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Table of Contents

Title and Author (s)

Page

DOUBLE SIDED ANTENNAS FOR ULTRA WIDEBAND APPLICATIONS Sara Afifah Binti Abu Bakar & Noor Akmalun Nisa‟ Binti Man

3

DEVELOPMENT OF COCONUT SPLITTING DEVICE USING HYDRAULIC SYSTEM (PROTOTYPE) Hjh Sharizan Binti Hj. Abdul Halim

10

THE DEVELOPMENT OF MESSENGER ANIMAL TRAP Muhd Muslim Bin Abu Bakar & Noor Sufiza Binti Ahmad Kuganesaan S/O Rajangeran, Mugilan S/O Rajagopal, Sri Taran S/O Kannappan, Dinesh Kumar S/O Ramachandran & Kuga Deva S/O Manimaran

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THE DEVELOPMENT OF SISAL FIBER EXTRACTION MACHINE Khairuddin B. Ishak & Mohd Rosli B. Saad M. Luqman, N. Fatini, N. Syahirah, Yagheswaran, Amir Iddin

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THE DEVELOPMENT OF WATER TREATMENT EDUCATION KIT (TEK15) Somashana A/L Prakasam & Noor Rafidah Binti Md. Osman M. Haniff, Muda Iskandar, M. Nazrol Najmi & Sarvanaraj

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THE DEVELOPMENT OF LOOSE PALM FRUIT WITH MANUAL APPLICATION Ahmad Firdaus B. Zawawil Anwar & Mohd Pahmi B. Saiman M. Azizan B. Sapari, Ahmad Syakir B. Ghazali, M. Kamil B. Omarkayam, M. Aizuddin B. Jameel, Nurul Asyilah Bt. Ahmad

33

THE DEVELOPMENT OF PRESS BEARING TOOL Zulkiffli B. Bakar & Hjh Sharizan Binti Hj Abdul Halim Aruni B. Zulkifli, M. Imran B. Ramlan, M. Faiz B. Hamzah

38

THE DEVELOPMENT OF SEMI-AUTO ANIMAL FOOD PELLET (SAFP-15) MACHINE Mazlan B. Che Mustafa & Md. Baharuddin B. Abdul Rahman N. Syahira Bt. Mahizan, Noraqilah Bt. Abdul Wahab, M. Shukri B. Mohamad, N. Syafiqa Najwa Bt. Mohd Saberi

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THE DEVELOPMENT OF FLUORESCENT LIGHT REMOVER Kumaran A/L Sundraj & Syafirul Ikmar B. Shaharudin Asahel A/L Soundrapaman, Abd. Muaz B. Kamal Baharin, Luqman Hakim B. Salehan, M. Amalluddin B. Zulkifli

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FOUR (4) STROKE ENGINE COMPRESSION RATIO MEASUREMENT FOR TEACHING AID Badrul Sakinah Bt. Haji Sanusi & Mohamad Tarmizi bin Abu Seman M. Azhar B. Ismail, M. Faiz B. Azmy, Azarul Amir B. Abd. Ghani, Logha A/L Anbarasu

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THE DEVELOPMENT OF ELECTRICAL MOTOR RUBBER TAPPING MACHINE (EMRT-15) Yuniza Bt. Ahmad & Mohd Pahmi B. Saiman M. Nazrin, Keong C. S., M. Aliff Farhan, M. Ariff, Intan Humairah

56

MODIFICATION OF CRUSHER MACHINE ON COUPLING MH 45 RS M. Fadli B. Abdul Hamid & Md. Najib B. Talibin M. Faiq, M. Marwan Mu‟izz, A. Azim, S. Norliana

60

THE DEVELOPMENT AG LIFTING MACHINE Mohd Tajudin B. Abd Karim & Mohd Rosli B. Saad Easuvaran S/O Raman, M. Mustafa B. Omar, M. Yusuf B. M. Fauzi, Mif Tahud Din B. Min Fari

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THE DEVELOPMENT AND DATA COLLECTION OF SPUR GEAR LEARNING KIT Mohd.Najib bin Haji Talibin & Noor Rafidah Binti Md. Osman Norsyuarina Bt. Mohamad, M. Amarrun Naim B. Harun, M. Alif Alifi B. Jaafa, M. Zabidi B. Zainuddin & Nurul Fatihah Bt. Ishak.

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THE DEVELOPMENT OF AUTOMATIC SKATEBOARD Norfadliyah Bt. Abdul Hamid & Md. Baharuddin B. Abdul Rahman M. Raffiq B. Rosli, M. Ammar B. Kamaluddin Darus & `Aisyatul Amla Bt. Mohammad

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THE DEVELOPMENT OF PORTABLE BACKDROP Mohd Hafirizal Bin Omar & Mohamad Salim Bin Abdul Wahab Faizal, A. Wafi, M. Azlan, Halimatun Saadiah & Nur Hazirah

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SUSTAINABLE PRODUCT DESIGN AND MANUFACTURING Maizul Afzairizal Mohd Adnan & Mohamad Taufik A Rahman

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THE DEVELOPMENT OF RICE WASHER MACHINE Noor Sufiza Binti Ahmad & Aswandi B. Yaakob Priyaraj Rajakumar, Marthininaidu Vasudiven, Nurmaisarah B. Nasir, Roslina Bt. Che Hasim

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THE DESIGN AND DEVELOPMENT OF A NOZZLE TO SUIT LIQUID FUEL THRUST DEVICE Ahmad Firdaus Bin Zawawil Anwar

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THE DEVELOPMENT OF V- CLAMP PIPING MACHINE Nurhasliza Binti Rosli

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SIMPLE HARMONIC MOTION KIT (SHM KIT) Kamarul Hisyam Bin Haji Osman @ Othman, Nik Abdullah Bin Nik Hassan, Tan Chin Chai

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BATIK FIXATION THROUGH INFRARED

Muhammad Nasir bin Marzuki, Surianis Binti Dalimin, Norhafizah Akmal bt Sukri

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DOUBLE SIDED ANTENNAS FOR ULTRA WIDEBAND APPLICATIONS

Sara Afifah Binti Abu Bakar* Tel: +6016-2610923 Email: afifah@psp.edu.my

Noor Akmalun Nisa’ Binti Man* Tel: +6019-2177790 Email: akmalun@psp.edu.my

*Mathematics, Science and Computer Department, Seberang Perai Polytechnic, Penang, Malaysia.

ABSTRACT In this paper, a comparison between full size and half size on double sided antenna for Ultra Wide Band (UWB) communication is being proposed to know the output of the bandwidth range. The antenna designs have been simulated using CST Microwave Studio. The antenna covers the UWB spectrum from 3.1 to 10.6 GHz, and had a return loss below than 10 dB throughout the entire band. A compact antenna area of 30.0 x 60.0 mm2 is obtained. The material used is FR-4 epoxy glass substrate that has dielectric constant, εr=4.4 and the dielectric thickness; h =1.6mm. The antenna also gives omnidirectional radiation characteristics with reasonable gain values over the same frequency band.

Keywords: Double-sided, Ultra Wide Band (UWB) antenna, return loss, omni directional

1.0 INTRODUCTION UWB technology has the advantages of high data transmission rates, low complexity, high precision ranging, easy connections among a large number of devices such as laptops, high definition TVs, digital and very low interference and (B. Saidaiah et al., 2012). In 2002, the Federal Communications Commission (FCC) announced its decision to allow the unlicensed use of the frequency band from 3.1 to 10.6 GHz for UWB communication systems (Elizabeth Rufus et al., 2008). Therefore in order to avoid a large return loss and matching problem, UWB antenna impedance must achieve 7.5 GHz bandwidth. For the ideal case, antenna radiation patterns, impedance matching and gains should be stable across the entire band. An Omni directional radiation patterns are needed which means wave is radiated in all directions. A stable antenna needs to be small enough to be compatible to the UWB unit. One of the popular antennas in the present day communication scenario is micro strip antenna. The micro strip antenna radiates a relatively board beam broadside to the plane of the substrate. Thus the micro strip antenna has a very low profile, and can be fabricated using printed circuit techniques. This implies that the antenna can be made conformable, and potentially at low cost. Other advantages include easy fabrication into linear or planar arrays, and easy integration with microwave integrated circuit. This type of antenna is used extensively in many applications such as ground penetrating radar (K. R. Mahmoud, 2010), wireless communications and mobile station (Kulwinder Singh et al., 2012). In UWB antenna design, several double sided antenna based configurations have been reported (Liang Zhou Shaobin liu et al., 2010; Manabu Yamamoto et al., 2010; M. Fernando et al., 2010; Mohammad Tariqul Islam et al., 2010; S. Didouh et al., 2012 .In this paper, the work is focusing on the antenna with circular disc shape, which has advantages of smaller area, better return loss in high frequency and wider bandwidth.

2.0 ANTENNA DESIGN The structure of the full-size antenna is shown in Figure1 below. The material used is FR-4 epoxy glass substrate that has dielectric constant, εr = 4.4 and the dielectric thickness h =1.6mm with the size of W×L = (30×60)mm2. Micro strip lines having 50Ω input impedance are used for feeding the antenna as shown in Figure 1 and Figure 2. The width of the feed line is wf

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= 2.7 mm, the radiating element consists of two overlapped circular discs of radius r1 =7.05 mm. Two circular slot of radius r2= 13 mm have been cut out from the ground plane as shown in Figure 3. The various characteristics of bow tie antenna, such as input impedance and return loss strongly depend on the form of current radiated from the antenna (S. Didouh, M. Abri and F. T. Bendimerad, 2012).

Figure 1: Full size Fabricated of a Double Sided Antenna

The diameter of circular discs bow-tie patch can be obtained by:

Eq 1:

r

D

5.0

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(b)

Figure 2: Geometry of a Double Sided Antenna (a) Top view(b) Bottom view

Figure 3: Dimensions of a Double Sided Antenna

(a) Full size (b) Half size

The basic configuration for the UWB double sided antenna is shown in Table 1. Analyses of the feeding structure are shown in Figure 4 and Figure 5. These analyses are conducted in order to assess the influence of the dimension of the strip feed line on the antenna performance and to find the optimal impedance bandwidth.

Table 1: Dimensions of a Double Sided Antenna

BASIC CONFIGURATION VARIABLE DIMENSION (mm)

Substrate W L

30 60

Patch r1 lf wf

7.05 16 2.7

Ground Plane r2 13.1

From Figure 4, as the width of the micro strip feed increases, the resonant frequencies are also shifted to the right hand side. This indicates that the impedance of the feed lines are increases will affect the resonance of the antenna.

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Figure 4: Return loss of various width of micro strip feed

The shape of the response stills the same although the length of the micro stip feed line changes as shown in Figure 5. It also will affect the resonance based on the impedance at the feed line.

Figure 5: Return loss of various length of micro strip feed

3.0 METHODOLOGY For this project, CST Microwave Studio Suite 2011 is chosen because this is the software for electromagnetic analysis and design at high frequency range. The dimensions of the antenna as discussed in the previous section are needed in order to draw the micro strip antenna in electromagnetic, EM structure drawing. The substrate material for this project that is designed using CST Microwave Studio software is FR-4 (loss free) type and normal substrate type, which the dielectric thickness is 1.6mm for this substrate. After all important parameters are set up, the designed antenna is simulated. After the simulation process, the micro strip antenna will be fabricated on the printed-circuit-board (PCB) double-sided of FR4 type. Then the measurement was done by using vector network analyser. Some characteristics of antenna can be displayed by network analyser such as return loss, input impedance, VSWR and bandwidth.

4.0 RESULT AND DISCUSSION A. Full size Full size of bow-tie micro strip antennas have become popular in the present day communication scenario due to their compact in nature compared to rectangular patches. Design of bow-tie micro strip antenna is based on design of triangular micro strip antenna. The bow-tie patch actually is the combination of imaginary image of two triangular patches which are fabricated in a single substrate.

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i. Return Loss The return loss (RL) is a parameter which indicates the amount of power that is lost to the load and does not return as a reflection. From the simulated observation, the antenna has a return loss of -52.518 dB and -27.519dB at 3.4GHz and 7.5GHz as shown in Figure 7. With the following geometry antenna exhibits very good results due to return loss lower than -10dB from the frequency range of 3.1GHz to 10.6GHz. As shown in Figure 7, it is clearly seen that there is a frequency shift between the simulated and measured result. Due to inaccuracy in fabrication process, the size of the patch will differ from the actual size. This will definitely bring to the shifting in the operating frequency.

Figure 7: Return loss of a Double Sided Antenna ii. Bandwidth Bandwidth of the antenna expresses its ability to operate over a wide frequency range. Based on graphs in Figure 8, it can be seen that the bow-tie antenna has a return loss of -52.518 dB and -27.519dB at 3.4GHz and 7.5GHz. With the following geometry antenna exhibits very good results due to return loss lower than -10dB from the frequency range of 3.1GHz to 10.6GHz. The result shows the bow-tie antenna has a wider bandwidth. These values are accepted in order to fabricate the antenna because the return loss should be below than -10dB to operate properly.

Figure 8: Bandwidth of Double Sided Antenna

iii. Radiation Pattern The simulated circular discs antenna radiation patterns for the two resonant frequencies are shown in Figure 9 and Figure 10 respectively. The figure also shows E-plane and H-plane for circular discs bow-tie antenna. The main lobe obtained antenna of 3.4719GHz has a magnitude of - 1.5dB and the 3dB angular width is 50.0o. At 7.5027GHz, the magnitude observed is 1.5dB with its angular width of 47.2o. From the simulation results, the wave is radiated in all directions.

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Figure 9: Far-field radiation pattern for 3.4GHz

Figure 10: Far-field radiation pattern for 7.5GHz B. Half size i. Bandwidth The S parameters of half size double sided antenna is shown in Figure 11. Note that the full-size and half-size double sided antennas both cover the whole UWB band, while the half-size bow-tie slot antenna area has a 50% reduction compared with the full-size bow-tie slot antenna (ShiweiQu, and ChengliRuan, 2005). The simulated and measured S11 of the bow-tie slot half-size antenna also showed a good agreement is obtained due to all ranges were operated below than 10dB from the frequency range of 3.1GHz to 10.6GHz. Figure 11 show the dot line prefers for the result of simulation, then for continuous line prefer of measured result.

Figure 11: Double Sided Antenna

4.0 CONCLUSION The designs of circular discs double sided antennas have been performed by simulation. Half size antenna is proposed by halving the full size symmetrical antenna. The bow-tie antenna has a good return loss and the bandwidth for VSWR < 2 has been achieved for the entire UWB frequency range 3.1 – 10.6 GHz. From the results, circular discs antenna have its advantages and the important characteristics of the antennas have been shown above.

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5.0 BIBLIOGRAPHY

B. Saidaiah, A. Sudhakar and K. Padma Raju. (2012). ―Modeling andAnalysis of an Efficient Bow-Tie Antenna for UWB Applications,‖ International Journal of Emerging Technology and Advanced Engineering, Vol 2, No. 10, pp. 158-163

Elizabeth Rufus, Zachariah C Alex, and P VivekChaitanya, (2008). ―A modified Bow-Tie Antenna for Microwave Imaging Applications.‖ Journal of Microwave, Optoelectronics and Electromagnetics Application, Vol. 7, No. 2, pp. 115-122

K. R. Mahmoud. (2010). ―Design optimization of a bow-tie antenna for 2.45 GHz RFID readers using a hybrid BSO-NM algorithm‖, Progress In Electromagnetics Research, pp. 105-117

Kulwinder Singh, Yadwinder Kumar and Satvir Singh. (2012). ―A modified bow tie antenna with U-shape slot for Wireless applications‖, International Journal of Emerging Technology and Advanced Engineering,Vol. 2, Issue 10, pp. 147-152.

