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Emm 3508 - Group 8 PDF
Emm 3508 - Group 8 PDF
ENGINEERING DESIGN II
Semester 2, 2018/2019
Group No. : 8
1.0 Introduction 1
6.0 Conclusion 16
7.0 References 17
8.0 Appendix 18
1.0 Introduction
Palm oil is essential to consumer that led to increasing the palm oil production.
Previously, sickle and pole were used to harvest palm oil where the sickle is attached to pole
by rope or welding. Length of pole was chosen according average height of palm oil tree. This
manual method shown in Figure 1 consumes a lot of time and energy.
Palm oil motorized cutter had been introduced by MPOB in 2007. Motorised cutter
provides faster, easier and safer pruning and harvesting. It is designed for comfortable controls
to ensure maximum workers comfort. MPOB claimed that it easy to use and is less and was
able to increase harvesting productivity by more than double This will reduce the harvesting
time and increase the production.
The objective of this project is to improvise the previous design in EMM 3507. In
previous design, weight is the only aspect that is focussed on. In this project, the motorised
cutter is designed based on sustainable method.
Malaysian Palm Oil Board (MPOB) was the first organizer that introduce mechanize
palm oil harvesting tool. They also come out with CANTAS where is powered by a petrol
engine and utilises with a chisel and C- sickle. CANTAS model has shown below in Figure 2
It has been proved that CANTAS can reduced the harvesting time and energy used.
The productivity can get 560 to 750 bunch per day. The production is depending on
topography of the estate, operator skill and cropping level. Harvesting rate are different
between mechanize cutter and conventional. This shows that labour cost can be reduce using
this mechanize machine. The cutter does not restrict to topography of estate.
1
3.0 Palm Oil Motorised Cutter
The palm oil motorised cutter is designed based on sustainable methods that focusses on
operational efficiency, safety, functionality, productivity, material use, ease of operation and
maintenance.
3.2 Pole
For pole, operational efficiency is on how the pole can withstand pressure and force
from other load to prevent bending. The pole is designed for lightweight purposes. The
motorised cutter used oval shaped pole. This is to increase surface contact area that produces
a firmer hand grip during handling. Stiffness at y axis will reduce pole deflection and allow
harvesting for higher plant.
The improvement proposed for pole part is to place kill switch at the hand grip area (on
pole) for emergency cases. The kill switch will stop entirely the operations of motorised cutter.
Besides, the pole is designed to have groove at both ends to provide more strength in joints
between parts. The pole has a fixed length of 1.8 meter because the motorised cutter is
designed purposely for normal height palm oil tree which range 2.8 meter to 3 meters.
Initially, the material of pole is carbon fibre since the focus of the previous design is
lightweight. Carbon fibre is expensive that lead to a higher price for the motorised cutter. This
will lessen the marketability of the cutter since the selling price is not affordable. So, aluminium
is chosen to replace carbon fibre. Aluminium is durable, not easily broken and has a lower
thermal expansion.
2
The improvement for this part is to include all mass of wire connectors and study how
the electricity flows from the power supply to sickle.
3.4 Motor
Torque of the motor is capable to cut the brunch. Motor chosen has compatible torque
for an average brunch. It is offers extremely good performance, but it can also be overdriven,
and it will draw more current. The motor chosen suitable for cutting and the motor provides
speed reduction and torque multiplication.
3.6 Sickle
Sickle had been chosen since it require small force but produce more cutting energy
due to the slicing principle. The sickle, with its unique design, could effectively get access to
the fronds as well as the bunch stalks during the harvesting process.
Cutting with sickle also require lesser force compared to others. This is because slicing
cut only need the cutting edge to slice and not penetrate the material. The frond will start to
bend due to its own weight and this bending will cause the fibres to be in a stress state and
eventually cut.
Spring steel materials is the best material for sickle blade. It is a high-carbon steel wire
known for its impressive ability to withstand the stress of compression and decompression
without breaking or becoming deformed.
3
4.0 Detailed Selection and Calculation
4
Specific Cutting Force (min) = 119.7 N/𝑐𝑚2 x 4.5 𝑐𝑚2
= 538.65 N
Specific Cutting Force (max) = 119.7 N/𝑐𝑚2 x 6 𝑐𝑚2
= 718.2 N
538.65 N+ 718.2 N
Average Cutting Force, 𝐹𝑐 =
2
= 628.425 N
𝒇
Fc =
𝒄𝒐𝒔 𝑩
where
𝐹𝑐 : Cutting Force
𝐹𝑃 : Pulling Force
B : Cutting Oblique
Oblique cut is a cut with the edge which is not perpendicular to the direction of knife motion.
Greater oblique angle will reduce force needed. Optimum oblique angle in cutting the fronds
is 45°.
5
For efficient cutting, the sickle has been designed with a ‘C-shaped’ profile. This profile has
been found to be effective in providing efficient cutting as well as reducing the vibrations
transferred to the operator during the cutting operation.
