outdoor units between Heat
Pump
Clothes dryer utilizing air conditioning waste heat schematic drawing
(United States Patent 5437106, 1995).
Illustration showing the air from the outdoor unit is not totally used.
Figure 8:
Clothes Dryer Model: SDM-901
15
Figure 9:
Illustration drawing to show the principle drying mechanism of
16
Figure:
4(a), 4(b)
Figure 5:
Figure 6:
13
15
SDM-901 clothes dryer using “Solid Work 2005” software.
Figure 10: Air Ducting
28
Figure 11: Suzuki Power Window Drive motor
29
Figure 12: Lead-acid battery
30
Figure 13: PLC Control System
34
Figure 14: Smart Storage sensory system using “Ladder Builder for KV”
software
Figure 15: Conceptual designs
35
41
Figure 16: sketching of conceptual design 3
43
Figure 17: SolidWorks 2005 software
44
Figure 18: Sketching Tool
44
Figure 19: Each part of design sequent orderly
45
Figure 20: Self Tapping Screw
46
Figure 21: Riveting Process
47
viii
Figure 22: Front Cover using AutoCAD 2002 software
48
Figure 23: Back Cover using AutoCAD 2002 software
48
Figure 24: a) Simulation show how the door functioning b) SSS in static mode
50
Figure 25: Improvement of simulation design using AutoCAD 2002 software.
51
Figure 26: SSS Circuit diagram
52
Figure 27: a) The front view of SSS; b) The control panel and battery where
situated; c) the front door which can be opened and closed for
inserting clothes.
Figure 28: a) The back view of SSS; b) the motor; c) door for ducting
52
52
Figure 29: a) window for switching on the control panel; b) windows for
inserting small size clothes; c) main door for clothes inserting; d)
hinges and magnet
Figure 30: a) control panel connected with battery; b) inside the control panel;
c) 2 sensors at the corner top of SSS.
Figure 31: a) ducting attached to out door unit by using rubbery rope while b)
showing the ducting attached to SSS by using magnets
Figure 32: The technician manually testing the SSS function
53
Figure 33: The door closed automatically when the rain comes
61
Figure 34: The clothes secure from getting wet due to heavy rain
61
Figure 35: The SSS testing at night with the helping of unnatural drying agent
62
Figure 36: Comparison testing between SSS and conventional hanging
65
Figure 37: Testing procedure where using bare hand. Note that lower arm still
dank after an hour
Figure 38: Air velocity is a factor for both methods drying time
66
Figure 39: a) ducting attached to SSS, b) the shirt dries at morning
67
Figure 40: The design of out ventilation
68
Figure 41: Changing design from a to b
69
Figure 42: a) corroded hinge and b) corroded bolt
70
ix
54
55
60
66
LIST OF TABLES
Table 1:
PSM I Gantt Chart
19
Table 2:
PSM II Gantt Chart
20
Table 3:
The screening matrix for the design concept of Smart Storage
57
System
Table 4:
Showing the bill of material for SSS Project
x
56
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
SSS
-
Smart Storage System
PLC
-
Programmable Logic Controller
3D
-
Three Dimensional
CAD
-
Computer Aided Design
xi
CHAPTER 1
INTRODUCTION
1.1
Introduction
The characteristic features of the climate of Malaysia are uniform temperature; high
humidity and copious rainfall and they arise mainly from the maritime exposure of the
country. Winds are generally light. Situated at the equatorial doldrums area, it is
extremely rare to have a full day with completely clear sky even in periods of severe
drought. On the other hand, it is also rare to have a stretch of a few days with completely
no sunshine except during the northeast monsoon seasons.
Malaysia has a tropical climate with high temperatures and rainfall all year round.
Rainfall is heavy and usually occurs in the form of thunderstorms. The main differences
of climate within the country are due to differences of altitude and the exposure of the
coastal lowlands to the alternating northeast and southwest monsoon winds. Southwest
monsoon winds blow from April to September while the northeast monsoon occurs from
November-February. March and October are the transition months between the
monsoons, characterized by light and variable winds (Reza Azmi, 2003).
The northeastern coasts of Malaysia experience very wet weather conditions during the
northeast monsoon season as they are exposed to the northeasterly winds.
Temperatures do not differ much from month to month, and there is no large daily range
of temperature. Night-time temperatures can be oppressive due to high humidity.
1
Conditions are cooler in the hills but this is balanced by higher humidity and rainfall,
and less sunshine. Although Malaysia has a warm and humid climate, severe heat stress
is rare. The transition months (March and October) can be uncomfortable because winds
are light and humidity may be higher. In the afternoons, conditions on the coast are often
relieved by sea breezes. Over the east coast districts (Kelantan, Terengganu, Johor,
Pahang), November, December and January are the months with maximum rainfall,
while June and July are, generally, the driest months (Reza Azmi, 2003).
