New Design and Evaluations of Palm Fruit Collector

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New Design and Evaluations of Palm Fruit Collector

Zulkiffli Bakar^1*, Md Najip Talibin¹, Muhammad Nasir Marzuki¹

1 Mechanical Engineering Department, Politeknik Seberang Perai, Penang, Malaysia

*Corresponding Author: [email protected] Accepted: 15 June 2022 | Published: 30 June 2022

DOI:https://doi.org/10.55057/ijarti.2022.4.2.6

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Abstract: This paper focus on design & evaluation of mechanical machine to reduce loose oil palm fruits at mini estate. Loose oil palm fruit means loss of income to small/medium farmer.

Every bunch of cutting will cause at least 5% of oil palm fruit fall separated on the ground. If these are not been collected, oil palm planter would loss big profit besides paying the cost of maintenance. This project design based on project-based learning (PjBL) approach to generate new design based on product development. The methods of scanning concept on design with morphological analysis produce final solution of final roller collector product design. The evaluation of product data’s show that all impact factors are considers at maximum quality of product. This data will help project development team to produce Roller Collector Machine at final stage. The impact of effective mechanism of roller collector machine will increase farmer incomes.

Keywords: Palm Fruit Collector, Machine, Design, Evaluation, Loose oil palms, Increase income, farmer

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1. Introduction

Loose oil palm fruits become one of the most critical factors in harvesting and collecting process. The uncollected loose fruits been estimated for about 3 - 4% of bunch weight.

Traditionally, the technique for collecting the loose fruits usually uses hand and collected into bucket, plastic bag or gunny (Yahya et al., 1997). It is been identified the efficiency of the technique can contribute in an efficient collecting process which can save time, manpower, debris separation and the quality of the fruits. Collection of loose fruit cause big problem to this crop entrepreneur (Wong, 2001). Loose fruit normally picked up by using hand and put together into bucket, plastic bag or gunny. Other than that, there were also different options like using rake, planks and scoop (Wong et al., 1982). Farmer has to bend over to collect loose fruit on the ground and move from tree to tree. Time to collect fruit usually take almost 30%

from harvesting time (Corley & Tinker, 2013). This method causes waste of time, trouble the farmer and cause back pain. This roller collector is the compact mini machines which use manual mechanical mechanism. It’s works by rolling synthetic rubber to collect loose oil palm.

The mechanism of roller will gripping loose palm fruits and it will move into bucket with separator.

The product design objectives; -

i. To produce small oil palm roller collector machine design & evaluation.

ii. To produce oil palm roller collector machine at lowest cost.

iii. To collect loose oil palm without damage.

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iv. To minimize the waste of loose oil palm at site.

The scope of the roller collector product design focus on; - i. Small medium oil palm farmer as end user

ii. Working zone for 1 hectare of oil palm farm iii. Average collector in bracket at 1kg to 2kg weight iv. Reduce the loose oil palm average to 1- 0 % at site

v. Overall weight of the roller collector machine is below 1.5kg vi. The cost below Ringgit Malaysia (RM) 100.00

2. Literature Reviews

This product develops based on two cases of loose palm fruit collector method and equipment use at the mini estate. Some location, the conventional methods still used to collect the loose oil palm fruit. They are using nail rake, hand basket and net to collect the loose fruit on the ground. Below, figure 1 shows the manual process which is not effective in loose fruit collection process.

Figure 1: Manual process in loose fruit collection

Currently, there are several types of loose fruit collectors such as roller picker (Anand, 1998), mechanical loose fruit collector (Hitam & Zamri, 1996) and disc plate collector (Mohd Hudzairi, 2013). However, there are several design concepts that can be improved in terms of the surface condition during operation, minimum damage towards the fruits, quantity of the loose fruit and cost for the tool. In practice, the method of collections should be suitable to operate in many conditions either for wide range or small scale of field. In addition, the operator should be comfortable during operation and produce maximum collection of loose oil palm at farms (Mazlan et al., 2014). Therefore, the criteria of the new design of the roller collector capable to works well in different types of field, friendly for operator and loose fruit, and higher productivity (Ooi, 1996). This product design based on Figure 2: The simple effective product was produced at the market.