It is called a ‘C-sickle’ which enables the cutting force (Fc) to act in-line with the reaction
force (Fr), thus giving maximum cutting force (efficient cutting), and at the same time
minimizing significantly the vibrations transferred to the operator. Figure below shows all
forces that act on sickle to perform the cutting action.
Spring Steel
Materials of sickle
Materials
Figure 4: Forces act on sickle and the specification of the sickle designed
𝑭𝒄 + 𝑭𝑷 + 𝑾 > 𝑭𝒓
where
𝐹𝑐 : Cutting force required to accomplish the cutting
𝐹𝑃 : Pulling force applied by workers
W : Weight of sickle
𝐹𝑟 : Reaction force from worker to counter cutting force developed
x : Maximum distance where point 𝐹𝑐 can be applied
𝛿𝑥 : Distance of point 𝐹𝑐 from sickle holder
Cutting is performed when the sum of Fc (Cutting Force), Fp (Pulling Force) and W (Weight
of sickle) is greater than Fr (Reaction Force).
6
4.3 Torque of Crank Slider
Torque produced by crank slider will move the sickle. So, the value of torque produced must
be more than pulling force needed to cut the frond.
62
49.324 N.m = x 𝑇𝐴
22
𝑇𝐴 = 17.5 N.m
Diameter Gear A 22 cm
Diameter Gear B 62 cm
where
H (kW) = power of motor
n (rpm) = speed of motor
60 000 (1.1)
W= = 2.1 kN
𝜋 (20)(500)
7
4.5 DC Motor
Motor is placed at Gear A. So, the value of speed and torque of Gear A is the value from the
motor. Torque required from motor is 17.5 N.m.
Motor used in this motorised cutter will produced 500 rpm of speed and operates at 1.1kW
power. So, torque produced is
= 21 N.m
Torque produced by motor is more than torque needed for gear A to move the crank slider.
8
4.6 Displacement of Crank Slider
Crank slider should reach maximum displacement of 80 mm to cut the most matured frond.
Diameter Gear B 62 cm
Length of r 31 mm
Length of l 74 mm
Maximum displacement, x 80 mm
where
r = radius of Gear B
𝜃1 = crank angle
𝑟
𝜃2 = 𝑠𝑖𝑛−1 ( sin 𝜃1 )
𝑙
y = 180 – (𝜃1 + 𝜃2 )
x = √𝑟 2 + 𝑙2 − 2(𝑟)(𝑙) cos 𝑦
r = 31 mm
𝜃1 = 180
31
𝜃2 = 𝑠𝑖𝑛−1 ( sin 180 ) = 0
𝑙
y = 180 – (180 + 0 ) = 0
x = √𝑟 2 + 𝑙2 − 2(𝑟)(𝑙) cos 𝑦
l = 74 mm
9
4.7 Cutting Speed of Crank Slider
The cutting speed of sickle is the velocity of crank slider. Sickle is attached to the sickle
sleeve which is the slider from the crank slider mechanism. From the journal, the velocity
needed to cut the fronds is about 8 to 15 mm/s.
Maximum cutting speed is when the crank angle = 270°
𝑟 2 sin 𝜃1 cos 𝜃1
𝑣 = −𝑟 𝑠𝑖𝑛𝜃1 −
√𝑙2 − 𝑟 2 𝑠𝑖𝑛2 𝜃1
Length 1.8 m
Mass 1.01 kg
Thickness 0.002 m
Value of a 0.02 m
Value of b 0.015 m
Mass = Density x Volume
Mass for full oval = 2.7 g/cm³x (π x 2 x1.5x 180)
= 4.58 kg
10
Statical moment of pole
Q = A’y’
Inertia of pole
1
Inertia = Ix + Iy = (π AB ) (A2+B2)
4
1
= (π (0.02)(0.015)) (0.022 + 0.0152)
4
= 1.47 x 10-7 m4
1
Inertia = Ix + Iy = (π AB ) (A2+B2)
4
1
= (π (0.018)(0.013)) (0.0182 + 0.0132)
4
= 9.0605 x 10-8 m4
=
5.63 x 10-8 m4
11
Maximum Bending Stress Maximum Shear Stress
𝑀𝑐 𝑉𝑄
σ max = t=
𝐼 𝐼𝐿
Figure below shows the Free Body Diagram, Shear Diagram and Moment Diagram of the
motorised cutter.