1.2
Problem Statements
Clothing is one of the basic needs for human. Clothing protects the vulnerable nude
human body from the extremes of weather, other features of our environment, and for
safety reasons. The practical function of clothing is to protect the human body from
dangers in the environment: weather like strong sunlight, extreme heat or cold, and
precipitation, for example like insects, noxious chemicals, weapons, and contact with
abrasive substances, and other hazards (Wikipedia, 2007). Each time the clothes are
used, it needs to be cleaned before it can be used again. This to make sure the clothes to
be hygienic and free from dangerous bacteria.
However, nowadays people still depends on the nature in drying clothes. It is a routine
for one to wash and dry their denim and clothes through out the year. As a conventional
method sun energy is using as a major source to dry clothes. Unfortunately, nature will
never be the same all the way. It is always sometimes raining and various seasons.
Besides, human now are really busy with their job and most of the family are now
working parent. Thus, a smart drying storage is proposed to encounter these problems.
We cannot change the way of nature to solve the problem but the way or the method of
drying can be thought and applied.
2
1.3
Objectives
To make sure that this project meets the goals and requirement, the objectives of this
project are defines below according to the points:
To design a smart storage for drying purposes focus on residential used.
To fabricate the replication of smart storage mechanism.
To simulate a smart storage functions and investigates the effectiveness of the
overall idea.
1.4
Scope of study
Scope:
1.5
Study on mechanisms that help into smart storage automation.
Detail design of a smart storage residential used.
Design criteria will focus on application, economical aspect and flexibility.
Conclusion
The major problems while drying clothes is unexpected weather changing. New
evolution of invention has to be made for solving these problems. In reviewing the needs
of the project that been specified, this project will give the opportunity to student to
show their abilities and gaining variety of engineering skill especially in conducting a
potential benefit products.
3
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
In this chapter, it wills mainly discussing about the general operation, principles and
mechanisms that related to the Smart Storage studies. Some of previous research and
studies were included into this chapter to support the development of ideas for Smart
Storage System (SSS) concept and design.
2.2
Evaporation Process
Evaporation is the process by which molecules in a liquid state (e.g. water)
spontaneously become gaseous (e.g. water vapor), without being heated to boiling point.
It is the opposite of condensation. Generally, evaporation can be seen by the gradual
disappearance of a liquid, when exposed to a significant volume of gas. The reason a
liquid evaporates is that its molecules are all in motion in nearly random directions and
speeds, and the energy of that movement can be compared to the heat needed to boil that
liquid. On average, none of the molecules have enough energy to be considered
"boiling", or else the liquid would turn into vapor quickly. When the molecules collide,
they transfer energy to each other in varying degrees, based on how they collide.
Sometimes the transfer is so one-sided that one of the molecules ends up with enough
4
energy to be considered past the boiling point of the liquid. If this happens near the
surface of the liquid it may actually fly off into the gas and thus "evaporate".
Liquids that do not appear to evaporate visibly at a given temperature in a given gas (e.g.
cooking oil at room temperature) have molecules that do not tend to transfer energy to
each other in a pattern sufficient to frequently give a molecule the "escape velocity" the
heat energy necessary to turn into vapor. However, these liquids are evaporating, it's just
that the process is much slower and thus significantly less visible (Silberberg, Martin A.,
2006).
2.2 Types of dryer
2.2.3 Traditional dryers
Traditional dryers continuously draw in the cool, dry, ambient air around them and heat
it before passing it through the tumbler. Afterwards, the resulting hot, humid air is
simply vented outside to make room for more dry air to continue the drying process. The
traditional design makes no effort to recycle the heat put into the load, and so is quite
inefficient. Nevertheless, the basic design is simple, reliable, and cheap.
2.2.2
Spin dryers
These machines simply spin their drums faster than a typical washer could in order to
extract additional water from the load. They may remove more water in two minutes
than a heated tumbler dryer can in twenty, thus saving significant amounts of time and
energy. Although spinning alone will not completely dry clothing, this additional step
5
saves a worthwhile amount of time and energy for large laundry operations such as those
of hospitals or hotels.
2.2.3 Condensation dryers
Just as in a normal dryer, condensation dryers pass heated air through the load.
However, instead of exhausting this air, the dryer uses a heat exchanger to cool the air
and condense the water vapor into either a drain pipe or a collection tank. Afterwards,
this air is run through the loop again. The heat exchanger uses ambient air as its coolant,
therefore the heat produced by the dryer will go into the immediate surroundings instead
of the outside.