Figure 2: The simple effective product

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3. Design Methods

3.1 Scanning Concept with Mophological Analysis

This product design methods cover with scanning concept and morphological analysis that includes three phase (3) of final product design:-

Phase 1

Product literatures reviews and oil farms investigations. It includes the problems faces for each oil palms farmer regarding loose oil palms and the effective cost to buy.

Phase 2

Product design, in this phase the group’s teams will sketch of simple design for each expert member based on the investigation and literatures review with morphological analysis for best solution of product design. To select the best design the group members will enter the method of final good product selection call “Scanning Concept”. This concept will cover all factors that give a good design based on positive impact value given by all members.

Table 1: Scanning Concept

From the table, a relative score of “better than” (+), “same as” (0), or “worse than” (-) is placed in each cell of matrix to represent how each concept rates in comparison to the reference concept relative to the particular criterion.

Phase 3

In this phase, all experts panel will investigate the final design and give the comment and suggestions based on problems that they see as final stage of morphological analysis needs. All comments and suggestion will cover to upgrade the next final design before entering the (ICOMP) competition.

3.2 Final Product Design i. Roller Collector

This roller collector as a main mechanism to grab the loose oil palms. This roller collector works as the wheel and grappler tool to collect loose oil palms.

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Component 1: Roller Collector

ii. Separators

The separators work as main separate equipment. Where it will drop the loose oil palms into bucket. All separator stays at the top inside roller collector to ensure all loose oil palms will segregate properly into the bucket.

Component 2: Separator

iii. Bucket

The bucket works as tanker for loose oil palm goes in while roller collector working. The bucket will separate the waste of wooden or others with loose oil palm fruits.

Component 3: Bucket

iv. Adjustable Handle

Adjustable handle works as a user handle to operate the machine. It’s also work as a supporter to the bucket and flexible use for loose oil palm transfer.

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Component 4: Adjustable Handle

v. Final Design

Based on last phase of reviews process by experts. The additional re-design concept of roller collector machine comes out. This new final design considers overall comments of expert’s panels. Below the components of project roller collector explanations.

Design 1: Final Design

3.3 Product Applications

Process 1: Product Operation

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3.4 Product Cost Estimation

The expectation of selling price of this produce in below RM100.00. This project is a low-cost project which is affordable for farmer and estate workers. However, the costing is based on the price of component only.

Table 2: Product Cost Estimation

No Items Cost (RM)

1 Roller Collector 40.00

2 Separator 15.00

3 Bucket 15.00

Total 70.00

Based on economic analysis, this new design of roller collector will help farmer for easy collecting loose fruits in less working hours. With the less of RM100.00 for fabrication, this product can help all farmers to buy this equipment.

4. Design Data’s Analysis

Each parts of product design has done by using Autodesk Inventor 2014. The product analysis measurement & evaluation process to ensure all components will give maximum quality of performance. Tables below describe all elements that has been evaluates.

Table 3: Data analysis for bucket

Material(s) Reaction Force on Constraints

Name PC/ABS Plastic Constraint

Name

Reaction Force

Magnitude Component (X,Y,Z) Fixed

Constraint:1

50 N 0 N

0 N 50 N General Mass Density 0.357273 g/cm^3

Yield Strength 54.4 MPa Ultimate Tensile Strength 54.1 MPa Stress Young's Modulus 2.78 GPa

Poisson's Ratio 0.4 ul

Shear Modulus 0.992857 GPa

Based on design analysis for bucket, the material of PC/ABS plastic has been choosing as a suitable material for this product design. The data’s shown that mass density at 0.357273 g/cm^3, yield strength at 54.4 MPa, Ultimate Tensile Strength at 54.1 MPa. For stress data testing show for Young's Modulus is at value of 2.78 GPa, for Poisson's Ratio is at value 0.4 ul and for Shear Modulus is at value 0.992857 GPa. Otherwise for reaction force on constraints of bucket the fixed constraint at magnitude value 50N.

