11

Phase 2: Design and plan

Preparation
Phase 1: Preparatory research
activity: gathering relevant 4. Identify design
information requirements

1. Gather relevant
5. Shredder machine
information on the existing
components design,
design of an artificial
size and capacity
shredder
calculation

2. Identify local materials 6. Design

available in the study area conceptualization
that are possible to use in
7. Preparation of
constructing the shredder
design drawings
machine

3. Fresh coconuts husk

physical characteristic
determination
Phase 3: Fabrication

8. Materials
procurement

Phase 4: fresh coconut waste

shredder machine 9.9.Materials
Materials
11. Pre-testing Preparation
preparation

12. Raw materials 10. Fabrication

10. Fabrication of
preparation machine
of Machine
components and
components and
13. Final testing parts assembly
assembly
parts

14. Data collection and data

analysis

Figure 1. Conceptual Framework

 12

Phase 1: Preparatory research activity: gathering relevant

information

Stage 1: Gather relevant information on the existing design of a shredder

In this stage, all data needed was gathered by means of reading journals, books,

and other relevant sources of information regarding the topic. All variables or parameters

that are given in the literature are collected as an initial data for designing the machine.

Such like: motor working capacity, coconut fiber characteristics, maximum speed of the

motor and all materials that are commonly used for fabricating a shredder machine.

Stage 2: Identify local materials available in the study area that are possible to use in

constructing the shredder machine

Based on the given information about the materials that has been use in

fabricating a shredder machine from the literature, it has been obtained by inquiring from

any hardware store near the location where the study was conducted. All material given

had been provided from the store in order to minimize the cost and delay of fabrication.

Materials that are unavailable from the market were needed to do an adjustment and look

for the possible materials that are related or capable for the requirements of the system.

Stage 3: Fresh coconut husk physical characteristic determination

The maximum size or dimension of the raw materials was the main basis of the

hopper design.
 13

Phase 2: Design and plan Preparation

Stage 4: Identify design requirements

Factors that had been considered on designing a waste coconut shredder machine

for young coconut husk were stated. In order to attain the desired design and performance

of the machine, the following included factors have a big help to the researcher.

I. Working capacity of the motor

Another factor in the design that was considered is the working capacity of

the motor. In this factor, the designer determined the speed of the blades

needed in order to cut the subjected raw materials. Based on the study of

Y. Prashant et. al., 2014) ¼ hp single phase AC motor can extract the

coconut fiber from the husk, and it was driven by pulley and connected

through the v-belt with the speed of 240 rpm. According to (I. M. Sanjay

Kumar, Dr. T. R. Hemanth Kumar, 2015) in order to cut the coconut husk

into small pieces, the angular speed of the shaft is 1440 rpm.

II. Location of the workplace

The location of the workplace had been considered to the design factors of

the machine; it had a big help to make the machine more flexible and can

perform the work well in any different area.

 14

Stage 5: Shredder machine components design, size and capacity calculation

One thing that the researcher had been considered was the availability of the

resources to be use, in order to reach the desired design and finish within the given period

of time. Maximizing the amount of raw materials to be shredded and the working

capacity of engine to handle the whole system is very hard situation. Finding a materials

and selecting its property like required speed per unit time of the engine to crush the raw

materials, sizes and characteristics of blades, and even the durability of the materials will

such a big help in designing the system of the machine.

Machine design and machine elements are the basis of the main principle on

equations and calculations.

5.1 Shredding chamber

The shredding chamber is the main components of the shredding system. In this

section, the raw material is subjected to crush to produce the desired output. It is made up

of galvanized iron sheet (gauge 16).

5.2 Blades

The blade is also a part of shredding section. It will place inside the shredding

chamber and driven by the diesel engine through the belt and pulley. It will be made-up

of leaf springs that forge to turn it into a thin and sharpened blade. It is place into a solid

shaft connected to the rotor which is made up of steel plate. There was a space between

the blades with the corresponding distance provided by the improvise spacer made up of

steel pipe that cut into desired length provided by the design. The main function of this

component is to cut the fresh coconut husk into small pieces to attain the desired output.
 15

5.3 Diesel Engine

The diesel engine is the main source of energy in the system. It will drive the

pulleys that are connected to the blades by means of V-Belt. The designer will be using

the diesel engine in order to make the machine more portable and independent. Whereas,

it designed to operate wherever area it’ll be placed, as well as it can easily bring it to the

workplace.

5.4 V-Belt and Pulley

Are the one who made the blades rotates. The angular velocity of the blades

depends upon the diameter of the driven pulley. The pulley will be connected into the

shaft parallel to the blades hub by means of key, and was driven by the belt to make it

functional. The design will use V-Belt in order to make the chain more fitted and don’t

have a slacks, as well as the belt must have some teeth to prevent the slip.

5.5 Frames

It is also a component of the system that holds every parts of the system. It will be

made-up of angular bar and steep pipe for a lighter machine. The design of frame will

depend upon the amount of forced exerted by its load.

5.7 Feed Hopper

The Hopper is the component of the machine where the raw material will place.

In this component, the researcher will notice the maximum shredding capacity of the

machine at a time
 16

5.8 Tensioner

It is also a component of the machine that place into the belt and pulley section. It

helps the engine to minimize its load upon the starting of the operation. Its main function

is to hold the connection of the shredding chamber and the driver by means of tighten and

slacking the belt that are connected on the two said components.

Stage 6: Design conceptualization

In designing a waste coconut shredder machine for young coconut husk, several

concepts were applied. Adjustments had been done upon the research is at the

development stage, in order to minimize the wasting of time as the final design of the

system is undergo.

Stage 7: Preparation of design drawings

The designs of the machine have been done using AutoCAD software. The detail

included was based on the requirements of the system design.

Phase 3: Fabrication

Stage 8: Materials procurement and order

The choice of materials was based on availability in the market and supplier

that offered and lowest price was selected for the purchasing of the materials needed for

fabrication components.
 17

Stage 9: Materials preparation

All materials and equipment needed for fabrication of the blade, case, diesel

engine were well prepared so that there was no interruption and delay in the fabrication.

Stage 10: Fabrication of machine components and parts assembly

Making layout on each of the components of the machine was necessary to

maximize the use of the materials and also to limit waste of materials during fabrication.

On the component of the machine motor or engine that gives force undergoes to blade,

the fabrication was according to the design of machine and correct dimension. After

fabrication, all parts and components of the system had been assembled and then the

shredder machine was prepared for the testing.

Phase 4: Fresh coconut waste shredder machine

Stage 11: Pre-testing

After the fabrication of the components was assemble. Pre-testing had been

conducted and monitored by visual observation if the system components were stable and

on normal condition before final testing was conducted. It was done in almost a minute of

operation.

Rectification

In this stage of the study adjustment and repair was conducted in order to

provide the effective needs that cause error during the pre-testing stage.

Stage 12: Raw materials preparation

 18

Preparations of raw materials are done by per kilogram of fresh coconut waste as

an input for batch of testing on the machine.

Stage 13: Final testing

After preparation of raw materials and the coconut shredder machine, the

operation had been started the coconut waste was measure before feeding into the

coconut shredder machine.

Stage 14: data collection

After the actual testing of a coconut shredder machine the author collected data

using weighing scale, stop watch and tachometer. All data were gathered and recorded to

evaluate the actual performance of the shredder machine.