Because the heat exchange process simply cools the Internal air using ambient air, it will
not dry the air in the internal loop to as low a level of humidity as the fresh, ambient air.
As a consequence of the increased humidity of the air used to dry the load as well as the
increased complexity of the design, this type of dryer requires more time and energy
than a traditional dryer. However, it is a valid option where long, intricate ducting would
be required to vent a traditional dryer.
2.2.4 Heat pump dryers
Whereas condensation dryers use a passive heat exchanger cooled by ambient air, these
dryers use a heat pump. The hot, humid air from the tumbler is passed through a heat
pump where the cold side condenses the water vapor into either a drain pipe or a
collection tank and the hot side reheats the air. In this way not only does the dryer avoid
the need for ducting, but it also conserves much of its heat within the dryer instead of
exhausting it into the surroundings. Heat pump dryers can therefore use less than half the
energy required by either condensation or traditional dryers.
6
As with condensation dryers, the heat exchanger will not dry the internal air to as low a
level of humidity as the ambient air. With respect to ambient air, the higher humidity of
the air used to dry the clothes has the effect of increasing drying times; however,
because heat pump dryers conserve much of the heat of the air they use, the already-hot
air can be cycled more quickly, possibly leading to shorter drying times than traditional
dryers, depending on the model.
2.2.5
Mechanical steam compression dryers
New types of dryer in development, these machines are a more advanced version of heat
pump dryers. Instead of using hot air to dry the clothing, mechanical steam compression
dryers use water recovered from the clothing in the form of steam. First, the tumbler and
its contents are heated to 100 °C. The wet steam that results purges the system of air and
is the only remaining atmosphere in the tumbler.
As wet steam exits the tumbler, it is mechanically compressed (hence the name) to
extract water vapor and transfer the heat of vaporization to the remaining gaseous steam.
This pressurized, gaseous steam is then allowed to expand and is superheated before
being injected back into the tumbler where its heat causes more water to vaporize from
the clothing, creating more wet steam and restarting the cycle.
Like heat pump dyers, mechanical steam compression dryers recycle much of the heat
used to dry the clothes, and they operate in a very similar range of efficiency as heat
pump dryers. Both types can be over twice as efficient as traditional dryers. However,
the considerably higher temperatures used in mechanical steam compression dryers
result in drying times on the order of half as long as those of heat pump dryers.
7
2.3 Recently/Past studies
Followings are some of previous research and studies that had been develops to
encounter problems, which are state in chapter 1. There are 3 innovations where each
one build with different concept and operating mechanism but sharing same objective of
working principle, to drying clothes.
2.3.1 Heat Pump Assisted Clothes Dryer
In densely built urban high-rise flats, natural drying of clothes is a problematic
household chore that is aesthetically unacceptable as well. Natural drying of clothes in
Malaysia is a very time consuming process because of year round humid climate, limited
sun rays and restricted air flows. The use of conventional electrical dryer is a practical
but expensive solution for drying clothes, as it is inherently an energy intensive process.
Hence, a search for a low cost solution for drying clothes is quite relevant and more so
in the context of the growing use of air conditioners and progressive compactness of
apartments (Ameen, A , 2004).
2.3.1.1 Design
Accordingly, the clothes dryer has been conceived and built as shown in Fig.1. It houses
the condensing unit and the evaporator of a typical split type air conditioner commonly
used in high-rise apartments to utilize the condenser heat hitherto wasted for drying
clothes. Fig. 2 shows a schematic diagram of the clothes dryer comprising refrigerant
circuit (1-2-3-4), air circuit for space cooling (A-B-C) and the circuit for cloth drying
(D-E-F). Clothes are hung inside the cabinet and dried wrinkle free. Clothes can be dried
in two modes (a) open system and (b) closed system. In open system mode (Fig. 3a)
clothes are dried by the condenser waste heat while cold air is used to cool the room(s).
8
In closed system mode (Fig. 3b) air returning from the drying chamber is dehumidified
by the evaporator and then heated by the condenser resulting in faster cooling. Drying of
a batch of spin-dried clothes takes about 45 minutes for close system mode and 60
minutes for the open system mode compared to 150 minutes in a commercial dryer and
more than 282 minutes for natural drying indoors. Wrinkle-free drying and subsequent
storing of clothes in this dryer has another advantage of eliminating mould and fungi so
common in humid climates. Developing an integrated air conditioner cum dryer is thus a
practical proposition because the cost of the drying cabinet is marginal and the benefits
are tangible (Ameen, A , 2004).
Figure 1: Schematic Diagram of Heat Pump Assisted Clothes Dryer Main Components
(Ameen, A , 2004).
