CHAPTER 5 75
ANALYSIS AND DISCUSSION 75
5.0 INTRODUCTION
75 5.1
ANALYSIS 76
5.1.1 Manual Static Analysis
76 5.1.2
Computer Simulation 77
5.1.2.1 Result on the upper casing
77 5.1.2.2
Result on the lower casing 78
5.2 SELF CLEANING MECHANISM
80 5.3
ROTATION OF CUTTING DISC 81
5.4 CALCULATION ON THE WEIGHT OF THE SILICONE USED
81 5.5
CALCULATION ON THE WEIGHT OF POLYURETHANE USED 82
5.5.1 Lower Casing
82 5.5.2
Upper Casing 82
5.6 THE MATERIAL
83 5.7
FUSED DEPOSITION MODELLING 83
5.8 THE DESIGN
83
CHAPTER 6 84
CONCLUSION 84
BIBLIOGRAPHY 85
APPENDIX 88
LIST OF FIGURES
CHAPTER 2
Figure 2. 1: Malaysia had produced 41.3 of world palm oil production in 2008 8
Figure 2. 2: Export trend of major oil until 2008 MPOB, 2008 9
Figure 2. 3: The Six Wheeler MPOB, 2008 11
Figure 2. 4: The grabber MPOB, 2008 11
Figure 2. 5: Leaf emission rate varies with palm age MPOB, 2008 14
Figure 2. 6: Canopy form of oil palm leaves MPOB, 2008 14
Figure 2. 7: The spikelets MPOB, 2008 15
Figure 2. 8: Fresh fruit bunch MPOB, 2008 15
Figure 2. 9: Short oil palm trees stem MPOB, 2008 16
Figure 2. 10: Cylindrical shape stem of oil palm MPOB, 2008 17
Figure 2. 11: Thick superficial adventitious mat of oil palm root MPOB, 2008 18
Figure 2. 12: The fibrous superficial root system MPOB, 2008 18
Figure 2. 13: Traditional harvesting method using sickle cutter MPOB, 2008 19
Figure 2. 14: Latest technology developed by MP OB known as CANTAS™
20
CHAPTER 3
Figure 3. 1: Flow Chart 25
Figure 3. 2: Basic structure of House of Quality 32
Figure 3. 3: House of Quality of Pneumatic Mini Disc Cutter 35
Figure 3. 4: Morphological Chart 38
Figure 3. 5: Objective Tree 42
Figure 3. 6: Final Concept 44
CHAPTER 4
Figure 4. 1: Prototype Developement Process 46
Figure 4. 2: Isometric View of Exterior Look 48
Figure 4. 3: Isometric View of Interior Look 48
Figure 4. 4: Isometric View of Exterior Look 49
Figure 4. 5: Isometric View of Interior Look 49
Figure 4. 6: Isometric View of Axial Impeller 50
Figure 4. 7: Isometric View of Impeller Sub 51
Figure 4. 8: Fused Deposition Modelling Machine 52
Figure 4. 9: Interior Look of FDM Machine 52
Figure 4. 10: The for segments of upper casing 54
Figure 4. 11: Joint segments 54
Figure 4. 12: Box construction 56
Figure 4. 13: Modelling Clay Base 57
Figure 4. 14: Leakage Inspection 57
Figure 4. 15: The completed model is kept on flat and safe place 58
Figure 4. 16: Completed Male Mold 59
Figure 4. 17: Mixing Machine 60
Figure 4. 18: The Silicone 60
Figure 4. 19: Pouring hardener intothe silicone 60
Figure 4. 20: Completed female mold 62
Figure 4. 21: Setting up sprue on upper casing 62
Figure 4. 22: Setting up sprue on the lower casing 63
Figure 4. 23: Cured Lower Casing Part 64
Figure 4. 24: Cured Upper Casing Part 64
Figure 4. 25: Lathe machine is used in producing impeller sub 65
Figure 4. 26: Safety precaution in handling lathe machine 65
Figure 4. 27: Continuous measurement 66
Figure 4. 28: Drill Press Machine 68
Figure 4. 29: Bandsaw Machine 69
Figure 4. 30: Inner besring insertion 71
Figure 4. 31: Back bearing insertion 71
Figure 4. 32: Bearing insertion in upper casing 71
Figure 4. 33: Axial impeller respective slots 72
Figure 4. 34: Supporting pad with axial impeller 72
Figure 4. 35: Pressuruzed air distributor 73
Figure 4. 36: Installing pressurized air distributor 73
Figure 4. 37: Complete product 73
CHAPTER 5
Figure 5. 1: Force Distribution in Static Analysis 76
Figure 5. 2: Von Mises Stress in Upper Casing 77
Figure 5. 3: Deformation Analysis in Upper Casing 78
Figure 5. 4: Von Mises Stress in Lower Casing 78
Figure 5. 5: Deformation Analysis in Lower Casing 79
Figure 5. 6: Air Distribution Along the Hose 80
Figure 5. 7: Self-Cleaning Working Principle 80
Figure 5. 8: Rotation of Cutting Disc 81
LIST OF TABLES
CHAPTER 2
Table 2. 1: The increasing need of labour throughout years until 2008 10
CHAPTER 3
Table 3. 1: Product Design Specification PDS 37
Table 3. 2: Concept Generation 40
Table 3. 3: Scoring Method 43
CHAPTER 4
Table 4. 1: Technical Detail on Fused Deposition Modelling 53
Table 4. 2: Typical properties of silicone mixture 61
CHAPTER 5
Table 5. 1: Mechanical properties of Aluminium Alloy 77
LIST OF SYMBOLS
F
P
= Pulling Force N
F
R
= Reaction Force N
F
C
= Cutting Force N
W =
Weight N
x
= Maximum distance where the force can be aplliedmm
Ʃ =
The sum of δ
x
= Change in distance mm
η =
Safety factor s
ut
= Ultimate tensile strength Nm
2
σ
max
= Maximum stress Nm
2
W =
Wide cm H
= Height cm
L =
Long cm
CHAPTER 1
INTRODUCTION