Liang Zhou Shaobin Liu and Yu Chen (2010). ―Novel Compact Bow-Tie Slot Antennas for Ultra-Wideband Applications.‖ Proceedings of International Symposium on Signals, Systems and Electronics (ISSSE2010).

Manabu Yamamoto, Daisuke Tokuyama and Toshio Nojima. (2010). ―Design of Quasi-Millimeter Wave Leaf-Shaped Bowtie Array Antenna for UWB Applications‖, IEEE Antennas and Propagation Society International Symposium, pp. 180-185. M. Fernando, K. Busawon, M Elsdon and D. Smith,m. (2010). ―Fundamental Issues in Antenna design for Microwave Medical Imaging Applications,‖ 7th International Symposium on Communication Systems Networks and Digital Signal Processing, pp. 795 – 800

Mohammad Tariqul Islam, RezaulAzim and NorbahiahMis. (2010). ―Design and

Optimization of a Printed Rectangular Antenna for Ultra Wideband Applications‖, International Conference on Microwave and Millimeter Wave Technology, pp 283-286.

S. Didouh, M. Abri and F. T. Bendimerad.( 2012). ―Multilayered Bow- Tie Antennas Design For RFID And Radar Applications Using A Simple Equivalent Transmission Line Model‖, International Journal of Computer Networks & Communications, Vol.4, No.3, pp.65-61.

S. Didouh, M. Abri and F. T. Bendimerad. (2012). ―Multilayered Bow-tie Antennas Design for RFID And Radar Applications Using A Simple Equivalent Transmission Line Model‖, International Journal of Computer Networks & Communications,Vol.4, No.3, pp. 121-126.

ShiweiQu, and ChengliRuan. (2005).―Quadrate Bowtie Antenna With Round Corners.‖ IEEE International Conference on UWB, pp. 1-4.

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DEVELOPMENT OF COCONUT SPLITTING DEVICE USING HYDRAULIC SYSTEM (PROTOTYPE)

Hjh. Sharizan Binti Hj Abdul Halim Tel: +6019-5617068 Email: sharizan@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic,

Penang, Malaysia.

ABSTRACT

This project is using a hydraulic system to open and split the young coconut. From the observation, the existing equipment used a jig concept whereby they used a sharp hollow cylinder to penetrate and open up the water flow. But, they have to trim the fibre first before penetrate through the sharp hollow cylinder provided. After that, they have to use machete to split the shell to get the soft coconut jelly. However, our product is just one time process. The base design is made by mild steel with machine size is 0.85 m x 0.46 m x 1.45 m. We used stainless steel for the blade and clamping device since the material is metal rust resistance and it durable. When the operator push start button, the hydraulic will start actuated the clamping device and then blade will penetrate from bottom and opened up the shell. This allowed the water drained out. When the blade go inside deeply it will split the coconut shell into half. This device will split two (2) coconuts shell per minute, gained the 100 percent of the water, and at the same time we can taste the soft coconut jelly. With this device, it is easy to handle, clean and safe. It‟s required only one person to operate. The device has a clamping mechanism to hold coconut in place since coconut has a various sizes and shapes. For the cleanness, we added the filtering device for the water. We hoped that it can be commercial, user friendly, faster splitting device and clean. Keywords: Development, Coconut Splitting Devise, Hydraulic System, prototype

1.0 INTRODUCTION Currently Malaysian government is focuses on the industrial development of small and medium enterprises (SMEs) in rural areas as a medium that can contribute to the national income. To answer the call, the government is encourage people to designed a machine based food production can help entrepreneurs and consumers. Therefore, we are focusing on making Coconut Splitting Device Using Hydraulic System since young coconut water and jelly is one of national favourite beverage. A hydraulic clamping device for the axial clamping of bodies of rotation, especially tools, onto a revolving mandrel is provided. It has a base body fixed to a mandrel and a rotary piston which is suspended in a floating manner inside the base body and is axially slayable relative to the base body via a closed-circuit hydraulic system and setscrews. (Albert Schrem,1992). According to Darilyn Campbell-Falck et al, (2000) the immature coconut, contain less ‗meat‘ or endosperm and is mostly fluid. As the coconut ages, the ‗meat‘ thickens and becomes tougher. Because the younger coconut contains more fluid, these are generally chosen for intravenous fluid administration. Each coconut contains approximately 500 to 1,000 millilitres of fluid. Coconut water (CW) is commonly known in Malaysia as refreshing drinks. It contains many minerals and vitamins that can be categorized as soft nutritious drinks yet refreshing. Soft coconut jelly is delicious to eat. Coconut water was significantly sweeter, caused less nausea, fullness and no stomach upset and was also easier to consume in a larger amount compared with CEB and PW ingestion. In conclusion ingestion of fresh young coconut water, a natural refreshing beverage could be used for whole body, rehydration after exercise (Mohamed Saat et al, 2002). Coconut splitting device is a new design by using hydraulic system; to cut and split the coconut shell. It also can extract the coconut water. The scientific name for the young coconuts is Coco Nucifera. According to Jose C. Jackson et al (2004), changes in chemical composition of

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coconut (coco nucifera) water, including total and soluble solids, titratable acidity, turbidity, ash, lipids and sugar, were investigated in four varieties of coconuts at four stages of maturity of the fruit. CW contains sodium, potassium, chloride and glucose as rehydrate fluid. Young coconut water usually contains 99% fat free, low carbohydrate 99% and 99% less sugar. CW however, has been used as an oral rehydration in patients with diarrhoea to replace fluid loss from the gastrointestinal tract (Chavalittamrong et al, 1982). People believed that the coconut water could cure diarrhoea, choler and chicken pox. The coconuts have a various sizes and shape. Therefore, it is a challenge for us the design the clamping mechanism in order to hold the coconut in place. For the cleanness we add the filtering device for the water. The existing equipment used jig concept whereby they used a sharp hollow cylinder. This jig concept still has to trim the fibre first on the top of the coconut, and then penetrate through the sharp hollow cylinder provided. After drained out the water, they have to split the shell to get the soft jelly. The demand and supply for the young coconut is very high for local consumers and to attract the tourism. A supplier can make profit by selling the coconut and the water seller can sell the coconut water and the soft jelly. As a result, the objective for this project is to produce a Coconut Splitting Devise using Hydraulic system that adheres to the following criteria:

i. A machine driven by an electric power and hydraulic system. ii. A portable design, easy to control and an organized system. iii. A device that has a clamping mechanism to hold various sizes and shape of coconut

and water filtering system. This project will focus on electric power and hydraulic system for the operation of the machine in order to speed up the timing for splitting the coconut shell. The device has a clamping mechanism to hold in place since coconut has a various sizes and shape. It‘s also included the water filtering device. This is to ensure the cleanness of the coconut water before customer drink. The main mould is made by stainless steel since it not rusty and cutting blade is using stainless steel. Main body is made by mild steel and L shape mild steel.

2.0 REVIEW OF COCONUT SPLITTING DEVICE BY USING HYDRAULIC SYSTEM The research of this project is based as the flow chart below:

Research the standard grade and size of

coconut and shape

Research the types of blade to split the

coconut shell

Research for clamping device and filtering

water

Identify handling problem while operate the

device

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Table 2.0: Process of Desiign Concept for Coconut Splitting Device using Hydraulic

System 2.1 TRADITIONAL METHOD There are various types of blades for cutting and extract the coconut water in the market. a) Using machete or an axe to trim the coconut fibre

The advantage of this method is easy to trim or slice the coconut fibre. They used either an axe or machete. To gain the water, it has to go through several times to trim the fibre until reach to the soft shell. Disadvantage of this method is used a lot of energy to trim and slice the fibre. Indirectly, the user is tired, tired waist, articulating arms, and shoulders. This manual method is quite complicated. The coconut should be held firmly with one hand, holding the bottom of the coconut while the other hand holds a machete. If there are any omissions or errors, injury is likely to occur.

Figure 2.1 a): Traditional Method using machete to extract the coconut water

Literature review for the device

Study the advantage and disadvantage the

machine in the market

Design concept using the hydraulic system

Analysis Data / Calculation Volume, Force

of Cylinder

Testing and improvement design

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b) Jig Concept using Sharp Hollow Cylinder The advantage of this method is easy just to trim the coconut fibre on top. Then chop or stab the coconut into the sharp hollow cylinder. This concept is faster compare to the traditional method to drain the water. Disadvantage of this method is used a lot of energy to chop or stab the coconut. After drained out the water, the user has to use machete to split the coconut shell to gain the soft coconut jelly. This mean the user have to do twice; trim, chop and split. If there are any omissions or errors, injury is likely to occur.

Figure 2.1 b): Jig Concept using Sharp Hollow Cylinder

3.0 PROJECT DEVELOPMENT (METHODS)

3.1 STANDARD COCONUT SIZE AND SHAPE To build the device, we have to do a research regarding the coconut size and shape. We measure the width, height and diameter of the coconut in centimetre. For this research, we measured FIVE (5) young coconuts as a standard of our study. We used a standard grade of young coconuts. The table below shows the results:

No. Of Coconut

Width (cm) Height (cm)

Diameter (cm)

1 18 23 53

2 18 19 54

3 19 21 55

4 18 22 60

5 17 22 52

Average 18 21.4 54.8

Figure 3.1 (i): Size of Coconut in Malaysia

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3.2 GANTT CHART AND IMPLEMENTATION

Figure 3.2 (i): Gantt chart shown the activities of the Development of Coconut Splitting Device

3.3 SCHEMATIC DIAGRAM FOR HYDRAULIC SYSTEM This coconut splitting device is driven by hydraulic system because it's easier to arrange the pneumatic components. It is a combination of 4 Cylinder Three Action (DAC). When the switch is pressed, the hydraulic pump operation and movement of the hydraulic cylinder is controlled using a 4/3 valve, either to lower or raise the cylinder rod. The oil container filled when the cylinder are upward, then 4/3 valve is controlled to ensure that the cylinder rod in a state of decline. It is started pressing and clamp the coconut until it touched the cutting blade. At the same time, cutting blade will begins to penetrate inside coconuts shell to enable drained out the coconut water. Then the blade opened out and split the shell into half.

Figure 3.3 (i): Schematic Diagram for Hydraulic system

3.4 DESIGN CONCEPT Base design is made by mild steel with machine size is 0.85 m x 0.46 m x 1.45 m. The machine weight is 40 kilograms and only one operator to operate the device. Power supply is 240 V / 1

A

P T

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pH / 50 Hz mean while pump rating is 2 litres per min flow rate. The blade made by stainless steel and the container made by aluminium.

Figure 3.4 (i): Isometric View the Coconut Splitting Device

Figure 3.4 (ii): Clamping Device

Figure 3.4 (iii): Blade Design

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Figure 3.4 (iv): Filter Design and the water Container

Figure 3.4 (v): Complete design (front and side view) of Coconut Splitting Device

3.5 MATERIAL SELECTION In designing Coconut Splitting Device, there are several materials to select depend on the purpose and usefulness of a product to be produced. Usually the raw material selected has to be suitable with the project purposes. Material selection is based on the strength, rust resistance and resilience of the materials in the production of products. Among the raw materials used are angle bar, stainless steel, aluminium, acrylic resins, mild steel, and others. Others component considered such as cutting blades, the position of the three actions cylinder, hose connector, tyre and hydraulic pump and cylinder.

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Bil. Raw Material Component

1 Iron Angle Bar Base 2 Iron Hollow Bar Base 3 Acrylic Sheets Cover 4 Stainless Steel Blade and clamping 5 Mild Steel Base 6 Gas Bonnet Damper 7 Hydraulic Pump 8 Hydraulic cylinder 9 4 / 3 Way Directional Control Valve Cylinder / Actuator

10 Hose Connector Hydraulic hose 11 4 tyre Movement 12 Aluminium Container

Figure 3.5 (i): List of the Raw Material and Component

3.6 PROCESS FLOW CHART OF STANDARD OPERATION SYSTEM (SOP) Below is the process flow chart for the device and Standard Operation System:

4.0 ANALYSIS (VALUE/COST/BENEFITS, FORECAST) Design is also a process of rational decision-making and trying to choose the best solution in accordance with the scope required. In any design, problems are viewed from different aspects and solutions made in various ways such as using mathematical analysis, the experience of the existing dam and problem solving using the results of research or experimental design. As a conclusion, the design of the products below are based from a few things to consider, such as, product is easy to install, the product is easy to re-open, the product credibility easily taken care of and maintained and the product has the characteristics of a good security.

Figure 3.6 (i): Process Flow of the Operation Standard Procedure for Coconut Splitting Device

Allocated the coconut inside the clamping

device

Push the start button and the actuator for

extend cylinder is on and start to clamp

Clamping device will grip the coconut and

the cutting blade will penetrate inside the

shell

The shell will crack the water will drained

out and filtering inside the container

The retract cylinder will split the coconut

into half. Easy to access the soft coconut

jelly

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4.1 COST AND PERFORMANCE The cost for fabricate this machine is about RM3,911.00, which included cost for raw material RM 921.00, cost for hydraulic pump and cylinder is RM2600.00, machine cost RM300.00 and overhead cost is RM90.00. Although the cost is of hydraulic pump and cylinder is quite high but the ability to get consistency of clamping and blade penetrate is achieved. Furthermore this hydraulic pump, cylinder and the hose connector was sponsored by someone. 4.2 BENEFITS Even though the cost of hydraulic in not economic to build this device but the quality of splitting coconut evenly into half was achieved. In one minute this device can split two coconuts. Only one operator is need to operate but it required skilful worker for maintenance the system. 4.3 TEST RUN During the first test run, the machine runs smoothly. However from our observation, we can detect movement of coconut inside the clamping device. When the operator allocates the coconut it could stay firmly. So, we made some adjustment to the top clamp with 4 rods bolt and nut. Then second test run, everything is in places

5.0 CONCLUSIONS As a conclusion this product has been completed successfully due to its schedule. By using this device is good for medium and huge industries. This is because the cost to buy and maintain the system is quite high. We hope it can be commercialise and benefit to other user or education. Our product is just one time process. For the purposed of our study, we used five (5) standard grade of young coconut and we measured the width, height and diameter of the young coconuts in centimetre. When the operator push start button, the hydraulic will start actuated the clamping device and then blade will penetrate from bottom and opened up the shell. This allowed the water drained out. When the blade go inside deeply it will split the coconut shell into half. This device will split two (2) coconuts shell per minute, gained the 100 percent of the water, and at the same time we can taste the soft coconut jelly. With this device, it is easy to handle, clean and safe. It‘s required only one person to operate but it will require skilled labour to maintenance. The device has a clamping mechanism to hold coconut in place since coconut has a various sizes and shapes. For the cleanness, we added the filtering device for the water. We hoped that it can be commercial, user friendly, faster splitting device and clean

6.0 BIBLIOGRAPHY

Albert Schrem. (1992): Hydraulic Clamping Device. Assignment of Assignor Interest

Chavalittamrong B., Pidatcha P., and Thavisri U. (1982): Electrolytes, sugar, calories, osmodarity and pH of beverages and coconut water. Southeast Asia. J-trop. Medical Public Heath. 13: 427-431

Darily Campbell-Falck, Tamara Thomas, Troy M. Flack, Narco Tutuo, and Kathleen Clem. (2000): Intravenous Use of Coconut Water, The American Journal of Emergency Medicine. Vol 18, Issue 1, Pages 108-111

Jose C. Jackson, Andre Gordon, Gavin Wizzard, Kayanne McCook and Rosa Rolle. (2004): Changes in Chemical composition of coconut (Coco Nucifera) water during maturation of the fruit. Journal of the Science of food and Agriculture. Vol 84, Issue 9, pages 1049-1052, July 2004

Mohamed Saat, Rabindarjeet Singh, Roland Clamin, Sirisinghe and Mohd Nawawi. (2002): Rehydration after Exercise with Fresh Young Coconut Water, Carbohydrate-Electrolyte Beverage and Plain Water. Journal of Physiological Anthology and Applied Human Science

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THE DEVELOPMENT OF MESSENGER ANIMAL TRAP

Muhd Muslim Bin Abu Bakar Tel: +6013-2899525 Email: muslim@psp.edu.my

Noor Sufiza Binti Ahmad

Tel: +06013-9825060 Email: sufiza@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic,

Penang, Malaysia

Kuganesaan S/O Rajangeran, Mugilan S/O Rajagopal, Sri Taran S/O Kannappan, Dinesh Kumar S/O Ramachandran & Kuga Deva S/O Manimaran

ABSTRACT Messenger Animal Trap is an environment friendly project that produced to save garden and agriculture from rodents and other pests. It also can help to save our own pets from get trapped and death in the cage. This machine is using a system that based on combination of mechanical and electronic components and concept. The main function of this project is to trap pest that destroy and harm to garden farm and agriculture places. This machine can be used in any condition and produce alert to the user so that the user will be in full awareness if any animal entering the cage. Messenger Animal Trap is made of steel and electrical component that helps to alert the user once there is animal trapped in the cage. The sensor help the cage to close automatically once there is any animal entering the cage to eat the bait. By inventing this product, users did not have to worry about the plant in their gardens or their agriculture place because this machine will help prevent from rodents and other pest animals.