9
Design and Development of
Smart Storage System
for Clothes Drying
Thesis submitted in accordance with the requirements of the
Universiti Teknikal Malaysia Melaka for the Bachelor Degree of
Manufacturing Engineering (Engineering Material)
By
Zamri Bin Ahmad
Faculty of Manufacturing Engineering
May 2008
APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as fulfillment of the
requirement for the Bachelor of Manufacturing Engineering (Engineering Material) with
Honours. The members of the supervisory committee are as follows:
……………………………………………….
Mr. Syahrul Azwan Bin Sundi @ Suandi
(PSM Supervisor)
Faculty of Manufacturing Engineering
3
DECLARATION
I hereby, declare this thesis entitled “DESIGN AND DEVELOPMENT OF
SMART STORAGE SYSTEM FOR CLOTHES DRYING” is the result of my
own research except as cited in the references.
Signature
:
……………………………….
Author’s Name
:
Zamri Bin Ahmad
Date
:
May 8th 2008
4
ABSTRACT
It is a routine for one to wash and dry their denim and clothes through out the year. As a
conventional method sun energy is using as a major source to dry clothes. Unfortunately,
nature will never be the same all the way. It is always sometimes raining and various
seasons. Besides, human now are really busy with their job and most of the family are
now working parent. Thus, a smart drying storage is proposed to encounter these
problems. To implement the development of this prototype, many steps have to perform.
Starts with project planning, information searching and then further with prototype
construction, there are been manage well until the recent progression that lead the way to
produce a final functional prototype of Smart Storage System. By analyze and study
about the previous researches, its help more to understand the concept and the application
to be use for this prototype. In addition to have a good result of this project, the
information about drying mechanism is also gathered from the published books, articles
and journals as guidelines. Through the literature review in the chapter 2, the idea of
design concept is contributed from the current product that available in the market place.
Some new idea also had been generate by the good example of the current used products.
Furthermore, the conceptual design presented for design development is selected by
according to the screening concept. Progression will continued for the next development
phase by referring to the methodology guidelines in the chapter 3 in this report. All of
additional information regarding to the result of Smart Storage System development is in
chapter 5 and 6.
i
ABSTRAK
Adalah menjadi rutin bagi seseorang itu mencuci dan mengeringkan pakaian mereka
sepanjang tahun. Kaedah konvensional menggunakan cahaya matahari sebagai sumber
utama bagi tujuan pengeringan pakaian. Namun begitu, cuaca tidak akan sama sepanjang
masa.. Hujan pada satu-satu masa dan musim yang pelbagai. Disamping itu kehidupan
manusia pada masa kini semakin sibuk dengan pekerjaan. Oleh yang demikian, sistem
penyimpanan pintar dicadangkan bagi mengatasi masalah ini. Bagi melaksanakan
pembangunan prototaip ini, banyak langkah perlu dilaksanakan. Bermula dengan
perancangan projek, pencarian maklumat dan kemudian terus kepada pembinaan
prototaip, dengan pengurusan yang baik sehingga kepada kemajuan mutakhir untuk
mengeluarkan sebuah prototaip system penyimpanan pintar. Analisis dan kajian
mengenai penyelidikan yang lalu, dapat membantu lagi bagi memahami konsep dan
aplikasi yang diperlukan dalam pembinaan prototaip. Tambahan pula untuk memiliki satu
keputusan yang baik bagi projek ini, maklumat tentang mekanisme pengeringan turut
dikumpul melalui buku rujukan, artikel mahupun jurnal sebagai rujukan tambahan.
Melalui kajian persuratan pada bab 2, idea untuk merekabentuk dijana melalui produk
yang sedia ada di dalam pasaran. Rekabentuk konsep yang dipilih bagi projek ini dipilih
melalui kaedah skrin. Perlaksanaan peringkat seterusnya adalah mengikut metodologi
pada bab 3 dan informasi berkenaan keputusan pembangunan prototaip SSS pada bab 5
dan 6.
ii
ACKNOWLEDGMENTS
First at all, Alhamdulillah and praise to Allah,
I manage to complete my Final Year Project – Projek Sarjana Muda.
I also would like to offer thanks and deepest gratitude from the bottom of my heart for all
the support, encouragement and inspirations I obtained through out the duration of this
project. The help rendered to me priceless, be it from the smallest of its kind to the
largest. They include;
My supervising lecturer, Mr Syahrul Azwan Suandi of which we had a good working
relationship, and who offered tremendous help and encouragement,
My family, who inspired me whether through the storm and carry on,
My friends and peers who are good companions in times of need.
Wassalam….
