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DESIGN AND DEVELOPEMENT OF PNEUMATIC MINI DISC
OIL PALM FRUIT STALK CUTTER
MUHAMMAD AFANDI BIN DARWIS
B040810284
A report submitted in partial fulfilment of the requirements of the award of the degree of
Bachelor of Mechanical Engineering (Design and Innovation)
Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka (UTeM)
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CANDIDATE’S DECLARATION
“I hereby declare that the work in this thesis/project is my own except for quotations and summaries which have been duly acknowledged. The thesis/project has not been accepted for any degree and is not concurrently submitted in candidate of any other
degree.”
Signature : ...
Name : MUHAMMAD AFANDI BIN DARWIS
ID Number : B040810284
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ACKNOWLEDGEMENTS
Apart from the efforts of myself, the success of Pneumatic Mini Disc Oil Palm Cutter depends largely on the encouragement and guidelines of many others. I would like to take this opportunity to express my humble gratitude to the people who have been instrumental in the successful completion of this project.
I would like to show my greatest appreciation to Prof. Madya Dr Ir Abdul Talib bin Din. I can't say thank you enough for his tremendous support and help. I feel motivated and encouraged every time I attend his meeting. Without his encouragement and guidance this project would not have materialized.
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ABSTRAK
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ABSTRACT
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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
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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
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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
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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
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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 MPOB 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
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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
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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
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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
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LIST OF SYMBOLS
FP = Pulling Force (N)
FR = Reaction Force (N)
FC = Cutting Force (N)
W = Weight (N)
x = Maximum distance where the force can be apllied(mm)
Ʃ = The sum of
δx = Change in distance (mm)
η = Safety factor
sut = Ultimate tensile strength (Nm2)
σmax = Maximum stress (Nm2)
W = Wide (cm)
H = Height (cm)
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CHAPTER 1
INTRODUCTION
1.0 INTRODUCTION
Projek Sarjana Muda (PSM) is one of the most important aspects of local university to evaluate their degree level students. Through PSM, students will be able to apply all the knowledge they had learnt in related field of engineering.
Engineering is first and foremost the application of knowledge. However, the application must be carried out with judgement, to ensure that the resultant system is effective and efficient, and that it is of benefit. The PSM is one of the primary the mechanisms used by the local university to provide students with an opportunity to gain experience in the practical, effective, efficient, and beneficial application of what you have been studying for the past several years. Naturally, student will continue to gain engineering experience after they graduate but the final year project will always be their first exposure to the full rigour of engineering practice. It is essential that the students learn from this exposure and practise all of the engineering methodologies involved. It is particularly important that they learn not just to apply what they know, but to apply it with judgement, with the ability to assess what they are doing and to be critical of it.
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1.1 BACKGROUND
Harvesting costs signify near 45% associated with total expenses in adult plantations. This activity is usually initiated whenever palms tend to be between 23 and 36 months. Precocity as well as early yields rely on environmental problems, the range, the quality from the nursery plantation, care throughout planting, as well as early administration. The initial bunches produced are little in size and consist no much oil, and they are normally not harvested.
In regards to a week prior to the first commercial harvesting, the palms tend to be cleaned (sanitary pruning) associated with old lifeless leaves as well as bunches. No green leaves ought to be cut, since a new palm needs them all. During
earlier harvesting rounds it is suggested to “steal” the bunch by means of cutting the
fresh bunch without having to cut any leaf. This practice might be done till bunches can be found to the height of 1 meter within the soil area.
Bunches might be cut utilizing a narrow chisel (5-8 cm width), having a metal handle about 1.2 m in length, or a little Malayan knife (sickle-shaped) mounted on a brief aluminium rod. The purpose is to reduce as much of green leaves as possible. As the palm grows older, the bunch weight increases, from about 2.5 kg at the beginning (2-3 years after planning), to 25 or even more kilograms within matured palms. However, the fruit bunch production decreases with its age.
A matured palm produces 8-13 bunches each year, which signifies about 140-175 kg associated with FFB (fresh fruit bunches), that will generate 30-38 kilograms. The optimum potential when it comes to FFB production is usually reached within commercial plantations once the palms tend to be between four and eight years old. During this period, yields could be between 15 as well as 40 tonnes of FFB each year, which signifies 3.3 - 8.8 tonnes of crude palm oil/ha (considering 22% extraction in the mill). The causes of such differences need to be found upon climate, earth, agronomic management, and obviously, the variety used.
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time. If the FFB is harvested too soon (unripe), it will contain less oil than its potential. If harvested past due, the actual oil is going to be partly deteriorated (free fatty acid accumulation). The actual ideal level of ripeness is actually evaluated through the harvester through bunch colour, texture, the change in colour, and the presence of loose fruits. Ripen fruitlets turn out to be soft, as well as change from a black coloration to shiny brown and finally to an opaque reddish-brown appearance at the tip and orange-reddish on the medium section.