Keywords: Development, Messenger Animal Trap

1.0 INTRODUCTION Animal trapping is a device used to catch animals whether for food or fur. This process has been part of human culture for thousands of years. It involves the use of a trap to catch an animal in its natural habitat, and can be applied to anything as small as a mouse and as large as a bear. During the Ice Age, people caught animals for fur pelts to protect their body from the cold. Today, people trap animals for survival, sustenance and even for money. Trapping is also used in houses to control damage done by these animals such as mousetraps. There are many differences in the animals trap cage nowadays. The changes are from death trap to animal trap and now our project (Messenger animal trap) included with ―sms‖ alert to the user. However, there are problems in the animal trap that are already in markets. The traps sold in market are not really safe for pet owner if used in house, farm or garden. Another thing is the pest/pets could be dead or injured if being leaved too long without food or water. Therefore, a new system is developed to overcome these problems. Messenger Animal Trap is a combination of mechanical parts and electrical components innovated to catch animal that is harm to our indoor and outdoor environment like forest, farm, garden, field and agriculture. The sensor will detect if animal entering the cage and then the system will send notify to the user of the messenger cage. In the designing stage, many aspects should be studied for producing a quality, effective and widely accepted product. Therefore, the objectives itself is the key target for the creation of the product. The main objectives to be achieved are that the system will alert us where ever we are in seconds and will save the life of our own pets without injuring them. Furthermore, we can trap animals/pest alive or on time in a short period of time. As a conclusion, we upgrade the animal trap cage to make it easier for the users to trap the destroying pests. By using the GSM system, the user can get the alert alarm wherever they are depending on their coverage signal. This cage also will benefit the bird hunters in the jungle.

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They can set/hide the trap cage and then just stay at home. If there is any animal get inside the cage, the trap user will get a message from the system. It is too helpful for those who want to trap animal alive and also increase the quantity of animal trapped per day.

2.0 METHODOLOGY In the discussion session, two ideas were proposed for this project. After research and discussion, we decided to used currently ―Animal Trap‖ which available in the market to study the design and then select the best process to create and assemble the components of the project. In general, the "Messenger Animal Trap" is fabricating using Arc Welding, soldering, and so on.

2.1 DESIGN This is the results of the discussion with the group members and found that the idea of two design concepts was selected. This is based on endurance and strength which was easier to made and finally the design with the messenger system box is fixed on top of the cage surface and the sensor is cut off when the cage gate is down and cut off the sensor cutter.

Figure 1: Assembly Drawing for Cage Animal Trap

Figure 2: Assembly Drawing

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2.2 FABRICATION All the small parts are connected by using welding. The process of joining the materials is by heating it up or using a filler rod to a suitable temperature. Even though the welded joint is only a bit but it will help to support the cage for making sure that the project is able to support high weight of animal and has a strong frame body. Since the material used to produce the project is mild steel, the type of welding method is limited to a few such as MIG welding. Other than that using GSM board to control the system is much easier and as a helping kit to the student might be able to see everything in open eyes. According to the design, four different shapes of mild steels were used to fabricate different parts of the cage trap base and body. Cage trap consists of cage frame, cage surface, cage closer frame (gate), and cage step over.

Figure 3: Sensor Circuit combination

Figure 4: Cage Trap 2.2.1 Parts of Messenger Animal Trap i) Arduino system For the risk of damaging the system that using Arduino board can be avoided because the parts that had been used are all fixed from outside. As for the quality it can be used for a long period of time. This system kit is adjustable and does not need an expensive cost to control the sensor level. Using a 12 volt battery, the system will function much longer then the ordinary battery and can be rechargeable. The open-source Arduino Software (IDE) makes it easy to write the code and upload it to the board. It runs on Windows, Mac OS X, and Linux. The environment is written in Java and based on Processing and other open-source software. This

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software can be used with any Arduino board. To control the trap we just need to push on rod for closing the gate to make it function.

Figure 5: Arduino System and Sensor Box

ii) Cage Modified mid steel animal cage was used to fabricate the frame and system box components. The part is mainly created by using ½‘‘ x 6mm mild steel welded with MIG welding and have been coated with anti-corrosion layer (Aluminium Oxide).

Figure 6: Cage Frame and System Box

2.3 Messenger Animal Trap Testing Analysis data has been collected for testing the system with simple messaging system user instruction with trapping sms settings. This messenger animal trap is fixed in a garden area and leaved for about 4 hours. The cage was setup in a place with some camouflage of tree branches and leaves on it. If the system light blink at the correct rate of 5 second per blink means the line is good at that place and the cage is ready to use and will trap any animal that enter the cage.

3.0 RESULT AND DISCUSSION 3.1 SMS Approval After the animal get trap, as a result we had received ―sms‖ to our phone. This figure shows the type of ―sms‖ we received in our phone.

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Figure 7: Testing using Digi Sim card and succeeded

3.2 SMS Timing As we compared both timing receiving to our both phone that was coded in Arduino System, we agreed that it is based on the type of SIM line that give the possibilities to receive ―sms― in time. The ―sms‖ received are in seconds after the sensor is cut so the objectives are proved that we are informed in seconds about the animal in the trap. 3.3 Safety Features of Project i) As our objective, this messenger trap could save life of animal when it alerts the user to take out the animal trap in the cage in a short time. ii) The body of the cage The body and frame of the cage is fully build with mild steel that is heat resistant and weather resistant. The frame is painted with anti-corrosion layer to prevent from corrosion because of weather and other conditions. iii) The system box The box which build on plastic is modified so that it can be resistant to weather and force. The box is a water resistant type so that the system will not damage if raining.

4.0 CONCLUSIONS As a conclusion this product has been completed successfully due to its schedule The Messenger Animal Trap can be applied whether indoor or outdoor environment. However, its used depends on the specifications to be determined in advance as to how the output to be produced and where it needs to be located. An appropriate materials will be an added value to the effectiveness of this product. There are some improvement being made whereby we used the bigger cage to trap big sizes and dangerous animals. This Messenger Trap can achieve better efficiency compared with normal trap. Lastly, this messenger animal trap is a cheaper machine compared with the other product from the same category.

5.0 BIBLIOGRAPHY Sandra Eriksson, Hans Bernhoff, Mats Leijon,,Ward, Jack (2004), the 555Timer IC. ,Renewable and Sustainable Energy Reviews, Volume 12, Issue 5, June 2008, Pages 1419-1434. Chiras, D. (2010). GSM Android System basics: a signal guide. Gabriola Island, BC,Canada: New Society Pub. Vardalas, John, Twists and Turns in the Development of Transistor, IEEE-USA Today‘s Engineer, May 2003.

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THE DEVELOPMENT OF SISAL FIBER EXTRACTION MACHINE

Khairuddin B. Ishak Tel : +6017-9286594 Email : khairuddin@psp.edu.my

Mohd Rosli B. Saad Tel : +6019-4809882 Email : rosli@psp.edu.my

Mechanical Department (Textile), Seberang Perai Polytechnic,

Penang, Malaysia

M. Luqman, N. Fatini, N. Syahirah, Yagheswaran, Amir Iddin

ABSTRACT Sisal fiber extraction machine is fiber production process that uses natural resource as the main medium. The purpose is to innovate the community about the system that is specially designed to help entrepreneurs who want to be active in the production the sisal fiber. Various process organized in providing knowledge about fiber production process. Handicrafts board is an important organization in the planning and design of each step in the introduction of sisal fiber production to be the final product to the general public in particular. This is because, generally know that the sisal is abundant natural contribute to the development of agricultural economy such as natural resources and others. Each course is organized using the manual method or method as the system of labour during fiber processing. Production is of this machine is an incentive to have save time while maximizing the use of natural resources that have been used.

Keywords: Sisal, Fiber & Extraction Machine

1.0 INTRODUCTION Sisal is scientifically known as Agave sisalana is one of plant from agavacea species which is grow for take the fiber from leaves. The most valuable part of the sisal plant is the fibre and therefore fibre extraction is one of the most important aspects of sisal production. A process of decortication is used to extract the fibres from the leaf tissues. Leaves are crushed and beaten by a rotating wheel set with grooved, so that only fibres remain. It is suitable for the manufacture of several products such as ropes, sacks, bags, carpets and mats, pulp for papermaking and handicrafts. The demand for sisal worldwide is currently on the increase because it is environment friendly in comparison with synthetic fibres. There are many techniques been used to extract sisal fibre such as traditionally and mechanical. However, those techniques have several issues for example take a long time to be individual fibre. Therefore, a new system of sisal fibre extraction is Sisal Fibre Extraction Machine. In the designing stage, many aspect should be studied in producing a quality, effective and widely accept product. Therefore, the objectives itself is the key target for the creation of the product. The objectives to be achieve are: i) To extract Sisal leaves into fiber. ii) To introduce Sisal fiber to public.

2.0 METHODS The method used to achieve our objectives is to use the system decorticator. How to produce these machines should be addressed to the three aspects such as design, fabrication and testing

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2.1 Design The sisal fiber extraction machine uses a 3-pin plug and is connect to an electric motor which provides power to rotate the roller. The rotation speed is control by the pulley that connected to the roller.

Figure 1: Final Product

2.2 Fabrication This machine is produced through several parts of the frame and roller speed calculation. Welding process required to assemble and strengthen the framework. Framework must have strength hold several parts when machine was on. 1-phase motor move 1400 rpm and it is too fast to make the extraction process. It will cause leaf and fiber damage. Gearbox is a way to reduce the speed of the motor. After using the gearbox roller speed will be 24 rpm and is particularly suitable for extracting the sisal leaves

2.3 Testing The machine is tested using a stopwatch to see the time taken to extract the sisal leaves and to be distinguished with the time taken by manual methods. In addition, this machine is tested to see if the roller speed can extract sisal leaf perfectly or not. After testing, this machine had problem about type of roller that we used.

3.0 RESULT By entering the sisal leaves into the machine through two roller and thread roller round leaves will turn out. Leaf surface is cracked slightly. This movement is repeated twice and cannot be because the surface of the leaves soften and cause the leaves to roll on the roller. Then, leaves that have broken the surface will be soaked in water to remove the epidermal layer of leaves. Then brush the leaf to produce fiber. Fiber produced is soaked in water to whiten the fiber. Then, dry the fibre untill it dries.

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Figure 1: Sisal Plant

Figure 2: Sisal fibre after extract

Figure 3: Final Product (Raw Sisal fibre)

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4.0 CONCLUSION Sisal Fiber Extraction Machine can really help students to improve their skills by the progress and until it‘s finished. In addition, student will be able to apply their knowledge and also what they have learnt in polytechnic. The theory that they had learnt can be applied to this project. This can help the student to be more practical on what they have learnt and give them experiences in order to get used to it before graduate.

5.0 BIBLIOGRAPHY G. W. Lock, Sisal — Longmans Green & Co., 1969.

Howard Scott Gentry, Agaves of Continental North America — University of Arizona Press,

1982; pp. 628–631.

Navin Chand, R. K. Tiwary, P. K. Rohatgi Regional Research Laboratory, Hoshangabad Road, Habinanj, Bhopal 462 026, India.

http://www.wildfibres.co.uk/html/sisal_fibre.html dview at 17 oct. 2015 ,11.40 a.m

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THE DEVELOPMENT OF WATER TREATMENT EDUCATION KIT (TEK15)

Somashana A/L Prakasam

Tel: +6013-4877518 Email: kuhan6475@gmail.com

Noor Rafidah Bt. Md. Osman Tel: +6012-4656578 Email: rafidah@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic,

Penang, Malaysia.

M. Haniff, Muda Iskandar, M. Nazrol Najmi & Sarvanaraj

ABSTRACT The water treatment equipment is a project designed to assist lecturers in teaching and learning. Method for treating water in the textile industry has three types: physical, chemical, and biological tools that have been produced using chemical methods in which it is carried out in stages. Chemicals used during this process is aluminium chloride (alum) and Polyaluminium chloride (PAC) Then, a treatment tool is intended to help treat wastewater in a lab dye textiles in Seberang Perai Polytechnic. Water treatment equipment is suitable for use by lecturers to facilitate teaching and learning for students. Keywords: Water Treatment, Education Kit

1.0 INTRODUCTION Water treatment describes a process used to make water more acceptable for a desired end use of textiles. The purpose of the water treatment process is to remove existing pollution in the water, or reduce the concentration of contaminants so that the water is suitable for the desired end use. For example is the use of water that has been used to restore the environment without causing adverse ecological effects. Water processing is aimed at involving treatment such as separation of solids using physical methods such as sedimentation and filtration, chemicals such as disinfection and coagulation. Chemical processes are also used in the treatment of wastewater and the chemical in used is Aluminium Chloride (alum) and Polyaluminum Chloride (PAC) . The process water can treat the Chemical Oxygen Demand, Biochemical Oxygen Demand and PH .

In the designing stages, many aspect should be studied in producing a quality, effective and widely accepted product. Therefore, the objectives itself is the key target for the creation of the product. The purpose of this project are to develop:- i) Teaching aids for wastewater treatment system. ii) Students more easily understand the stages of the water treatment process.

2.0 METHODOLOGY Manufacturing projects include 3 levels of welding process, the process of installation, installation process components. Next, a chemical used for the Aluminium chloride (alum) and Polyaluminium chloride (PAC). i) Aluminium chloride (alum) Aluminium is used to form tiny sticky particles called "floc" which attract particles of dirt

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Figure 1: Aluminium chloride

ii) Polyaluminium Chloride (PAC).

The process of flocculation of fine particles that cause it to clump together into floc. Floc may then float to the top of the water and under the water surface will produce sludge deposited.

Figure 2: Poly aluminium chloride

2.1 Design

Figure 3: Assembly Drawing

PART B PART A

PART C

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Figure 4: Final product

2.2 Fabrication i) welding process required to assemble and strengthen the framework of the project. ii) installation of pipes used to transport the wastewater lines. iii) Fan assembly on the cover used to beat with a whisk or stir the ingredients in water.