Zamri Ahmad
iii
TABLE OF CONTENTS
Abstract
i
Abstrak
ii
Aknowledgements
iii
Table of Contents
iv
List of Figures
viii
List of Tables
x
List of Abbreviations, Symbols, Specialized Nomenclature
xi
CHAPTER 1: INTRODUCTION
1.1
Introduction
1
1.2
Problem Statements
2
1.3
Objectives
3
1.4
Scope of study
3
1.5
Conclusion
3
CHAPTER 2: LITERATURE REVIEW
2.2.
2.1
Introduction
4
2.2
Evaporation Process
4
2.2
Types of dryer
5
2.2.3 Traditional dryers
5
2.2.2 Spin dryers
5
2.2.3 Condensation dryers
6
2.2.4 Heat pump dryers
6
2.2.5 Mechanical steam compression dryers
7
2.3
8
Recently/Past studies
2.3.1
Heat Pump Assisted Clothes Dryer
2.3.1.1
8
8
Design
iv
2.3.1.2
2.3.2
Clothes dryer utilizing air conditioning waste heat
2.3.2.2
2.3.3
13
14
Disadvantages
Clothes Dryer Model: SDM-901
2.3.3.1
2.4
11
Disadvantages
15
16
Disadvantages
17
Conclusion
CHAPTER 3: METHODOLOGY
18
3.1
Introduction
18
3.2
Project Planning
18
3.3
Process Flow Chart
20
3.3.1
Define Problem
22
3.3.2
Literature Review
22
3.3.3
Detailed Function and Design Requirements
23
3.3.3.1
External Search
23
3.3.3.2
Internal Search
24
3.3.4
Conceptual Design
24
3.3.5
Best Design Selection
24
3.3.5.1
3.3.6
Pugh Method
25
Detailed Design
26
Specify Material, function, condition and
Manufacturing Process
3.3.7.1 Material for Storage
26
3.3.7.2
Main Frame
27
3.3.7.3
Drying Mechanism
27
3.3.7.4
Air Ducting
28
3.3.7.5
Electrical and Electronic Component
28
3.3.8
Prototype Testing
30
3.3.9
Actual Condition
30
3.3.10
Patent and Manufacture for Marketing
31
3.3.7
3.4
26
31
Conclusion
v
CHAPTER 4: DEVELOPMENT OF PROJECT
4.1 Introduction
32
4.2
33
Simulation
4.2.1 Programmable Logic Controller (PLC)
4.3
37
Conceptual Design
37
4.3.1 Design 1
4.3.1.1
Advantages
37
4.3.1.2
Disadvantages
38
38
4.3.2 Design 2
4.3.2.1 Advantages
39
4.3.2.2 Disadvantages
39
39
4.3.3 Design 3
4.3.3.1 Advantages
40
4.3.3.2 Disadvantages
40
42
4.4 Design and Development
4.4.1
4.4
33
Designing Phase
42
4.4.1.1 Sketching Process
42
4.4.1.2 Simulation Phase
43
4.4.1.3 Developing Processes
46
49
Conclusion
CHAPTER 5: RESULTS
5.1
Introduction
50
5.2
The Prototype
50
5.2.1 Simulation
50
5.2.2
Redesign
51
5.2.3
The SSS Prototype Views
52
5.2.3.1 Front View
52
5.2.3.2 Back View
52
5.2.4
The SSS Part and Accessories
53
5.2.4.1 The Doors and Windows
53
vi
5.2.4.2 Control Panel
53
5.2.4.3 Ducting
55
5.2.5
5.3
The SSS Bill of Material
56
59
Prototype Testing
5.3.1
Comparison Testing
59
5.3.2
Sensor Testing
60
5.3.2.1 Manually Testing
60
5.3.2.2 Automatically Testing
61
5.3.3
Night Testing
62
5.4 Conclusions
63
CHAPTER 6: DISCUSSION
6.1
Introduction
6.1.1
6.2
64
SSS Advantages
64
Drying Time
65
6.2.1
On Sunny Day
65
6.2.1
At Night
66
6.3
Ventilation System
68
6.4
Problems
69
6.4.1 Changing Design
69
6.4.2 Adding Motor
69
6.4.3 Corrosion Problems
70
6.5
6.6
Suggestion for Further Improvement
71
72
Conclusions
CHAPTER 7 CONCLUSIONS
73
REFERENCES
74
APPENDIX
vii
LIST OF FIGURES
Figure 1:
Figure 2:
Figure
Schematic Diagram of Heat Pump Assisted Clothes Dryer Main
Components (Ameen, A , 2004)
Schematic Diagram of Heat Pump Assisted Clothes
(Ameen, A , 2004).