12
Total downward force at A = Weight of battery
= 1.2 kg (9.81)
= 11.772 N
= 1.01 kg (9.81)
= 9.9081 N/m
∑ 𝐹𝑦 = 0
By = 55.108 N
4.9 Vibration
Vibration produced from motor,
𝟐𝝅 𝑵
𝒘𝒏 =
𝟔𝟎
2𝜋 (500)
=
60
= 52.36 Hz
13
Maximum vibration that pole can withstand,
𝒎𝒈𝒍𝟑
𝜹𝒔𝒕 =
𝟒𝟖 𝑬 𝑰
= 3.055 x 10−4
𝑔
𝑤𝑛 = √
𝛿𝑠𝑡
9.81
=√ = 179.21 Hz
3.055 x 10−4
The pole can withstand the vibration produced by the motor since 179.21 Hz < 374.65 Hz
(1.7𝑥10−8 )(2.0𝑚)
𝑅= Diameter 1.5 mm
𝜋(0.0752 )
Length 2.0 m
Resistivity 1.7𝑥10−8
R = 1.9 V = IR
I = (6.237x106A)
14
4.11 Lithium Polymer Battery
Lithium Polymer Battery is used as the power supply for motorized cutter. Power
needed to move a cutting head is 500 rpm.
With 500 rpm, it needs a motor with 12-volt functioning to move the blade.
Battery Life
= 10000(mAh)/500(mA)*0.7
=14 hours Nominal voltage 12V
15
5.2 Analysis on Pole
Analysis on pole is crucial to make sure that the pole can withstand the force that
being given. Analysis and simulation (generative structural analysis) is conducted using
CATIA.
From the analysis, red colour shows the higher stress. The higher stress in the pole
are at the location of the worker’s hand to withstand force and area at the bottom of the pole.
6.0 Conclusion
The new proposed motorised cutter design does not improvise too much from previous
design. The new design does not only focus on the weight aspect but on its sustainability.
16
7.0 References
[1] Razak, J. (1997). Design and Development of an Oil Palm Fresh Fruit Bunch Cutting
Device.
[2] Hamedon, Z., Zahid, M.N.O., Tomadi, S.H. (2008). Design and Fabricate the Prototype of
a Motorized Cutter for Harvesting Palm Fruit.
[3] Jelani, A.R., Rizal, A., Gono, Y. (2017). Design and Fabricate the Prototype of a Motorized
Cutter for Harvesting Palm Fruit.
[4] Noordin, M. N. A., Hudzari, R. M., Azuan, H. N. (2016). Development of Standard Approach
for Sickle Blade Manufacturing.
[5] Razak, J., Hitam, A., Jamak, J., Noor, M. (2008). CantasTM – A Tool for The Efficient
Harvesting of Oil Palm Fresh Fruit Bunches.
[6] Razak, J. (1998). Force and Energy Requirements for Cutting Oil Palm Frond.
[7] Ramayanty, B., Tineke, M., Wawan, H. (2015). Physical and Mechanical Properties of Palm
Frond for the Development of Palm Oil Waste Chopper and Pressing Machine Design
8.0 Appendix
17
ASSEMBLY DRAWING
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Isometric view 5
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Scale: 1:1
Front view
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DESIGNED BY:
I _
G8
DATE:
H _
3/19/2019
CHECKED BY:
PROF. MADYAR. NURAINI & DR. AZIM
G _
DATE: F _
20/03/2019
SIZE E _
A4 DASSAULT SYSTEMES D _
C _ 1
1
1:1 - SICKLE 1 B _
This drawing is our property; it can't be reproduced or communicated without our written agreement. A _
H G B A
H
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R0.39
R11
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Isometric view
Scale: 5:1
Side view Front view
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DESIGNED BY:
I _
G8
DATE:
H _
3/19/2019
CHECKED BY:
PROF. MADYAR. NURAINI & DR. AZIM
G _
DATE: F _
20/03/2019
SIZE E _
A4 DASSAULT SYSTEMES D _
C _ 1
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This drawing is our property; it can't be reproduced or communicated without our written agreement. A _
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R31
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Scale: 3:1
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DESIGNED BY:
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G8
DATE:
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3/19/2019
CHECKED BY:
PROF. MADYAR. NURAINI & DR. AZIM
G _
DATE: F _
20/03/2019
SIZE E _
A4 DASSAULT SYSTEMES D _
C _ 1
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This drawing is our property; it can't be reproduced or communicated without our written agreement. A _
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Isometric view
Scale: 3:2 3
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DESIGNED BY:
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G8
DATE:
H _
3/19/2019
CHECKED BY:
PROF. MADYAR. NURAINI & DR. AZIM
G _
DATE: F _
20/03/2019
SIZE E _
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This drawing is our property; it can't be reproduced or communicated without our written agreement. A _
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G8 I _
DATE:
H _
3/19/2019
CHECKED BY:
PROF. MADYAR. NURAINI & DR. AZIM
G _
DATE: F _
20/03/2019
SIZE E _
A4 DASSAULT SYSTEMES D _
C _ 1
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Scale: 3:1
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DESIGNED BY:
I _
G8
DATE:
H _
3/19/2019
CHECKED BY:
PROF. MADYAR. NURAINI & DR. AZIM
G _
DATE: F _
20/03/2019
SIZE E _
A4 DASSAULT SYSTEMES D _
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3:1 - CONNECTOR 6 B _
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5:1 - BEARING 7 B _
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