2.3 Testing Tests were conducted to see the strength of the frame to accommodate the load aquarium tank filled with water by 3 kilograms. Next, tests were also conducted to the aquarium tank and found that no leakage occurs during pipe installation on aquarium tank.

3.0 DATA Data for different quantity of volume in tank and time taken.

Tank Time taken (min) Volume (liter)

Tank 1 (waste water dye) 5 6 Tank 2 (with PAC) 50 4 Tank 3 (with Alum) 40 3 Tank 4 (filter) 30 2 Tank 5 (give oxygen) 20 1

Table 1: Data Testing

Data of water treatment concept:

Tank Impurities efficiency (%) pH Number

Tank 1 80 4.5 Tank 2 70 5.7 Tank 3 50 6.1 Tank 4 20 6.6 Tank 5 10 7.2

Table 2: Data of water treatment

2.3 Safety Features Project

i) The cover of the machine The cover head and cover box of the machine is to protect the disk rack when the machine

on the run mode. It also to prevent the water with chemical from spitting out. ii) The push button The push button function as ON/OFF button but it also functioning as emergency button to Stopped the process.

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2.4 Project Cost Cost is important because it will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of the project can be higher. This is because the market is driven by extensive production costs and prices of goods sold. Project costs for the Water treatment Education Kit detailed in Table 3.

Component Cost (RM)

iron 70

aquarium 75

perspex 100

pipe 3

water pump 10

oxygen pump 20

motor 3

sponge & carbon filter 15

gam silicon 8

fan 5

wire tube 1

wires 1

valve 4

battery 4

alum 4

pac 4

additional 173

TOTAL 500.00

Table 3: Project Cost 4.1 The System The system of the project is based on water flow in the process covering 5 stages that include first stages tank contain filled waste water dye. After that, in the second stage tank is filled with chemicals (PAC) that is used to fine particles flocculation process that causes it to clump together into floc. Next third stage, only the top layer is only taken for entry into the tank and the tank is filled with Alum is used to form a sticky particles called "floc" which attract particles of dirt. Next, fourth tank, water supplied by third tank will flow through the carbon filter and sponge. Water will flow back and forth in the tank after filtered water through a straw. Finally, at the last stage, the water will be channelled given oxygen using an oxygen pump, the water will be known as DO (dissolved oxygen) and will be sent to a laboratory to be tested for BOD (Biological Oxygen Demand) and COD (Chemical Oxygen Demand).

5.0 CONCLUSION Students can develop their skills while developing the water treatment project. Student can develop contribute an idea, teamwork and solving problems. In addition, students can practice what they have learned during their studies at the polytechnic. Students will also be skilled in designing products to be created and produced such that erupted in the minds of students.

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6.0 BIBLOGRAPHY Andriamirado, L., Asensi, D., Ballard, T., Bele, P., Bernard, M., Bourdelot, J., Brunet, J.,

& Cachot, L. (2007). Water treatment handbook 1 (7th ed.). Rueil-Malmaison, France: Degrémont

Experimental Methods in Wastewater Treatment - M.C.M. van Loosdrecht, J. Keller, P.H. Nielsen, C.M. Lopez-Vazquez and D. Brdjanovic

Faecal Sludge Management - Linda Strande, Mariska Ronteltap and Damir Brdjanovic Publication Date: Nov 2013 - ISBN - 9781780404721

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THE DEVELOPMENT OF LOOSE PALM FRUIT WITH MANUAL APPLICATION

Ahmad Firdaus B. Zawawil Anwar

Tel: +6019-5535580 Email: firdausz@psp.edu.my

Mohd Pahmi B. Saiman Tel : +6016-4488064 Email: pahmi@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic,

Penang, Malaysia.

M. Azizan B. Sapari, Ahmad Syakir B. Ghazali, M. Kamil B. Omarkayam, M.

Aizuddin B. Jameel, Nurul Asyilah Bt. Ahmad

ABSTRACT Seed Collector Tool for Palm is a project that is aimed at solving the problems faced by oil workers in oil palm plantations. The idea is obtained after undergoing the review process before the project is implemented. The problems identified are workers in oil palm plantations have difficulty collecting the remains of a broken oil seeds of fruit bunches. In addition, workers take some time to collect palm kernel corresponding resolution. The tool can collect seed oil in large quantities without the use of labour completely and save time quotes. It is also possible to separate between the seeds and waste time. With this project, can solve the labour‟s problem in the oil palm plantation. Its use is effective in addition to producing quality work, it‟s also helps to maintain a healthy life style in doing a job. Keywords: Development, Lost Palm Fruit, Manual Application.

1.0 INTRODUCTION Palm Oil Seed Collector Tool is a product that is designed to simplify the process of collecting oil palm seeds that get loose more effectively than manual techniques. This tool uses a completely mechanical concept and durable material that is lightweight metal. Can be used to dump oil palm seeds that get loose. Scooping palm kernel uncoupled in large quantities at a time, thus helping to separate between palm kernel and waste - a waste by shaking the device. In the production of these products, many factors that should be considered and studied as the quality, effectiveness and affordable products are widely accepted. Thus, the objectives themselves are the main target for a certain product. The objective of this product is to simplify the process of collecting oil palm seeds that get loose after cutting ripe oil palm fruits. Turn drive is revolutionizing the conventional technology. Finally able to save time collecting palm kernel uncoupled.

2.0 METHODOLOGY 2.1 Assemble Drawing The device is fully designed using durable metal without using any motor or electrical wiring. Consisting of a handle, plunger, scoop, shaft and basket. The plunger lies in changing the position of the tool holder for angle between the handle and basket. Scoop fastened to the shaft using the bolt screws.

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Figure 1: Assembly Drawing Item Quantity Part Number Description

1 1 Scoop Steel Plate

2 1 Plunger Steel Rod 1/4‘‘ 3 1 Shaft - 4 1 Basket Steel Rod 2mm 5 1 Handle Steel 6 1 Bolt & Nut -

Table 1: List Part

Figure 2: Final Drawing

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Figure 3: Product Fabrication

Figure 4: Final Product

3.0 DISCUSSION This tool can be produced after the discussion and selection of three early sketch of the product. After selecting the product design, material selection process suitable for producing the product. Some problems occurred during testing tools that palm kernel out of the body but the problem can be solved by changing the distance between the spokes sport back.

3.1 Functionality This tool can be used to collect oil palm seeds that get loose after cutting process oil palm fruits that ripen at once can separate the oil palm seed and waste. In addition, the handle can be adjusted in order to facilitate used to take him. Has three adjustable angle between the handle and body for user comfort. 3.2 Durability These devices are manufactured using durable materials such as mild steel to ensure long lifetime. In addition, can be exposed to a variety of warm weather and rain. The product surface has been coated with paint to prevent corrosion.

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3.3 Project cost Costs are important because they affect the total cost spent on the project. If the project costs are minimized likely potential for marketing the project is high. This is because a good project can be marketed at a reasonable price. The project cost Palm Seed Collector Tool are listed in Table 2.

Component Detail Price (RM)

Skru, bolt dan nat 5 unit 2.50 Rod Besi 1‖ 1.5 Meter 22.50 Rod besi ¼‖ 1 Meter 8.00 Jejari besi 2mm 2 Meter 14.00 Plat besi 1 (15‖ x 15‖) 12.00 Cat spray can 1 unit 8.00

Total 81.00 Table 2: Product costing

This product has been tested in terms of time to get better results than older techniques of collecting palm kernel uncoupled using a hand. Testing time has been taken at random from several plants and palm kernel number. The time it takes on average, and split test results are listed in Table 3

Method Time Taken (sec)

Old 120 New 60

Table 3: Data’s analysis 4.0 CONCLUSION Oil Palm Seed Collector Tool can solve the problem of oil palm plantation workers to collect palm kernel uncoupled especially for smallholders and private. The tool is easy to use for employees without requiring complex techniques. In addition, these tools are easy to carry anywhere because the handle can be adjusted to be short and mild. Using durable materials to ensure a long lifespan. Through trial tool in oil palm plantations, this tool is very effective and speed up the collection over time the old technique of using hands to collect palm kernel. Finally we can achieve the objectives of the project.

5.0 BIBLIOGRAPHY ABO-RADY, M.D.K., KHALIL, M.M., AHMED, H.S. (1987) The use of shredded date

palm leaves as a substrate in horticulture II Growth and yield of tomato and cucumber. Date Palm Journal 5 (2).

BARREVELD, W.H. (1959) Comparison of local and Indian tapping of date

palms. Libya (unpublished)

Badmus GA (1990). Factors affecting the design of a fruit bunch harvesting system of tall oil palm trees in plantations. Nigerian Journal of Palms and Seeds 11:1: 102-1114. Egwu, Sam (2008). Nigeria: Agriculture - Palm Oil - The Country's Untapped Potential. In The Daily Trust. 28th April.

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FAO (2009). The major significance of ‗minor forest products‘. Retrieved on 23rd March, 2009 GASPERINI, Gustavo. (1913) Ulteriori studi sul vino di Palma della Libia (Laghbi or Leghbi). Atti dei Georgofili. Institute of Forestry Research, (NIFOR) (1989). History, activities and achievement. NIFOR Bulletin; 2nd Edition, Benin City. pp.26-27. National Open University of Nigeria (NOUN) (2004). Export Crop Agriculture. In Geography of Nigeria. Heinemann Educational Books: Lagos.

Orji, M. U. (2006). Microbiological and Chemical Studies on Nigerian palm oil with particular reference to the effect of extraction methods on oil quality. PhD dissertation

Orji, M. U. and Mbata, T. I. (2008). Effect of extraction methods on the quality and

spoilage of Nigerian palm oil . African Journal of Biochemistry Research. 2:9: 192-196. Retrieved on 23rd March, 2008

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THE DEVELOPMENT OF PRESS BEARING TOOL

Zulkiffli B. Bakar

Tel: +6012-4644870 Email: zulkiffli@psp.edu.my

Hjh. Sharizan Binti Hj. Abdul Halim Tel: +6019-5617068 Email: sharizan@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic, Penang, Malaysia.

Aruni B. Zulkifli, M. Imran B. Ramlan, M. Faiz B. Hamzah

ABSTRACT

Today‟s industry uses increasingly complex machines, some with extremely demanding performance criteria. Bearings are a one of the common component in machinery. In industrial applications, bearings are considered as critical mechanical components and a defect in such a bearing causes malfunction to machine. Failed machines can lead to economic loss and safety problems due to unexpected and sudden production stoppages. These machines need to be monitored during the production process. There are many cases about workers are getting themselves injured and majority are hand injuries. For example, in motorcycle workshop, the worker is often use hammer when dealing with the defect bearing and to insert the new bearing into it housing. Because of that method some of new bearing can be used for a while because bearing had defect. Basically, there are hydraulic press bearing machine that usually been used in the workshop but that‟s not mean that all workshop had that machine. This is because the machine was too big and not all workshops can have that machine. So base on our observation and ideas, we have concluded to make a portable press bearing that use pneumatic concept. The scope of our project is for motorcycle workshops. Most of motorcycle workshop didn‟t have hydraulic press bearing because of the price and the size of that machine. The production of portable press bearing is to prevent the problems that have arisen so that a lot of bearing efficiency loss can be prevented or reduced to a very low level.

Keywords: Press Bearing, Tool, Development

1.0 INTRODUCTION Bearing is a common component in machinery. The basic purpose of a machine bearing is to provide a near frictionless environment to support and guide a rotating shaft. There are many types of bearing available nowadays. General bearing styles are utilized at this time which is the rolling element bearing. For lower horsepower and lighter loaded machines, the rolling element bearing is a popular choice. Nowadays in automotive industrial, bearing definition is getting more due to the working circumstance. According to the observations, mostly in changing the components that use bearing workers use hammer to insert and taking out those bearings from its components. These method can make the bearings damage and thus can cause malfunction to machines.

1.1 Project Objectives The objective of this project is to produce press bearing that capable for material handling task which meet the criteria below: i). To make a portable press bearing ii). Easy to use. iii). To prevent work piece from damage.

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2.0 METHODOLOGY The methodology is the methodology and principles to solve problems that emerge in the making or creating something by using method, research, technique, equipment and so on. In this chapter, we will pay attention to produce our projects.

2.1 Designing and Fabrication In the designing stage, many aspects should be studied in producing a quality, effective and acceptable product.

Figure 1: Assembly Drawing The press bearing tool uses a pneumatic cylinder which is need a compressed air as the medium of performance. The extract and retract of the cylinder control by push button. After that we make an adjustable table for holding and make the cylinder move back and front. Then we made a base platform for the table.

Photo 1: Final Product (Press Bearing)

3.0 SAFETY FEATURES PROJECT

3.1 The Pushbutton The pushbutton that been used for the project was manual rotary type. The pushbutton was a 4/3 way working principle. In this working principle, the pushbutton has it neutral position where we can extract the rod and make it stay at the length needed.

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4.0 PROJECT COST Cost is important because it will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of projects can be higher. This is because the market is driven by extensive production costs and process of goods sold. The project cost for Press Bearing is detailed in the table below (Parviz F. Rad, Ph.D. 2002).

Type Of Material Price( RM )

Pneumatic Cylinder 175.00

Push Button 50.00

Pneumatic Tube 3.00

Connecting tube compressor 2.00

Connecting tube pneumatic (4) 10.00

Bearing Casing 40.00

Total 280.00

Table 1: Project Costing

5.0 CONCLUSION This press bearing idea can overcome the problem in motorcycle workshop which didn‘t have suitable tools to deal with component that have bearing. By using it, there will no injury can sustained because of not using the right tool. Lastly, this product can be achieving the objective of inserting and pulling out bearing from component in motorcycle component.

6.0 BIBLIOGRAPHY

Carlisle, Rodney (2004). Scientific American Inventions and Discoveries, p. 266. John Wiley & Sons, Inc., New Jersey. ISBN 0-471-24410-4

Cheng, Chi-Neng. (2005). Design and Control for the Pneumatic Cylinder Precision

Positioning Under Vertical Loading Harris, Tedric A. (2000). Rolling Bearing Analysis (4th ed.). Wiley-Interscience. ISBN 0-

471-35457-0.

Majumdar, S.R. (1995). Pneumatic System: Principles and Maintenance. New Delhi: Tata McGraw-Hill. N.N. (R. Stribeck), Kugellager (ball bearings), Glasers Annalen für Gewerbe und Bauwesen, 1901, No. 577, p. 2-9, Published 01. July 1901

R. L. Schaeffer and J. T. McCalve. Probability and Statistics for Engineers. PWS-Kent Publishing Company, Boston, USA, 3rd edition, 1990.

Rad, P.F. (2002). Project Estimating and Cost Management. Management Concepts. ISBN 9781567261448. Retrieved 2015-09-14.

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THE DEVELOPMENT OF SEMI-AUTO ANIMAL FOOD PELLET (SAFP-15) MACHINE

Mazlan B. Che Mustafa

Tel : +60194105443 Email: mazlan@psp.edu.my

Md. Baharuddin B. Abdul Rahman

Tel : +6011-11535950 Email : mdbahar@psp.edu.my

Mechanical Engineering Department, Seberang Perai Polytechnic,

Penang, Malaysia

N. Syahira Bt. Mahizan, Noraqilah Bt. Abdul Wahab, M. Shukri B. Mohamad, N. Syafiqa Najwa Bt. Mohd Saberi

ABSTRACT

Semi-Auto Animal Food Pellet Machine is a machine that is created by using presses method (compression). This machine is produced is intended to accelerate the process of preparing animal food pellets in addition to reducing the use of labour in the preparation of these pellets. Not only that, these machines also allow small farmers to produce pellets with a faster and more easily in large quantities. Based on the experimental results, the resulting machine is capable of functioning with a stable and durable. However, the quantity of pellets produced by this machine is not much compared with the big machine that is already available in the factory, but this pellet machine can reduce the time taken for the production of pellets. Overall, with the projects Machine Semi-Auto Pellet Feed is expected to disclose to small farmers that these machines are environmentally friendly as well as to help reduce the cost of production of small farmers in producing or buying pellets animal (rabbit) in the store.