Opened System ; Closed System (Ameen, A , 2004)
9
10
10
3(a), 3(b)
3D representation of the Cloth Dryer ; Prototype Cloth Dryer
(Ameen, A,2004)
11
12
Figure 7:
The different position of air conditioner outdoor units between Heat
Pump
Clothes dryer utilizing air conditioning waste heat schematic drawing
(United States Patent 5437106, 1995).
Illustration showing the air from the outdoor unit is not totally used.
Figure 8:
Clothes Dryer Model: SDM-901
15
Figure 9:
Illustration drawing to show the principle drying mechanism of
16
Figure:
4(a), 4(b)
Figure 5:
Figure 6:
13
15
SDM-901 clothes dryer using “Solid Work 2005” software.
Figure 10: Air Ducting
28
Figure 11: Suzuki Power Window Drive motor
29
Figure 12: Lead-acid battery
30
Figure 13: PLC Control System
34
Figure 14: Smart Storage sensory system using “Ladder Builder for KV”
software
Figure 15: Conceptual designs
35
41
Figure 16: sketching of conceptual design 3
43
Figure 17: SolidWorks 2005 software
44
Figure 18: Sketching Tool
44
Figure 19: Each part of design sequent orderly
45
Figure 20: Self Tapping Screw
46
Figure 21: Riveting Process
47
viii
Figure 22: Front Cover using AutoCAD 2002 software
48
Figure 23: Back Cover using AutoCAD 2002 software
48
Figure 24: a) Simulation show how the door functioning b) SSS in static mode
50
Figure 25: Improvement of simulation design using AutoCAD 2002 software.
51
Figure 26: SSS Circuit diagram
52
Figure 27: a) The front view of SSS; b) The control panel and battery where
situated; c) the front door which can be opened and closed for
inserting clothes.
Figure 28: a) The back view of SSS; b) the motor; c) door for ducting
52
52
Figure 29: a) window for switching on the control panel; b) windows for
inserting small size clothes; c) main door for clothes inserting; d)
hinges and magnet
Figure 30: a) control panel connected with battery; b) inside the control panel;
c) 2 sensors at the corner top of SSS.
Figure 31: a) ducting attached to out door unit by using rubbery rope while b)
showing the ducting attached to SSS by using magnets
Figure 32: The technician manually testing the SSS function
53
Figure 33: The door closed automatically when the rain comes
61
Figure 34: The clothes secure from getting wet due to heavy rain
61
Figure 35: The SSS testing at night with the helping of unnatural drying agent
62
Figure 36: Comparison testing between SSS and conventional hanging
65
Figure 37: Testing procedure where using bare hand. Note that lower arm still
dank after an hour
Figure 38: Air velocity is a factor for both methods drying time
66
Figure 39: a) ducting attached to SSS, b) the shirt dries at morning
67
Figure 40: The design of out ventilation
68
Figure 41: Changing design from a to b
69
Figure 42: a) corroded hinge and b) corroded bolt
70
ix
54
55
60
66
LIST OF TABLES
Table 1:
PSM I Gantt Chart
19
Table 2:
PSM II Gantt Chart
20
Table 3:
The screening matrix for the design concept of Smart Storage
57
System
Table 4:
Showing the bill of material for SSS Project
x
56
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
SSS
-
Smart Storage System
PLC
-
Programmable Logic Controller
3D
-
Three Dimensional
CAD
-
Computer Aided Design
xi
CHAPTER 1
INTRODUCTION
1.1
Introduction
The characteristic features of the climate of Malaysia are uniform temperature; high
humidity and copious rainfall and they arise mainly from the maritime exposure of the
country. Winds are generally light. Situated at the equatorial doldrums area, it is
extremely rare to have a full day with completely clear sky even in periods of severe
drought. On the other hand, it is also rare to have a stretch of a few days with completely
no sunshine except during the northeast monsoon seasons.
Malaysia has a tropical climate with high temperatures and rainfall all year round.
Rainfall is heavy and usually occurs in the form of thunderstorms. The main differences
of climate within the country are due to differences of altitude and the exposure of the
coastal lowlands to the alternating northeast and southwest monsoon winds. Southwest
monsoon winds blow from April to September while the northeast monsoon occurs from
November-February. March and October are the transition months between the
monsoons, characterized by light and variable winds (Reza Azmi, 2003).
The northeastern coasts of Malaysia experience very wet weather conditions during the
northeast monsoon season as they are exposed to the northeasterly winds.
Temperatures do not differ much from month to month, and there is no large daily range
of temperature. Night-time temperatures can be oppressive due to high humidity.
1
Conditions are cooler in the hills but this is balanced by higher humidity and rainfall,
and less sunshine. Although Malaysia has a warm and humid climate, severe heat stress
is rare. The transition months (March and October) can be uncomfortable because winds
are light and humidity may be higher. In the afternoons, conditions on the coast are often
relieved by sea breezes. Over the east coast districts (Kelantan, Terengganu, Johor,
Pahang), November, December and January are the months with maximum rainfall,
while June and July are, generally, the driest months (Reza Azmi, 2003).