The time needed to achieve maturity varies based on palm age, the variety and environmental conditions, but usually takes between 5.5 and 6 months from the time of anthesis (pollination). Typically, bunches tend to be harvested within young palms when 10 or even more loose fruit are discovered. For matured palms, the amount of loose fruit is decreased to 5. In order to gather peak proportion associated with bunches using the optimum level of ripeness; harvesting cycles need to be relatively short: every 8-15 days, depending upon palm grow older and time from the year (bunch density).
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1.2 PROBLEM STATEMENTS
Shortage of labour recently has forced all parties involved in the industry to find ways and means to at least maintain the profit through balancing the productivity and the production cost. The traditional sickle method of harvesting oil palm fresh fruit bunch takes a lot of time and reduces production efficiency. So, it is clearly there is an immediate need to formulate and develop a technology that can cut fruit bunches easily and efficiently.
Because of the urgent need, most tools have been developed without considering the necessary technical information for cutting frond and fruit bunches. The physical properties of the material, reaction of the material against the cutting edge, method of cutting, cutting angle and speed of cutting have not really been considered.
Product that can really satisfy engineering needs comes with really great cost
and unaffordable. CANTAS™ is the latest technology developed by Malaysian Palm
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1.3 OBJECTIVES
The objectives of this project are:
a) To create a power tool that is a. Cost saving
b. Environmental friendly c. Safe
d. User friendly
e. Able to be commercialized
f. To run analysis on the best design that can reduce energy consumption
b) To design a cutting tool that is reliable, efficient and easy to handle
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1.4 SCOPES
The scopes that need to be covered throughout this project are:
a) To design and develop a pneumatic oil palm fruit stalk cutter using multiple mini disc cutter
b) The design is developed to replace the traditional sickle cutter
c) To formulate and develop a technology that can cut fruit bunches easily and efficiently.
d) The design is only focusing on the cutter mechanism itself excluding design of the pole and the air compressor
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CHAPTER 2
LITERATURE REVIEW
2.0 INTRODUCTION
The literature review is really a description from the literature that is highly relevant to a specific field or even topic. It gives the general idea of what has been said, who the key writers are, what are the prevailing theories and hypotheses, what questions are being asked, and what methods and methodologies are appropriate and useful. As such, it is not in itself primary research, but rather it reports on other findings.
The literature review might be purely detailed, as within an annotated bibliography, or it might provide a vital assessment from the literature inside a particular area, stating in which the weaknesses as well as gaps tend to be, contrasting the actual views associated with particular writers, or increasing questions. This type of review will not just be considered as summary but will even evaluate as well as show associations between various materials, to ensure that key styles emerge. A descriptive evaluation however should not just checklist and paraphrase, but ought to add remark and enhance themes as well as trends.
This literature review will generally give an overview or the ‘big picture’ of
what will be conducted throughout this project. These include i) The information on palm oil tree
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330, 1% 860, 2% 800, 2%
420, 1%
19100, 44% 17735, 41%
1160, 3% 400, 1% 2100, 5%
Cote d'Ivoire Nigeria Columbia Ecuador Indonesia Malaysia Thailand
Papua New Guinea
Others 2.1 BACKGROUND
The oil palm is the most productive species among oleaginous plants.
Malaysia is currently the world's biggest producer of this particular plant. However, the Malaysian palm oil is now facing competition not only from other oil and fat industries but also from other palm oil producing countries. Rising competition in the world market, declining in price, and shortage of labour are some of the factors influencing the well being and future of oil palm industry.
2.1.1 Palm Oil Industry in Malaysia
In 1960, Malaysia plays only a minor part in producing oil palm with a total cultivated area of 55 000 hectares and production of 92 700 tonnes per annum. In 1995, however, the total area planted with oil palm increased to about 2.358 million hectares producing about 7.6 million tonnes of crude palm oil, which was about 64% of the total world's production. It is estimated that by the year 2005, Malaysia may produce 10 million tonnes of crude palm oil and 2.5 million tonnes of palm kernel (Dato' Khalid, 1996).
As the world’s biggest exporter of palm oil, Malaysia accounted for 15.14
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also seen as a beacon for sustainable development in agriculture (Yusof, 2007; Chan, 2003).
Although the industry is facing competitions from other edible oils produced by other countries, and the campaigns by soybeans society not to buy palm oil, it is expected that the prospect of this industry will be boosted further in the 90's, through the opening of several new markets especially Myanmar and Vietnam in Asia, Tunisia, Morocco and a few countries in Africa and South America Demand will also grow in many developing countries such as India, China and other European Union countries due to the tight supply condition of other fats and oils in the world market. In Malaysia, however, the high production cost of palm oil is mainly due to the high labour cost. Presently, labour cost in the plantation is about 30 to 35% of the total production cost (Turner and Gillbank, 1982).