Keywords: Semi-auto, Animal food pellet, Machine, Development 1.0 INTRODUCTION Semi-Auto Animal Food Pellet Machine is a machine that is created by using presses (compression). This machine is produced is intended to accelerate the process of preparing animal food pellets in addition to reducing the use of labour in the preparation of these pellets. There are few products in market today which focusing on the production and sales of the machines are restricted to large factories, it also produces pellets in large quantities to be sold and marketed to farmers. However, most of the machines are expensive, bulk, and heavy. Small farmers who work in food producing animals often have problems in preparing animal food pellets as the cost of the machines used in the market are high. Therefore, a machine which is cheaper than other machine that already exist in industry. This machine produced a machine that has a similar concept as the other machines but cheaper and simpler. This machine is designed by our design sketch itself and can be changed according to the wishes and needs of each user. In the designing stage, many aspects should be studied in producing a quality, effective and widely accepted product. Therefore, the objective itself is the key target for the creation of the product. The purposed to develop the machine are to accelerate the process of preparing animal food pellets. This machine also suitable for small farmers that can produce pellets more easily in large quantities. Other than that, it is also can reduce the cost of production for small farmers in the production of animal food pellets. The development of this product could be easier for small farmer obtained the pellet with more quantity with low costs.

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2.0 METHODOLOGY In general , the project " Machine Semi - Auto Pellet Feed " This involves a lot of mechanical machining processes such as milling machines , drilling machines , welding machines , grinding, cutting and others . In addition, the measurement process is also involved in the production of components and equipment for the project. All of these processes have continuity and connection with each other. So we are working system involves the design, installation and modification and testing results.

2.1 Designing and Fabrication The Semi-Auto Animal Food Pellet Machine uses a 3-pin plug and is connect to an electric motor to provide power to rotate a press roller. The rotation speed is control by the pulley that connects to the press roller. To make base of the Semi-Auto Animal Food Pellet Machine- build the complete circuitry that includes all critical parts such as press roller, mould, AC motor connect by pulley. The AC motor is combine with the pulley and timing belt to make sure the roller can roll and compress that pellet A complete machine must meet same requirements for the user and also able to complete and passed through repeated various test. We used most suitable material chosen for the machine is stainless steel because the strength and the mass of the materials. According the design, all of this machine shapes is same with machine that already have but the different is it is smaller than other.

Figure 1: Assembly Drawing (SAFP-15)

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Figure 2: Final Product (SAFP-15)

2.2 Project Cost Cost is important because it will affect the overall ost spend on the project. If the production can be reduced the potential for commercialization of projects can be higher. This is because total cost is driven by extensive production and prices of goods sold. Project cost of Semi-Auto Animal Food Pellet Machine detailed in table 1.

Material Price (RM)

Angle iron ½ 90.00

Stainless steel (6mm) 175.00

Arc welding rod 25.00

Paint anti-rust 35.00

Bearing (2205) 100.00

Bearing (2309) 76.00

Wheel 80.00

Pulley & timing belt 120.00

TOTAL 701.00

Table 1: Cost of the Project

3.0 DATA ANALYSIS

Quantity pellet out Rotation (rpm)

Time (second)

24 1 3 240 10 30 480 20 60

Table 2: Data Testing

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Weight (kg)

Quantity pellet out Rotation (rpm)

Time (min)

1 1440 60 3 3 2400 100 5 5 3840 160 8

Table 3: Data of Weight Pellet Powder Used

4.0 CONCLUSION Semi-Auto Animal Food Pellet Machine idea can overcome the problem for small farmer because this machine can facilitate the work of small farmers or farmers obtaining or producing animal food. Besides that, the size and weight of this machine can facilitate the user to put this machine anywhere. It taking a small space to accommodate this machine and can be stored easily because its smaller size it is able to save space. Last but not least, this machine can achieve a productive of Semi-Auto Animal Food Pellet Machine with lower cost machine compared with other product at the same categories.

5.0 BIBLIOGRAPHY

Advanced Explorations Inc.:Iron Ore Products Connecticut Agricultural Experiment Station (1898), Tenth Annual Report of the Storrs

Agricultural Experiment Station, Storrs, Conn. 1897, Pelton & King, pp. 208–209. Matz, Samuel A. (1991), The chemistry and technology of cereals as food and feed (2nd

ed.), Springer, p. 328, ISBN 978-0-442-30830-8. National Steel Pellet Company:Iron Ore Processing for the Blast Furnace. Pietsch, Wolfgang (2005), Agglomeration in Industry: Occurrence and Applications 1,

Wiley-VCH, p. 254, ISBN 978-3-527-30582-7.

Pelletizing of Iron Ores:[Meyer, Kurt. Pelletizing of Iron Ores. Springer-Verlag Berlin, Heidelberg, Verlag Stahleisen mBH, Dusseldorf, 1980.]

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THE DEVELOPMENT OF FLUORESCENT LIGHT REMOVER

Kumaran A/L Sundraj Tel:+6013-5186784 Email:kumaran@psp.edu.my

Shafirul Ikmar B. Shahrudin Tel:+6017-4991909 Email:syafirul@psp.edu.my

Department of Mechanical, Seberang Perai Polytechnic, Penang, Malaysia.

Asahel A/L Soundrapaman, Abd. Muaz B. Kamal Baharin, Luqman Hakim B. Salehan, M. Amalluddin B. Zulkifli

ABSTRACT

Fluorescent Light Remover is a project that is done to ease the users and also in order to guarantee the safety of the user from being electrocuted while changing fluorescent lights. This equipment is made to reduce the burden of the users especially technician and electricians. They don‟t have to risk their safety by using ladder or holding the light when changing it. This project is able to function properly without any technical problems. Moreover, the cost of this project is not expensive as other products with the same concept in the market. Overall with the usage of fluorescent light remover it is hoped to help technicians and electricians to reduce their burden while carrying out the respective works. Keywords: Fluorescent, Light, Remover, Development

1.0 INTRODUCTION Fluorescent light are basic needs in our daily life. It is used almost everywhere including households, schools, companies and offices. It is found that there are problems in industries and households when it comes to changing spoiled fluorescent lights. Usually, electricians are called over to fix the problem and electricians which attend the problem tend to use the help of ladders. This exposes them to the risk and falling and also getting electrocuted when changing the lights. The time required for them to carry out this task is usually long. These problems that a solution of a quicker and easier way to change the light is needed to ensure the safety and effectiveness of the work done. In the designing stage, many aspects should be studied in producing a quality, effective and widely accepted product. Therefore, the objective itself is the key target for the creation of the product. The first objective is to make the process of changing fluorescent light easier and effective. Technicians or electricians usually need a ladder and tools when changing a fluorescent light. By using this product, those tools can be put aside. Secondly, it can save the time. During the process of changing fluorescent lights, the electricians usually used a ladder, climbed then dismantle the light, replace it. Then then he has to test the fluorescent light. With this product, the time consumption can be saved and he can change without using a ladder. Lastly, this product is the cheapest compared to others. Our project mainly use components which are easy to get and low in price. The components are also durable, easy, light and free maintenance.

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2.0 METHODOLOGY 2.1 Design

Figure 1: Assembly drawing for Fluorescent Light Remover

Figure 2: Final Product

2.2 Fabrication The main components which were used in this project is materials like PVC and Aluminium. The Fluorescent Light Remover uses a 12 meter long adjustable pole connected to a UV-F Adapter (Female Adapter) and a UV-F Adapter (Male Adapter) which is then connected to a ‗TEE- Joint‘. Two PVC pipes are cut into the same size and is connected to the ‗Tee- Joint‘. Elbow Joint is then connected to the PVC pipe. After that, another two similar size PVC is then cut and then joint to the elbow joint vertically. Another tee joint is cut into half and then joint together and the end of the PVC pipe. Finally, the fluorescent grip which was designed by ourselves are connected by using aluminium. This grip contains foam insulation which is usually used in air conditioning pipes. This foam insulation has high resistant to heat which is what we need for this project. PVC pipes are used for safety reason because electricity cannot pass through it and it is light in weight. The usage of the aluminium is for the gripping purpose.

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2.3 Parts of Fluorescent Light Remover i) Adjustable Pole The Adjustable Pole is one of the main component in the Fluorescent Light Remover. It can be adjusted according to the required height to remove the fluorescent light.

Figure 3: Adjustable Pole

ii) Fluorescent Grip The fluorescent grip is a component which has been designed with precision. It is the combination of two different PVC pipe and also aluminium. The aluminium acts as a holding compartment for the two PVC pipes. It also acts as a clip for the fluorescent light when it is being opened. Moreover, a foam insulation has been placed inside to act as a gripping mechanism for the fluorescent light to avoid it from sliding or falling.

Figure 4: Fluorescent Grip

3.0 RESULT AND DISCUSSION Based on the data taken, the higher the height of the placed fluorescent light the longer the time taken to change it. This is because it requires precision to change the fluorescent light. That is the reason we recommend this product to the technicians and electricians because their work requires precision.

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3.1 Time Consuming Time taken to change Fluorescent Light Remover

HEIGHT OF LIGHT (M)

TIME TAKEN TO REMOVE (S)

TIME TAKEN TO FIX (S)

TOTAL TIME TAKEN TO

CHANGE (S)

4 15 20 35

7 25 30 55

10 30 50 80

Table 1: Time Consuming

3.2 Safety Features The safety feature of this project is very simple. Basically we used PVC pipe in which electricity can‘t flow through it. This is one of the main safety feature in our project. Secondly, the insertion of foam insulation. A kind of rubber which can withstand heat. This feature gives it a long term usage and also refrains it from getting burnt. Lastly, the angle in which the light is opened. We have adjusted the PVC compartment 45 degrees which means our body position will not be under the fluorescent light when it is being opened. This will not put us in harm‘s way if the light breaks.

3.2 Cost of the Product Cost is important because it will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of projects can be higher. This is because the market is driven by extensive production costs and prices of goods sold. The project cost for Fluorescent Light Remover are detailed in the Table below.

Components Price (RM)

PVC 20 Adjustable Pole 18

PVC Glue 4 Foam Insulation 2

White Tape 2 Aluminium 5

Spray (Red and Clear) 12

Total 65

Table 2: Project Cost

4.0 CONCLUSION The Fluorescent Light Remover is the solution for the electricians and technicians to change the lights. By using it, the changing of fluorescent lights can be more easily. An electrician can save more time and workforce. This equipment has better efficiency compared to the manual method. Furthermore, it‘s cheaper the others product in the market. Lastly, we produce an effective gripper to Fluorescent Light Remover.

5.0 BIBLIOGRAPHY

Arthur A. Bright, Jr.1949) The Electric-Lamp Industry: Technological Change and Economic Development from 1800 to 1947 (New York: MacMillan Co., 1949)

Brian Bowers, (1998) Lengthening the Day: New York: Oxford University Press

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Charles C. Bazerman, (1999): The languages of Edison's light, Cambridge, MA.: MIT Press)

James A. Cox, (1979.), A Century of Light New York: Benjamin Co., W. Bernard Carlson, Tesla (2013): Inventor of the Electrical Age, Princeton, NJ:

Princeton University Press Wiebe E. Bijker, Of Bicycles, Bakelites, and Bulbs (1995): Toward a Theory of

Sociotechnical Change Cambridge, MA: The MIT Press Wilfried Feldenkirchen, Werner Von Siemens (1994): Inventor and International

Entrepreneur. Columbus, OH: Ohio State Univ. Press

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FOUR (4) STROKE ENGINE COMPRESSION RATIO MEASUREMENT FOR TEACHING AID

Badrul Sakinah Bt. Haji Sanusi

Tel : +6012-5616494 Email : badrulsakinah@psp.edu.my

Mohamad Tarmizi B. Abu Seman Tel : +6019-4117466 Email : tarmizi@psp.edu.my

Mechanical Department, Politeknik Seberang Perai,

Penang, Malaysia.

M. Azhar B. Ismail, M. Faiz B. Azmy, Azarul Amir B. Abd. Ghani, Logha A/L Anbarasu

ABSTRACT

Various techniques have been experiments to measure the compression ratio in the engine. This project is suitable for use during the hours of teaching and learning. The project aims to be a teaching aid for the students of polytechnics for more details about how to measure the compression ratio in the engine four-stroke power. Keywords: 4 Stroke Engine, compression ratio, teaching aid

1.0 INTRODUCTION After weeks we made studies on the final project of our group, we found a problem faced by the students of the difficulty of making imagination on how to measure the compression ratio in the engine four-stroke power. The tool are designed to measure the compression ratio in the engine four-stroke power. For the measurement of the pressure ratio we took power four-stroke engine and using several tools such as Vernier calliper, syringe to get the precision compression ratio which is in power four-stroke engine. In addition, this tool is part of the teaching aids in the laboratory or workshop.

1.1 The Simple Formulas Therefore, our group, together with the project supervisor we have found a method to prove that the calculation of the compression ratio in the engine can be made by calculation formula and using a measurement tool. The compression ratio of the engine four-stroke power can be measured using the formula below and we'll compare the calculation practical with the theoretical calculation of the compression ratio of the engine.

which one b= Bores (diameter) cylinders

s = Length of the piston stroke Vc = Clearance volume, namely the volume of the combustion chamber

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2.0 DESIGNING AND FABRICATION As we know, there are two different types of engine compression ratio of four-stroke engines and two-stroke. Both engines have advantages and disadvantages of each. Among the designs is the power of four-stroke engines. Guided by the principle that they will use to calculate the compression ratio in the engine. The instrument used to measure the compression ratio is very needed in regard to getting an accurate reading in the calculation of the compression ratio in

the engine four-stroke. In addition, iron is used as a table to put the four-stroke engine.

Figure 1: Final Product Design

Photo 1: Final Product

2.1 Parts of 4 Stroke Engine i) Four-stroke Engine The engine is required to calculate an actual compression ratio in an engine four-stroke power. Calculation of the compression ratio in the power of four-stroke engines based on work done in the block, head and piston. In this project, we used Honda C70 motorcycle engine. Each engine brand has a different compression ratio

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Figure 2: 4 Stroke Engine (Honda C70)

ii) Trainer Kit Trolley We create our own trolley and this table is used to put four-stroke engines and measuring equipment.

Figure 3: Trainer Kit Trolley

iii) Vernier calliper Used to measure area size used in piston engine four-stroke power and also to measure distances between the strokes

Figure 4 : Vernier caliper

iv) Syringe Used to measure the volume of water in the four-stroke engine power in this experiments.

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Figure 5: Syringe

iv) Labsheet report Used as a guide on how to make experiments. In the report there are theory and formulas of four-stroke engine compression ratio. Students will take the data and calculate the compression ratio. After that, students will make discussions and conclusions after getting a count and compare the theory with practical.