1.2
Problem Statements
Clothing is one of the basic needs for human. Clothing protects the vulnerable nude
human body from the extremes of weather, other features of our environment, and for
safety reasons. The practical function of clothing is to protect the human body from
dangers in the environment: weather like strong sunlight, extreme heat or cold, and
precipitation, for example like insects, noxious chemicals, weapons, and contact with
abrasive substances, and other hazards (Wikipedia, 2007). Each time the clothes are
used, it needs to be cleaned before it can be used again. This to make sure the clothes to
be hygienic and free from dangerous bacteria.
However, nowadays people still depends on the nature in drying clothes. It is a routine
for one to wash and dry their denim and clothes through out the year. As a conventional
method sun energy is using as a major source to dry clothes. Unfortunately, nature will
never be the same all the way. It is always sometimes raining and various seasons.
Besides, human now are really busy with their job and most of the family are now
working parent. Thus, a smart drying storage is proposed to encounter these problems.
We cannot change the way of nature to solve the problem but the way or the method of
drying can be thought and applied.
2
1.3
Objectives
To make sure that this project meets the goals and requirement, the objectives of this
project are defines below according to the points:
To design a smart storage for drying purposes focus on residential used.
To fabricate the replication of smart storage mechanism.
To simulate a smart storage functions and investigates the effectiveness of the
overall idea.
1.4
Scope of study
Scope:
1.5
Study on mechanisms that help into smart storage automation.
Detail design of a smart storage residential used.
Design criteria will focus on application, economical aspect and flexibility.
Conclusion
The major problems while drying clothes is unexpected weather changing. New
evolution of invention has to be made for solving these problems. In reviewing the needs
of the project that been specified, this project will give the opportunity to student to
show their abilities and gaining variety of engineering skill especially in conducting a
potential benefit products.
3
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
In this chapter, it wills mainly discussing about the general operation, principles and
mechanisms that related to the Smart Storage studies. Some of previous research and
studies were included into this chapter to support the development of ideas for Smart
Storage System (SSS) concept and design.
2.2
Evaporation Process
Evaporation is the process by which molecules in a liquid state (e.g. water)
spontaneously become gaseous (e.g. water vapor), without being heated to boiling point.
It is the opposite of condensation. Generally, evaporation can be seen by the gradual
disappearance of a liquid, when exposed to a significant volume of gas. The reason a
liquid evaporates is that its molecules are all in motion in nearly random directions and
speeds, and the energy of that movement can be compared to the heat needed to boil that
liquid. On average, none of the molecules have enough energy to be considered
"boiling", or else the liquid would turn into vapor quickly. When the molecules collide,
they transfer energy to each other in varying degrees, based on how they collide.
Sometimes the transfer is so one-sided that one of the molecules ends up with enough
4
energy to be considered past the boiling point of the liquid. If this happens near the
surface of the liquid it may actually fly off into the gas and thus "evaporate".
Liquids that do not appear to evaporate visibly at a given temperature in a given gas (e.g.
cooking oil at room temperature) have molecules that do not tend to transfer energy to
each other in a pattern sufficient to frequently give a molecule the "escape velocity" the
heat energy necessary to turn into vapor. However, these liquids are evaporating, it's just
that the process is much slower and thus significantly less visible (Silberberg, Martin A.,
2006).
2.2 Types of dryer
2.2.3 Traditional dryers
Traditional dryers continuously draw in the cool, dry, ambient air around them and heat
it before passing it through the tumbler. Afterwards, the resulting hot, humid air is
simply vented outside to make room for more dry air to continue the drying process. The
traditional design makes no effort to recycle the heat put into the load, and so is quite
inefficient. Nevertheless, the basic design is simple, reliable, and cheap.
2.2.2
Spin dryers
These machines simply spin their drums faster than a typical washer could in order to
extract additional water from the load. They may remove more water in two minutes
than a heated tumbler dryer can in twenty, thus saving significant amounts of time and
energy. Although spinning alone will not completely dry clothing, this additional step
5
saves a worthwhile amount of time and energy for large laundry operations such as those
of hospitals or hotels.
2.2.3 Condensation dryers
Just as in a normal dryer, condensation dryers pass heated air through the load.
However, instead of exhausting this air, the dryer uses a heat exchanger to cool the air
and condense the water vapor into either a drain pipe or a collection tank. Afterwards,
this air is run through the loop again. The heat exchanger uses ambient air as its coolant,
therefore the heat produced by the dryer will go into the immediate surroundings instead
of the outside.