Table 4: Data analysis for roller collector

Name Polystyrene Constraint

Name

Reaction Force

Constraint:1

50 N 0 N

Yield Strength 43.4 MPa Ultimate Tensile Strength 44.8 MPa Stress Young's Modulus 3.2 GPa

Poisson's Ratio 0.353 ul Shear Modulus 1.18256 GPa

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The design analysis for collector, the material of Polystyrene has been choosing as a suitable material for this component design. This material considers as light and heavy-duty use. The data’s shown that mass density at 1.021 g/cm^3, yield strength at 43.4 MPa, Ultimate Tensile Strength at 44.8 MPa. Others side of stress data testing show for Young's Modulus is at value of 3.2 GPa, for Poisson's Ratio is at value 0.353 ul and for Shear Modulus is at value 1.18256 GPa. Otherwise for reaction force on constraints of collector the fixed constraint at magnitude value 50N.

Table 5: Data analysis for separator

Name Aluminum Constraint

Name

Reaction Force

Constraint:1

50 N 0 N

Yield Strength 275 MPa

Ultimate Tensile Strength 310 MPa Stress Young's Modulus 68.9 GPa

Poisson's Ratio 0.33 ul Shear Modulus 25.9023 GPa

The design analysis for separator, the material of Aluminum has been choosing as a suitable material for this component design. This material considers as light and efficiency of product applications. The data’s shown that mass density at 2.7 g/cm^3, yield strength at 275 MPa, Ultimate Tensile Strength at 310 MPa. Others side of stress data testing show for Young's Modulus is at value of 68.9 GPa, for Poisson's Ratio is at value 0.33 ul and for Shear Modulus is at value 25.9023 GPa. Otherwise for reaction force on constraints of separator the fixed constraint at magnitude value 50N.

Table 6: Data analysis for overall result summary

Name Minimum Maximum

Volume 8991340 mm^3

Mass 10.0008 kg

Von Mises Stress 0.00266337 MPa 213.433 MPa

1st Principal Stress -32.1119 MPa 192.321 MPa

3rd Principal Stress -143.329 MPa 12.5671 MPa

Displacement 107.612 mm 1167.52 mm

Safety Factor 0.46318 ul 15 ul

Stress XX -54.8214 MPa 75.4303 MPa

Stress XY -77.168 MPa 17.9306 MPa

Stress XZ -97.3782 MPa 31.2454 MPa

Stress YY -58.0948 MPa 58.2151 MPa

Stress YZ -35.7508 MPa 40.0563 MPa

Stress ZZ -75.8456 MPa 107.117 MPa

Based on overall design analysis for final product, the overall volume of the final product is at value 8991340 mm^3. The mass of final product based on all material choose is at value 10.0008 kg. Data’s analysis for minimum /maximum value of Von Mises Stress is at 0.00266337 MPa/213.433 MPa. The data’s for 1st Principal Stress at minimum/maximum are at value of -32.1119 MPa/192.321 MPa. Meanwhile for 3rd Principal Stress for minimum /maximum at value of -143.329 MPa/12.5671 MPa. Displacement data’s for minimum and maximum are at value points 107.612 mm and 1167.52 mm. To insure this product under safety ratio, the Safety Factor value for minimum and maximum points are at 0.46318 ul and 15 ul.

The data’s for those stress axis measurements show that the data for minimum and maximum at stress axis XX are at minimum/maximum at value of -54.8214 MPa/75.4303 MPa, for stress axis XY are at minimum/maximum at value of -77.168 MPa/17.9306 MPa, for stress axis XZ

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are at minimum/maximum at value of -97.3782 MPa/31.2454 MPa, for stress axis YY are at minimum/maximum at value of -58.0948 MPa/58.2151 MPa, for stress axis YZ are at minimum/maximum at value of -35.7508 MPa/40.0563 MPa, and for stress axis ZZ are at minimum/maximum at value of -75.8456 MPa/107.117 MPa.

5. Conclusions

Based on design analysis for final product design costing and data’s analysis, this new design of roller collector will help farmer to easy collect loose palm fruits with less working hours with maximum quality of product. With the less of RM100.00 for fabrication, this product can help all farmers to buy this equipment.

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