Figure 6: Lab sheet report

2.2 How to do experiment Nut of head should be opened to root out the head to calculate the volume of water that can be completed within the combustion chamber in the crater head. Then take a punched and put the glass on the surface of the crater at the head to ensure that the volume of the subscription right. Then disconnect the gasket for the calculation taken. The volume of the gasket is permanent and should be added to the volume taken at the top of the crater head. Enter the information that was taken readings in the table in the report. Next, make sure the piston is at the bottom of the stroke to calculate the length of a volume of the combustion chamber block. After the piston is positioned at the bottom, take the reading length of the piston. Next, open the nut block and remove the block out and grab the calculation of the circumference of the piston. Finally, combine the information that was obtained in the formula to calculate the compression ratio and calculate the amount. The results obtained must be attributed to one because it represents one of the pistons in the engine there.

2.3 Result Data And Discussion

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Vs = From head, the volume of water

Bore = 47 mm = 10.8 ml Stroke = 42 mm

Vs = CR =

= 72867.67 mm³ Vs = 72.867 cc = 7.7 : 1 After retrieving the data, students will make the discussion: 1. Counting / compression ratio between theory and practice 2. Find the percent error between the theoretical value and practical 3. State the experimental error found in experiment

2.4 Safety Features Project To ensure a high level of safety we have to make sure the material used for the production does not have the characteristics of passage of electricity. We use a motorcycle engine Honda C70 normal and dysfunctional to ensure that things do not always happen. In addition, we also emphasize the use of this tool, we use a sturdy metal table to ensure that the engine is in a stable position and not dangerous during the process of calculating the compression ratio in the engine.

2.5 Project Cost Our project has a low cost and affordable and can be marketed in all educational institutions that offer lessons on how to measure the compression ratio in the engine four-stroke power. Our project can benefit and help all students related to the engine. In addition, the safety of the project will also be in a high state because of high protection can be implemented to ensure that anything untoward is happening. In addition, we got something new for ourselves, for example in providing creative ideas and brilliant innovation for every conceivable idea.

Component Details Price (RM) Engine 4 stroke engine Honda C70, 72cc RM 300.00 Syringe Volume 10ml x 2 RM 3.00 Wheels 4‘ 2‘‘ x 4 RM 10.00 Gloves Abrasion Resistant, Cotton Size 9 x 2 RM 2.00 Spray 250ml, Green colour x 2 RM 20.00

Cutting tip Cutting Disc Slide Chrome 6" x 2 RM 10.00

Total RM 345.00 Table 1: Project Cost

3.0 CONCLUSION This project are helping students to understand the relation between the compression engine and four-stroke engines power. Also, this project helps the lecturer used as a teaching and learning tools to demonstrate to the students. The student have learnt the theory and with this project they could applied it.

4.0 BIBLIOGRAPHY

A. Oakley, H. Zhao and N. Ladommatos, (2001): ―Experimental Studies on Controlled Auto-Ignition (CAI) Combustion of Gasoline in a 4 Stroke Engine‖, SAE Paper 2001-01-1030

Alagumalai, Avinash, (2014): "Internal combustion engines: Progress and prospects," Renewable and Sustainable Energy Reviews, Elsevier, vol. 38(C), pages 561-571

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He, X, Durrett, R (2008): Late intake closing as an emissions control strategy at tier 2 bin 5 engine-out NOx level. Soci. Automot. Eng. 01, 0637

J. Lavy, J. Dabadie, et al.,(2000): ―Innovative Ultralow NOx Controlled Auto-Ignition

Combustion Process for Gasoline Engine: the 4-SPACE Project‖, SAE Paper 2000-01-1837

Paul Dempsey. ―How to repair Briggs & Stratton engine.‖ Ramadhas, AS, Jayaraj, S, Muraleedharan, C (2004): Use of vegetable oils as IC

engine fuels-a review. Renew. Energy. 29, 727–742 Rimfiel Janius. (1988). Asas-Asas Pembakaran Enjin Dalaman. Kuala Lumpur: UPM

Serdang.

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THE DEVELOPMENT OF ELECTRICAL MOTOR RUBBER TAPPING MACHINE (EMRT-15)

Yuniza Bt. Ahmad

Tel:+6013-4232259 Email:Yuniza@psp.edu.my

Mohd Pahmi B. Saiman

Tel:+6016-4488064 Email: pahmi@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic, Penang, Malaysia.

M. Nazrin, Keong C. S., M. Aliff Farhan, M. Ariff, Intan Humairah

ABSTRACT Automatic machines rubber tappers (EMRT-15) was develop in year 2015. This is a project designed with the aim to simplify the process of rubber tapping for the rubber tappers in Malaysia. Rubber tapping machine is designed such that it can be installed and reopened after the expiry of the rubber tapping process. This is because there is a rubber tapping machine was designed where it can‟t be opened after use and it will result in the theft of which would result in losses to the entrepreneur rubber plantations .Beside that, this machine is also designed using the concept of gear for moving this machine. Use a concept like this can save the cost of manufacturing machines and thus will reduce production costs for project development. Result of this project works in rubber tapping into simple, easy and cost-effective, time and work more efficiently and effectively. Keywords: Rubber tapping, Machine, Development

1.0 INTRODUCTION The observations and studies that have been done, the rubber industry is also necessary to use a new technology that can help the rubber tappers in carrying out their daily activities and help reduce the burden of completing all the work of this rubber tapping. Naturally the work of tapping is not an easy job to be done by all people of because it takes very much approximately manpower if it is a large area. Not only that, the technique of tapping the rubber trees also play an important role for the production of quality latex and more. Thus with the invention as a flow time of this modernization it would certainly be help entrepreneurs in Malaysia's rubber plantations. In the designing stage, many aspects should be studied in producing a quality, effective and widely accepted product. Therefore, the objectives itself is the key target for the creation of the product. The objectives to be achieved are: i) To develop a new electrical motor rubber taping machine ii) To produce an innovative rubber taping machine to end user.

2.0 DESIGN AND FABRICATION Automatic rubber tapping machine is a device that used for rubber tapping. It was build as for now-days enquiry for increasing the amount of rubber produce. It was also build for replacing the old tool that only use rubber tapping knife that need a lot of energy to finish up all the rubber tapping process in large area. This device just need to push the 'ON' switch button and it will operate itself to tap the rubber tree. A complete rubber tapping machine must meet safety requirements for the user and also be able to complete and passes through various tests. The most suitable material chosen for the body part is plate steel because the strength and the mass of the materials.

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2.1 The Design of Electrical Motor Tapping Machine i) The Components & Assembly Drawing Assembly drawing consists battery, gear, motor and cutter.

Figure 1: Assembly Drawing of EMRT -15

ii) Final Product of EMRT -15 Final product that tested on a tree.

Photo 1: Final Product of EMRT -15

2.2 Safety Features Project i) The cover of the machine

The cover for the main body is made to protect the electrical component in the machine that we used from the rain. It is also made to cover the body parts that was dangerous for user if we careless in using the machine.

ii) The On/Off button It functions as ON/OFF button but also function as emergency button to stop the process whenever emergency or abnormal sound and behaviour of machine occurs.

2.3 Project Cost Cost is important because it will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of projects can be higher. This is because the market is driven by extensive production costs and prices of goods sold. Project costs for the Motor Rubber Tapping Machine are detailed in Table 3.

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Component Detailed Price (RM)

Motor High torque power window motor

RM 50

Machine Track , main body RM 350 Motor speed

controller 0.2 A motor speed controller RM 83

Switch Normal ON/OFF switch RM 3 Sprocket and chain Sprocket size 42 RM 10

Battery 12v power supply RM 40

Total RM 486

Table 3: Project Cost

2.4 Product Component Testing Product testing is important to see the performance of Electrical Motor Rubber Tapping Machine. The detailed data‘s show in Table 4.

Component Testing Detailed Results

Motor High torque power motor speed

Good performance

Machine Track , main body testing Good condition Motor speed

controller 0.2 A motor speed controller Function

Switch Normal ON/OFF switch Function Sprocket and chain Sprocket size 42 Function

Battery 12v power supply Function & Save Energy

Table 4: Product Components Testing

3.0 CONCLUSION This rubber tapping machine‘s idea can overcome the problem in rubber plant industry with the new innovation that can help the rubber tapper in tapping the tree especially in a large area of planting. The user just need to put the machine onto the track and push the switch button as the track were ready attach to the tree. When the process of rubber tapping have finish the machine just need to take out from the tree and the track will be left on the tree for next tapping process. This machine can achieve better efficiency compared with manual tapping process using tapping knife. Last but not least, this machine can achieve the objective of tapping process with low cost machine production.

4.0 BIBLIOGRAPHY

Burns, Bill. "The Gutta Percha Company". History of the Atlantic Cable & Undersea Communications. Retrieved 14 February 2009.

Cornelius-Takahama, Vernon (2001). "Sir Henry Nicholas Ridley". Singapore Infopedia. Retrieved 9 February 2013.

Heinz-Hermann Greve "Rubber, 2. Natural" in Ullmann's Encyclopedia of Industrial Chemistry, 2000, Wiley-VCH, Weinheim. doi:10.1002/14356007.a23_225.

"Rubber and Other Latex Products". Retrieved 31 August 2014.

Jump up to:a b "Charles Marie de la Condamine". http://www.bouncing-balls.com/.

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Leng, Dr Loh Wei; Keong, Khor Jin (2011). "Mad Ridley and the rubber boom". Malaysia

History. Retrieved 9 February 2013.

"Casing Joint Design" (PDF). Report - Investigation of the Challenger Accident. US Government Printing Office. Retrieved August 29, 2015.

Koyama, Tanetoshi; Steinbüchel, Alexander, eds. (2011). "Biosynthesis of Natural

Rubber and Other Natural Polyisoprenoids". Polyisoprenoids. Biopolymers 2. Wiley-Blackwell. pp. 73–81. ISBN 978-3-527-30221-5.

Faraday, Michael (1822). "On Some New Electro-Magnetical Motion, and on the Theory

of Magnetism". Quarterly Journal of Science, Literature and the Arts (Royal Institution of Great Britain) XII: 74–96 (§IX). Retrieved 12 February 2013.

Tom McInally. (2012): The Sixth Scottish University. The Scots Colleges Abroad: 1575

to 1799 (Brill, Leiden, 2012) p. 115 "The Development of the Electric Motor,". Early Electric Motors. SparkMuseum.

Retrieved 12 February 2013. "The first dinamo?". travelhungary.com. Retrieved 12 February 2013

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MODIFICATION OF CRUSHER MACHINE ON COUPLING MH 45 RS

M. Fadli B. Abdul Hamid Tel: +013-4285485 Email: fadli@psp.edu.my

Md. Najib B. Talibin

Tel: +6013-4881554 Email: najib@psp.edu.my

Mechanical Engineering Department, Seberang Perai Polytechnic,

Penang, Malaysia.

M. Faiq, M. Marwan Mu’izz, A. Azim, S. Norliana

ABSTRACT

Modification that we do on the crusher machine was to improve this machine in which the shaft of the crusher has broken down. It became stuck and cannot be moved due to the wet material to be dried beforehand. Therefore, to overcome this problem, we have modified the shaft with put coupling between shaft crusher and shaft from sprocket. A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power. The coupling that we use was coupling MH 45 RS (Hyper Flex 45 Rubber Spares). Keywords: Modification, Coupling MH 45 RS, Crusher Machine

1.0 INTRODUCTION From the research, we had choose coupling MH 45 RS because the characteristics of the coupling suitable with this machine. The characteristics are high flexibility and excellent shock absorption, minimum space required with high speed, quiet and smooth operation and easy installation and maintenance free. The coupling also can be assemble and dismantle from the shaft. It is easy to do maintenance if the crusher machine occurring problem. The objective of our project is to improve and renew the crusher machines that meet the following criteria: i) To modification of crusher machine. ii) To use coupling MH 45 RS as efficient product.

2.0 DESIGNING AND FABRICATION

Figure 1: Loose Components

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Figure 2: Final Product

2.1 Part of crusher machine i) Coupling MH 45 RS Coupling MH 45 RS is an elastic couplings type. Elastic coupling incorporate a pre-compressed rubber component, which provides extra strength and long life. These couplings cater for all types of misalignment. The hubs are made of high strength aluminium alloy, making the coupling light and corrosion resistant. The rubber component damps shocks and provides smooth, quiet power transmission, thus protecting both the driving and the driving machines. Mounting is very simple. As the rubber component is a split insert, it can be mounted after the shafts have been aligned.

Figure 3: Loose Coupling

ii) Polish shaft Shaft is used to rotate the crusher.

Figure 4: Shaft Polishing

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2.3 Project Cost Cost to perform this project is important because if it too high, its possibility to be sold is low. The cost stated in schedule.

No Component Quantity Price

1 Bearing 2 RM 120 2 Polish Shaft 1 RM 20 3 Elastic Coupling 1 RM 80

TOTAL 4 RM 220

Table 2 : Project Cost

3.0 DATA ANALYSIS Modification of crusher machine on coupling MH 45 RS make it easy for maintained because it can assembles and dismantle.

Before modification After modification

Cannot be assemble Can be assemble Cannot be dismantle Can be dismantle

Difficult to be maintained Easy to maintained

Table 1: Test and Result Before mofified, the crusher machine only have one use one shaft only. The shaft installed from the pulley to the crusher causing the shaft cannot be unplugged from the crusher. Therefore, we use coupling as a connection between the shaft, it easily assemble and dismantle. In addition, crusher machine easily maintained so that the machine always well-maintained

4.0 CONCLUSION Modifications done is efficient and appropriate to the machine, therefore it can solve the problem with the machine. Selection of the coupling is also done carefully and accurately so that there are no problems in the future.

5.0 BIBLIOGRAPHY Bearing Industry Timeline, retrieved 2012-10-21. "Bicycle History, Chronology of the Growth of Bicycling and the Development of Bicycle Technology by David Mozer". Ibike.org. Retrieved 2013-09-30. Boyle, B. (2008). "Tracking the causes of coupling failure". Plantservices.com. Retrieved 7 January 2015. Engineering "mechanical engineering". The American Heritage Dictionary of the English Language, Fourth Edition. Retrieved: 19 September 2014. "Heron of Alexandria". Encyclopedia Britannica 2010 - Encyclopedia Britannica Online. Accessed: 9 May 2010. "NEF Taper-Lock Series". Tsubakimoto.com. Retrieved 7 January 2015. Pump Couplings from John Crane Metastream and Powerstream at Total Pump Soultions". Totalpumps.co.nz. Retrieved 7 January 2015

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Products : Couplings & Power Transmission: Shaft Locking Devices". Lovejoy- inc.com. Retrieved 7 January 2015 "U.S. Tsubaki POWER-LOCK Catalog" (PDF). Ustsubaki.com. Retrieved 7 January 2015. "Why a Grid Coupling - Features & Benefits, Design Basics, and Element Options". Couplinganswers.com. Retrieved 2014-12-22.