Because the heat exchange process simply cools the Internal air using ambient air, it will
not dry the air in the internal loop to as low a level of humidity as the fresh, ambient air.
As a consequence of the increased humidity of the air used to dry the load as well as the
increased complexity of the design, this type of dryer requires more time and energy
than a traditional dryer. However, it is a valid option where long, intricate ducting would
be required to vent a traditional dryer.
2.2.4 Heat pump dryers
Whereas condensation dryers use a passive heat exchanger cooled by ambient air, these
dryers use a heat pump. The hot, humid air from the tumbler is passed through a heat
pump where the cold side condenses the water vapor into either a drain pipe or a
collection tank and the hot side reheats the air. In this way not only does the dryer avoid
the need for ducting, but it also conserves much of its heat within the dryer instead of
exhausting it into the surroundings. Heat pump dryers can therefore use less than half the
energy required by either condensation or traditional dryers.
6
As with condensation dryers, the heat exchanger will not dry the internal air to as low a
level of humidity as the ambient air. With respect to ambient air, the higher humidity of
the air used to dry the clothes has the effect of increasing drying times; however,
because heat pump dryers conserve much of the heat of the air they use, the already-hot
air can be cycled more quickly, possibly leading to shorter drying times than traditional
dryers, depending on the model.
2.2.5
Mechanical steam compression dryers
New types of dryer in development, these machines are a more advanced version of heat
pump dryers. Instead of using hot air to dry the clothing, mechanical steam compression
dryers use water recovered from the clothing in the form of steam. First, the tumbler and
its contents are heated to 100 °C. The wet steam that results purges the system of air and
is the only remaining atmosphere in the tumbler.
As wet steam exits the tumbler, it is mechanically compressed (hence the name) to
extract water vapor and transfer the heat of vaporization to the remaining gaseous steam.
This pressurized, gaseous steam is then allowed to expand and is superheated before
being injected back into the tumbler where its heat causes more water to vaporize from
the clothing, creating more wet steam and restarting the cycle.
Like heat pump dyers, mechanical steam compression dryers recycle much of the heat
used to dry the clothes, and they operate in a very similar range of efficiency as heat
pump dryers. Both types can be over twice as efficient as traditional dryers. However,
the considerably higher temperatures used in mechanical steam compression dryers
result in drying times on the order of half as long as those of heat pump dryers.
7
2.3 Recently/Past studies
Followings are some of previous research and studies that had been develops to
encounter problems, which are state in chapter 1. There are 3 innovations where each
one build with different concept and operating mechanism but sharing same objective of
working principle, to drying clothes.
2.3.1 Heat Pump Assisted Clothes Dryer
In densely built urban high-rise flats, natural drying of clothes is a problematic
household chore that is aesthetically unacceptable as well. Natural drying of clothes in
Malaysia is a very time consuming process because of year round humid climate, limited
sun rays and restricted air flows. The use of conventional electrical dryer is a practical
but expensive solution for drying clothes, as it is inherently an energy intensive process.
Hence, a search for a low cost solution for drying clothes is quite relevant and more so
in the context of the growing use of air conditioners and progressive compactness of
apartments (Ameen, A , 2004).
2.3.1.1 Design
Accordingly, the clothes dryer has been conceived and built as shown in Fig.1. It houses
the condensing unit and the evaporator of a typical split type air conditioner commonly
used in high-rise apartments to utilize the condenser heat hitherto wasted for drying
clothes. Fig. 2 shows a schematic diagram of the clothes dryer comprising refrigerant
circuit (1-2-3-4), air circuit for space cooling (A-B-C) and the circuit for cloth drying
(D-E-F). Clothes are hung inside the cabinet and dried wrinkle free. Clothes can be dried
in two modes (a) open system and (b) closed system. In open system mode (Fig. 3a)
clothes are dried by the condenser waste heat while cold air is used to cool the room(s).
8
In closed system mode (Fig. 3b) air returning from the drying chamber is dehumidified
by the evaporator and then heated by the condenser resulting in faster cooling. Drying of
a batch of spin-dried clothes takes about 45 minutes for close system mode and 60
minutes for the open system mode compared to 150 minutes in a commercial dryer and
more than 282 minutes for natural drying indoors. Wrinkle-free drying and subsequent
storing of clothes in this dryer has another advantage of eliminating mould and fungi so
common in humid climates. Developing an integrated air conditioner cum dryer is thus a
practical proposition because the cost of the drying cabinet is marginal and the benefits
are tangible (Ameen, A , 2004).
Figure 1: Schematic Diagram of Heat Pump Assisted Clothes Dryer Main Components
(Ameen, A , 2004).
9