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THE DEVELOPMENT AG LIFTING MACHINE

Mohd Tajudin B. Abd Karim Tel: +6013-4884840 Email: tajudin@psp.edu.my

Mohd Rosli B. Saad Tel: +6019-4155191 Email: rosli@psp.edu.my

Department of Mechanical, Seberang Perai Polytechnic, Penang, Malaysia

Easuvaran S/O Raman, M. Mustafa B. Omar, M. Yusuf B. M. Fauzi, Mif Tahud Din B. Min Fari

ABSTRACT AG Lifting Machine is a project that is aimed to facilitate the process of lifting and shifting heavy objects in the workshop. There are several projects related to this theme but existing projects using hydraulic or motor to lift, it is also commonly used in heavy industry and also in the construction industry. But AG Lifting Machine is a special project for the purpose of working in the garage. AG Lifting machine also uses an air gun. Based on the experimental results, the resulting system is capable of functioning with a stable and easy to lift and shift heavy objects. . However, as a whole, with the project AG Lifting Machine is expected to reveal more to the public about the lifting process using an air gun that can be generated from the compressed air as well as being cost effective use of other existing energy. Keywords: AG Lifting, Development, Machine

1.0 INTRODUCTION Lifting machine is a device that can be used to lift heavy loads. Nowadays, the uses of machines is playing important role in industries. There are many types of machines that can make peoples work more safe and efficient. Machines will makes the peoples work easy and it also will do the work that cannot be done by humans. To lift an object we humans need lifting machines to make humans work easy. It was found that there are many types of lifting machine. To lift a heavy objects humans need a lifting machine to lift up. The lifting of objects generally occurs in construction sites, in factories and other industrial situations .Correct lifting can move large objects efficiently and reduce manual handling operations .Incorrect lifting however, can lead to disastrous accidents such incorrect lifting procedures cause injuries, loss of works time and property especially in workshop. People, machinery, loads, methods and the work environment, are all important factors for correct lifting. Provided that enough safety measure are fully implemented, lifting accidents can reduced. So in order to help lifting, we have implemented a lifting machine helps humans work easy in workshop usage. By doing this, it can helps lift heavy load objects in workshop and it also help to shift the object one place to another place.

1.1 Project Objectives The main purpose of implement this lifting machine is:-

i) To develop the lifting and shifting machine ii) To produce lifting machine is mainly implemented for workshop iii) To produce Lifting machine suit for wide and small workshop

3.0 METHODOLOGY The AG Lifting Machine uses compressed air to lift up heavy objects. Fixed 1 ton of chain block at the built frame which is balanced and strong enough. A sprocket was welded at the chain

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block‘s shaft. Fixed moving shaft in the middle of the frame and sprocket was welded into the shaft. Fixed the shaft which is welded with sprocket parallel to the chain block which is welded with sprocket. Connect a chain from sprocket in the shaft to the sprocket in the chain block. Nut welded at the end of shaft to connect with the air gun to rotate. The compressed air supply energy to the air gun the air gun activate and rotates the shaft. The shaft rotated the driver sprocket rotate the driven shaft also rotate equal by the connecting chain. The object lift up when the driven sprocket rotates the shaft inside chain block by rotates the chain in the chain block.

3.1 project design and fabrication As we know, there are many types of lifting machine. But every lifting machine has its own advantages and disadvantages of each. Among the design the stand should be strong and stable to lift heavy loads.

. Figure1: Assembly Drawing

The dimension of the vertical stand was eight feet and the horizontal stand was seven feet. The material used to build the frame was mild steel. The shaft that used in this project was stainless steel around seven and half feet. The diameter of the shaft was thirty two millimetres. The wheel that used was suitable to with stand the weight about one tonne. It also used thirty six dimension of sprocket as a driver and forty two dimension of sprocket as a driven. The chain block that used to lift the object was one tonne.

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Photo 1: Final Product (AG Lifting Machine)

4.0 SAFETY FEATURES PROJECT

4.1 The cover of the machine The cover for the both sprocket and chain of the machine is protecting the operation when the machine is running. Whenever the shaft rotates towards the sprocket by the chain it is very dangerous therefore it need cover to secure the operation and the user. It also to prevent from occur any accident.

5.0 PROJECT COST Cost is important because it will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of projects can be higher. This is because the market is driven by extensive production costs and prices of goods sold. The project cost for AG Lifting Machine is detailed in the Table below.

Components Price (RM) Mild steel 150

Chain Block 300 Shaft 120

Sprocket 20 Wheel 120

Cat 20

Total 730 Table 3: Project Costing

6.0 CONCLUSION The AG Lifting machine‘s idea can overcome the problem in mechanic workshop and any condition where to lift a heavy object and to shift it. By using it the work to lifting and shifting process of a heavy load will be easier. The machine can be achieving better efficiency compared with manual method that people using. Lastly, this machine can be achieve the objective of lifting and shifting process in the workshop purpose with a lower budget compared with the other product.

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7.0 BIBLIOGRAPHY

Quincy No. 2 Mine Hoist (1920) National Historic Engineering Landmark brochure, The American Society of Mechanical Engineers, 1984.

Henry D. Stover, Planing Machine, U.S. Patent 30,993, Dec. 18, 1860, 1861. John DeLancy Watkins and Robert Bryson, Mowing Machines, U.S. Patent Reissue 1,904, July 23, 1861.

Modulus of Elasticity, Strength Properties of Metals – Iron and Steel, retrieved 23

April 2009.

American Society of Mechanical Engineers (1906), Transactions of the American Society of Mechanical Engineers 27, American Society of Mechanical Engineers, p. 441.

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THE DEVELOPMENT AND DATA COLLECTION OF SPUR GEAR LEARNING KIT

M. Najib bin Haji Talibin

Tel: +013 4881554 Email: najip@psp.edu.my

Noor Rafidah Bt. Md. Osman Tel: +6012-4656578 Email: rafidah@psp.edu.my

Mechanical Department, Politeknik Seberang Perai,

Penang, Malaysia.

Norsyuarina Bt. Mohamad, M. Amarrun Naim B. Harun, M. Alif Alifi B. Jaafa, M. Zabidi B. Zainuddin & Nurul Fatihah Bt. Ishak.

ABSTRACTS

The spur gear learning kit is a kit that can help student to improve their learning skill about characteristics of gear. The product was developed using a set of spur gear with different size and total teeth. It shows that SGLK can help students to understand the function of the spur gear, the function of the teeth on the gear and the movement of the gear. With the availability of ' gear kit ' students can see a closer again every mechanism found on a gear. Through the ' gear ' kit also students are able to see more clearly again the speed generated by the gear according to the motor speed. This can facilitate the lecturers in the education system and technical support to the students. It also can shorten the learning time for students to prevent students from being bored Keywords : Spur Gear, Learning Kit, Development and Data.

1.0 INTRODUCTION Learning is a method of acquiring knowledge or skill through experience, practice learned or taught. Learning is traditionally practiced by most of the students are passive learning. Passive learning by memorizing all the information communicated by the instructor for lectures without student involvement in learning. Students are listening to a lecture and considering the facts given by the instructors. Learning that this should be changed to passive learning to active learning and allow students to focus on learning. Teaching methods and active learning can stimulate students to activate the existing knowledge and new knowledge is associated with. In addition, the Gear is a component in the form of a circular cylinder with a certain thickness and have teeth built around it (South DW & Mancuso JR ed,Mechanical Power Transmission Components, Dekker 1994)

The study is to examine the extent to which the level of understanding of students in understanding the movement and function of the gear. The objectives SGLK to help students see the spur gear mechanism of varying sizes and also helps students calculate the speed of the gear through photodetecter channelled through brass motor. Besides that, assists students in ways gear assembly according to the correct measures. 2.0 DESIGNING AND FABRICATION In this section some of the main components of the project are shown in the detailed drawings are produced using Inventor software 2011. The project has a motor that will result in the movement of the gears. In this painting we have demonstrated 3 spur gear in the size and number of teeth are different. The spur gear motor will move according to a predetermined

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speed. A complete gear kit must meet safety equipment for the user also able to complete and passed through repeated various tests. (Erdman AG & Sandor GN, Mechanism Design: Analysis and Synthesis, Prentice Hall 1997 includes epicyclical gear trains)The most suitable

materials chosen for the base of the gear kit is mild steel because the strength and the mass of the materials (Design News, 1998).

Figure 1: Assembly drawing

Figure 2: Spur gear drawing

2.1 Parts of Spur gear learning kit

i) Switch This switch is used to help drain the electric current to the circuit's gear kit. Switch we use is a switch that has been combined with a variable resistor. The variable resistor with a switch mounted so easy for a user to change the desired speed.

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Figure 3: Switch

ii) Holder Holder that we use is to hold the gear and shaft. Holder that we produce is easy flow holder. The holder can be disassembled and assembled with the other holder.

Figure 4: Holder

iii) Base The table base function as the main frame of this project. On its top it hold the motor, switch and holder of the gear. Table base is made from mild steel sheet. Mild steel sheet were cut

according to the mechanical drawing.

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Figure 5: Base

2.2 Spur gear Testing The data gathered from tests which have been carried out on the SGLK. Each set of data obtained have different speeds according to gear set that has been set as shown in Table 1 below.

Set Gear Time Taken (s) Speed (Rpm)

Set A 5 108.16 Set B 5 52.88 Set C 5 42.35 End 5 62.28______

Table 1: Data Testing

2.3 Safety Features Project i) The motor cover The motor cover that we have made to protect the motor when the machine is

running. Whenever the machine is running in very dangerous therefore it need cover to secure the machine and environment.

ii) The push button The push button function as ON/OFF button but also function as emergency button

to stop the process whenever emergency or abnormal sound and behaviour of machine occurs.

iii) The bolt and nut The bolt and nut we used it for the holder to hold the shaft and gear from moving while it was running. The reason why bolt and nut was chosen is because we can take it out and change the shaft and the other gear.

2.4 Project Cost Cost is important because I will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of projects can be higher. This is because the market is driven by extensive production costs and prices of goods sold. Project cost for the plate dryer are detailed in Table 3.

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No Components Quantity Price (RM) 1 Gear 1 box 300 2 Motor 1 180 3 Screws 24 0.50/unit 4 Shaft 4 20.00/unit Holder 15 100

6 Base 1 80.00 7 Switch 1 10.00 8 Variable resistor 1 10.00

Total 952

Table 3: Project Cost

3.0 CONCLUSIONS The conclusion that can be made in the production of this project is beneficial and some new things to the students such as issuing idea was sparked in mind to make it happen and have to make the design first. The spur gear kit learning produced for students can develop skills in any work done. In addition, students also gain benefits such as the opportunity to share interesting ideas for their projects.

4.0 BIBLIOGRAPHY Davis, J. R. Gear Materials, Properties, and Manufacture. Materials Park, Ohio: ASM International, 2005. Print. Engineer‘s edge.com,. 'Gear Types, Spur, Helical, Bevel, Rack And Pinion, Worm - Engineers Edge'. N.P., 2015. Web. 19 Mar. 2015. Erdman AG & Sandor GN, Mechanism Design: Analysis and Synthesis, Prentice Hall 1997 includes epicyclic gear trains McGraw-Hill (2007), McGraw-Hill Encyclopaedia of Science and Technology (10th ed.), McGraw-Hill Professional. MacKinnon, Angus (2002). "Quantum Gears: A Simple Mechanical System in the Quantum Regime". Norton, Robert L. (2004), Design of Machinery (3rd ed.), McGraw-Hill Professional. Nice, Karim. 'Spur Gears - How Gears Work'. How Stuff Works. N.P., 2015. Web. 19 Mar. 2015. Robertson, Adi (September 12, 2013). Seireg AA, Friction and Lubrication in Mechanical Design, Dekker 1998 contact, fluid film bearings, gear contact. Vallance, Alex; Doughtie, Venton Levy, Design of machine members (4th ed.), McGraw-Hill.

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THE DEVELOPMENT OF AUTOMATIC SKATEBOARD

Norfadliyah Bt. Abdul Hamid Tel: +6019-4750924 Email: norfadliyah@psp.edu.my

Md. Baharuddin B. Abdul Rahman

Tel: +6011-11535950 Email: mdbahar@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic, Penang, Malaysia.

M. Raffiq B. Rosli, M. Ammar B. Kamaluddin Darus & `Aisyatul Amla Bt. Mohammad

ABSTRACT Automatic Skateboard is a project undertaken primarily intended to facilitate transportation to students. The production of this project based on the problems experienced by some students who face problems of transportation to campus. Automatic Skateboard has the same function as other skateboard but differ on the application. It will move according to the instructions delivered through a connecting wire that connects the motor to the controller. Automatic Skateboard can`t move by its own unless it is controlled by the controller. It moved with the wheels mounted at the deck and one of the wheels were connected to the motor that capable to rotate whenever it‟s needed. Because it‟s using a wheels, it can only move on a flat surface rather than in a staircase places. It movement is controlled automatically. Keywords: Automatic Skateboard, development

1.0 INTRODUCTION Transportation is the movement of people and goods from one location to another. It is very important thing now days. There are various types of vehicles such as cars, trucks, motorcycles and others. There are also small transport such as skateboarding, rollerblading and others, who had to use force to move it. By improving the use of surfboards motor system is better. Automatic skateboard can save time and save space parking. Especially in polytechnic students can save their time for the class.

2.0 METHODOLOGY In general, this project Skateboard Automatic mechanical machining process involves a lot like a lathe machine, drilling machine, metal fabrication, cutting, joining and many others for the body parts. In addition, the measurement process is also involved in the production of components and equipment for the project such as chain and metal plate. All of these processes have continuity and relationship between each other. So we are working system involves the design, installation and modification and testing results.

2.1 Product Design

Figure 1: Assembly Drawing

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2.2 Product Fabrication First step, cutting the plate based on the size which have been listed. After that, welding the plate based on design we created. Second step assemble the board and the body briefly and make it balance. Third step tide the motor, tires, bearing, and sprocket make sure the screw tight and not dislodged when is running. For the fourth step use a strong chain and post on sprocket make sure not really tense and not loose. Fifth step run the skateboard and learn to stability know how to control that thing. For the last step repaint the project and make a testing also take a result.

Photo 1: Final Product

3.0 RESULT AND DISCUSSION 3.1 Save Time Data for time taken at same distance between using automatic skateboard and walking.

Types Distance (m) Time taken (minutes)

Walking

500

10

Automatic skateboard 500 5

Table1: Data Testing

*Automatic skateboard has achieve the objective 3.2 Comfortable Most 80% of our users comfortable with this automatic skateboard because it is easy to handle and more stabilize. It is also didn‘t use manpower to move it. This skateboard can go through any kind of surface because it have off-road tires.

4.0 SAFETY FEATURES PROJECT

i) The grip on board The grip on board is to avoid user slip from board when the machine is running. It is dangerous if there is no grip on board. It is also important for user comfort when controlling the machine.

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ii) Wear safety gears Users should wear safety gears before slide this automatic skateboard. It is include helmets, knee pads and elbow pads. It is important for user safety.

5.0 PROJECT COST In producing the project, the total cost of the project is emphasized. Production costs can be expressed as the expenditure involved in the operation of a project.

Components Cost (RM)

Bolt 8.00 Screw and nut 25.00

Non-insulated terminal 6.00 Throttle 82.00 Bearing 20.00

Off-road tires 190.00 Spray 22.00 Trunks 80.00 Motor 110.00

Controller 92.00 Battery 140.00

Sprocket 18.00 Raw material 191.00

Total RM 984.00

6.0 CONCLUSION This automatic skateboard idea can overcome the problem students from late to class, no parking space and air pollution. The objective of this product have been achieve. This is because it proves that using this product users can save more times than walking. It is also eco- friendly because it does not use any fuel.

7.0 BIBLIOGRAPHY

Bertman, Stephen (2005). p.35 Handbook to Life in Ancient Mesopotamia Check |url=scheme (help). Oxford University Press. Retrieved 2 August 2014. Bellis, Mary. History of the Electric Battery. About.com. Retrieved 11 August 2008

Faraday, Michael (1822). "On Some New Electro-Magnetical Motion, and on the Theory

of Magnetism". Quarterly Journal of Science, Literature and the Arts (Royal Institution of Great Britain) XII: 74–96 (§IX). Retrieved 12 February 2013.

Fink, Donald G.; Beaty, H. Wayne, Standard Handbook for Electrical Engineers, '14th

ed., McGraw-Hill, 1999, ISBN 0-07-022005-0. Fowler, H. W. (2009). David Crystal, ed. A Dictionary of Modern English Usage: The

Classic First Edition. Oxford University Press. p. 655. ISBN 978-0-19-953534-7. Retrieved 2010-10-23.

Filip M. Gieszczykiewicz. "Sci.Electronics FAQ: More Battery Info". repairfaq.org. Harris, Tedric A. (2000). Rolling Bearing Analysis (4th ed.). Wiley-Interscience. ISBN 0-

471-35457-0.

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Houston, Edwin J.; Kennelly, Arthur, Recent Types of Dynamo-Electric Machinery, American Technical Book Company 1897, published by P.F. Collier and Sons New York, 1902

Kuphaldt, Tony R. (2000–2006). "Chapter 13 AC MOTORS". Lessons In Electric

Circuits—Volume II. Retrieved 2006-04-11. Rosenblatt, Jack; Friedman, M. Harold, Direct and Alternating Current Machinery, 2nd

ed., McGraw-Hill, 1963.

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THE DEVELOPMENT OF PORTABLE BACKDROP

Mohd Hafirizal Bin Omar Tel: +6019-4802640 Email: hafirizal@psp.edu.my

Mohamad Salim Bin Abdul Wahab Tel: +6013-4882524 Email: salim@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic, Penang, Malaysia

Faizal, A. Wafi, M. Azlan, Halimatun Saadiah & Nur Hazirah

ABSTRACT Portable backdrop is a project implemented to mitigate wedding cost in terms of dais rental and dais delivery cost which requires transportation that large and follow customer needs. This project also designed to fill in space that is small or medium. Based on experiment result, project produced can function steady and nicely. However the portable backdrop it can be changed in shape become dais desired by consumer. The portable backdrop hoped can helping youth and group that not able to rent high cost dais and to marriage boutique. Keywords: Portable Backdrop, Development

1.0 INTRODUCTION Nowadays, Malaysian wedding feast need a dais to make it more gala. There are many types of dais which have different theme and the cost is very high. However, there problems is about the costing on transportation and to help low income earner that want a great wedding festive but could not afford it. Our objective is to develop new types of dais. Therefore, a new type of dais that can be changed it design, it has 3 types of design, easy to assemble and easy to carry. This dais need to be developed. This type of dais hopefully can save wedding cost, limit transportation cost, decorate the desired backdrop, and easy prepare.

2.0 METHODOLOGY Portable backdrop produced by us can be regulated according to house compound size.it also variable the height according to will. Apart from that, portable backdrops that we produce can changed its design to three proportions follow customer's needs.

2.1 Product Design

i) Part A – A very simple design or basic design of Portable Backdrop

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ii) Part B – design that have a roof to support a lighting decoration

iii) Part C – This design made for this dais to make it wider

2.2 Fabrication i) Base Can be matched according to size according to wanted size

Figure 1 : open base

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Figure 2: closed base

ii) Poles The height can be matched according to place.

Figure 3 : Poles

iii) Elbow Playing an important role to can change shape of pole desired

Figure 4 : Elbow

2.3 Testing This portable backdrop has been test, detail of testing in table 1:

Testing Result

Load 600kg (Max) Time 2.30 – 5 (minutes)

Table 1: Test and result

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2.4 Safety Features Project i) Base The base have many feet to support high burden, also possess gravity point that is low ii) Top Can support minor load, likes fabrics and other decoration accesories

2.5 Project Cost Cost to perform this project is important because if it too high, its possibility to be sold is low. The cost stated in schedule.

No Component Quantity Price

1 Steel bar 21 RM 400 2 Steel holder 15 RM 200 3 Bolt and Nut 1set RM 100

TOTAL 37 RM 700

Table 1 : Project Cost

3.0 DISCUSSION

3.1 Time consuming Portable backdrop assembly time is faster than the ordinary dais because Portable Backdrop has been design to easily assemble. 3.2 Price Portable Backdrop price when rented is cheaper because it only needs a car as transportation, but the ordinary dais needs a lorry for transportation. It rented just about RM 200 to RM 300 compared to ordinary price that is between RM 600 to RM 3000 and over. 4.0 CONCLUSIONS This Portable Backdrop can overcome the problem of high wedding cost because of the ordinary dais rented by the wedding boutique. The people with low income earner can make an awesome wedding with a cheaper price and because of it easy transportation.

5.0 BIBLIOGRAPHY

Buckley, Craig ―Addressing Infrastructure: Portable initiatives, collapsible forms‖ Fuse Magazine‖ 26:1, 20-29.

CHAPMAN, Gary: The marriage you have always wanted. Northfield Publishing, 2005, 152 pp.

CHAPMAN, Gary: The Family You've Always Wanted: Five Ways You Can Make It Happen. Chicago: Northfield Pub., 2008.

GARASCIA, Anthony, Before I do. Preparing for the Sacrament of Marriage. Ave Maria Press, 1999, 128 pp

GRAY, John: Men Are From Mars, Women Are From Venus: A Practical Guide For Improving Communication And Getting What You Want In Your Relationships. Harper Collins, New York 1992, 286 pp.

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HAHN, Kimberly: Life-Giving love: Embracing God´s Beautiful Design for Marriage,

Servant Publications, 2001, 375 pp.

Hornstein , Shelley ―Archiving an Architecture of the Heart‖ in Shelley Hornstein , Laura Levitt , and Laurence J. Silberstein eds. Impossible Images: Contemporary Art after the Holocaust (New York : University Press, 2003), 13-30.

MAY, William: Marriage the rock on which the family is built. Ignatius Press, second ed. 2009, 198 pp.

MAY, William E.: Sex, Marriage and Chastity: Franciscan Herald Press, 1981, 170pp.

Stenson, James: Lifeline. Scepter, 2005, 251 pp

Von Hildebrand, Alice: By Grief Refined. Franciscan University Press, 1

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SUSTAINABLE PRODUCT DESIGN AND MANUFACTURING

Maizul Afzairizal Mohd Adnan Tel :+6019-5609961 Email: maizul@psp.edu.my

Mohamad Taufik A Rahman

Tel :+6019-6596422 Email: taufik@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic Penang, Malaysia.

ABSTRACT

This paper consist the Design for the Environment (DfE) in all the concept and method that relate to DfE for design practice that seek to reduce the environmental impact of product and process. This study tried to determine the benefit of DfE to the company or manufacturer. The method that include in DfE such as the design, life cycle, Product Life cycle (PLC) approach, Life Cycle Assessment (LCA) and how the DfE concept implement in real life product. However, in this study it just focuses on Hybrid car. Study shows that there is a compulsory DfE concept in order to develop the Sustainability Development. At the same time, Multi global companies should play the role of „go green‟ concept to educate their consumer by the implementation of “green technology” and “green concept” in their product. Keywords: Design for the Environment (DfE), Life Cycle Assessment (LCA), Product Life Cycle (PLC)

1.0 INTRODUCTION Sustainable development refer to the mode development of how human can manage their resource which the aim is to meet human needs and at the same time preserving environment so that these needs can be met not only in the present, but also for future generations to come. Sustainable development with the concern for the carrying capacity of natural systems to ensure that the use of environment resources to satisfy the present demands accordingly with the social challenges faced by humanity (Giudice, et al. 2006: pg 1-25).The concept of sustainable development categorised into three constituent parts (Hauschid, et al, 2008) environmental sustainability, economic sustainability and socio–political sustainability. Life Cycle Assessment (LCA) is employed to forecast the impacts of different (production) alternatives to investigate the potential environmental effects of the whole system, thus being able to choose which the most environmental friendly (Giudice, 2006: pg 83-86). DfE employs a variety of design approaches where the aim is to reduce the overall human health and environmental impact of a product, process or service, where impacts are considered across its life cycle where it can only be obtain when all the entire life cycle of the product has taken into consideration at the early design stage.

1.1 Background of Study Ecodesign or Design for Environment was the activities where the aim was to improve the environmental performance of products (Hauschild, et al, 2003). There are three main concepts that fall under the Design for Environment umbrella: i). Design for environmental processing and manufacturing: Started from the mining of raw material. This includes the minimization the environment effect such as waste and hazardous by-products, air pollution, energy expenditure and other factors. This ensures that raw material extraction (mining, drilling, etc.), processing (processing reusable materials, metal melting, etc.) and manufacturing are done using materials and processes which are not dangerous to the environment or the employees working on said processes.

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ii). Design for environmental packaging: Involve with supply chain management and logistic. This ensures that the materials used in packaging are environmentally friendly, which can be achieved through the reuse of shipping products, elimination of unnecessary paper and packaging products, efficient use of materials and space, use of recycled and/or recyclable materials. iii). Design for disposal or reuse: The end-of-life of a product is very important, because some products emit dangerous chemicals into the air, ground and water after they are disposed of in a landfill. Planning for the reuse or refurbishing of a product will change the types of materials that would be used, how they could later be disassembled and reused, and the environmental impacts such materials have. By implementing the Design for Environment concept, it is a hope that the company can also promote the Go-green concept which means to pursue knowledge and practices that can lead to more environmentally friendly and ecologically responsible decisions and lifestyles, which can help protect the environment and sustain its natural resources for current and future generations. These paper will focus on Design for the Environment (DfE) concept that been implement on a product base company to identify a collective term of design practices that used to reduce the environmental effect cause by the product or the process of manufacturing. It also tries to determine how the company try to implement the practice to sustain in the business and at the same time promote the go-green technology within the DfE.

2.0 LITERATURE STUDIES Design for the Environment is a guideline that prevents pollution and the risk pollution to humans and environment. Hauschild, et al, (2003) reported that in 50 years to come, economic will performed with less than one tenth of the negative impact. Design for Environment (DfE) principles will eventually lead a company to minimize numbers and types of parts, reducing heat and power consumption, and deploying replaceable/upgradable modules which also tend to increase products‘ reliability and lifespan. Besides that, it will also promotes lower cost of materials and greater value at end of life; increasing the efficiency of assembly lines and will also help consumers and company to a more efficient storage and shipping which will in turn bring in competitive advantages due to less power consumption and reduced risk of supply-chain interruptions stemming from restricted substances. Hauschild, et al, (2003) stated that there are three main concepts that fall under the Design for Environment umbrella that is design for environmental processing and manufacturing, design for environmental packaging and design for disposal or reuse. Design for environmental and manufacturing involves in non-toxic process and production material, using minimum energy and minimizing the emission, waste and co-product. This is to make sure that raw material extraction such as mining; drilling, processing and manufacturing are done using materials which are not dangerous to the environment or the employers. Design for environmental packaging involves in the consideration are a minimum of packaging materials, reusable of pallets, recyclable packaging material and biodegradable packaging material. This is done so that the materials used in packaging are environmentally friendly and elimination of unnecessary paper and packaging products. A sustainable packaging will results in the improvement of the long term of longevity of natural ecosystems. Besides that, a sustainable packaging must meet the functional and economic needs of the present without compromising the ability of future generations to meet their own needs. Sustainability is not necessarily an end state but is a continuing process of improvement. The third concept in Design for Environment is design for disposal or reuse. Calcott et al. (2005) stated that the end-of-life of a product is very important, as some products could produces dangerous chemicals into the air, ground and water after they are disposed of in a landfill and planning for the reuse or refurbishing of a product will change the types of materials

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used. A few consideration in the third concept that is material selection to enable reuse, try to avoid filter material in plastics such as fibreglass. Besides that, the design itself should be easy to be disassembles and must be easily separated. Items used in automobiles, home appliances and furniture can are now made and design to be repairable and disassembly for recycling purpose. Even now, some of the items that are sold to public was made and constructed from recyclable materials such as steel, aluminium and glass. Most of companies nowadays tend to be extra careful in their selection of materials and manufacturing processes. This help companies to create products that are comparable in price and performance to non-sustainable products

2.1 Benefit for Companies 2.1.1 Consumer Awareness Recent survey on consumer awareness to the environment by Macromill (2010), there are 25% of consumer that are keen to contribute to environmental protection even it involves in some expense while another 50% are willing to contribute if no expense involves. 2.1.2 Better product design Franklin et al (2004) stated that green design emphasizes fewer parts and materials in product designs which will reduce the inventory volume required to produce the products .This will eventually lead to the reduction of hazardous materials in the products which in turn makes the workplace safer, and the accident potentials lower. Many companies nowadays do recognize that green design is consistent with competitive product design. 2.1.3 Regulation compliance Most of the companies that implement DfE will eventually complied government regulations regarding the environmental impact of products and production processes. Governments would give lots of attention the disposal and recycle of products at the end of their useful life and the material used by the items. Applying DfE is also more cost effective than trying to modify existing products and processes to meet governmental specifications. 2.1.4 Future regulations By implementing DfE strategies into their business plans, company will be better prepared to meet the future environmental challenges. For companies that do not implement DfE, they will be in a hard situation when new regulations take place. 2.1.5 Employees Satisfaction Many citizens are becoming more environmentally conscious and as employees they choose to work for environmentally conscious employers. 2.1.6 Increasing In Profitability One of the most important factors in changing industry's attitudes on environmental design is that DfE will eventually increase profitability. By reducing pollution at the source and designing products and processes will generally result in increased efficiency and reduced operating cost

3.0 METHODS The design stage in the new product development process is the most critical stage in the entire cycle. Ideas, objectives, and concerns addressed in this stage have a ripple effect throughout the entire NPD process. Companies have come to realize that in order to produce environmentally safe products in a cost effective manner, they must address environmental issues in the design stages of the NPD process. This is a process called green design or design for environment. A representation of systems engineering process flow is shown in Figure 1. The initial stage of design is classified as ―Concept Development.‖ This involves determining the needs of the system, exploring concepts, as well as formulating a well-defined

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concept or set of concepts. The second stage of systems engineering design is ―Engineering Development‖. In the Engineering Development phase the defined concepts undergo development, testing, evaluation and result in feedback which can re-direct the 4 concept development phase or lead into the final Post Development phase. Although Figure 1 is represented as a linear progression through the phases of design and development, in reality there are many feedback loops and embedded iterations within and between phases.

Concept Development

Need Analysis Concept Exploration Concept Defination

Engineering Development

Advanced Development Engineering Design Integration & Evaluation

Post Development

Production Operation & Support

Figure 1: Concept of Development

Green design is the systematic consideration of environmental health, safety, preservation, and restoration issues during the new product development process. Some of the issues which DFE addresses include: environmental management, product disposal, product safety, pollution prevention, ecology, resource conservation, accident prevention, waste management, and occupational health and safety. This makes green design a tool which enhances environmental quality, as well as market competitiveness. Figure 2 below show the flow process of new product based on Design for Environment Method.

DfE project organized

Product concept making (Utilization of QFDE)

Conceptual design

Qualitative design review on environmental aspect (Utilization of DfE checklist)

Detail design

Quantitative design review on environmental aspect (Utilization of LCA)

Production

Figure 2: Design for Environment Flow Tools Green design strategies can be broken into the two major categories of source reduction and waste management. Source reduction strategies attempt to eliminate the pollution at its source, while waste management strategies promote recycling, reusing, reclaiming, and refurbishing of parts and materials. Figure 3 below show the example of DFE strategy for the life cycle of the phone terminal with considering the two major categories of source reduction and waste management.

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Design Manufacture USE Disposal

Apply DfE

Principles

Water conservation Energy

conservation Reduce process

waste: Air emission Liquid waste Solid wastes

Energy Efficiency

Min packaging Minimum waste

in Maintenance

and repair

No toxic material

Components Reusable

Remanufacturable recyclable

Figure 3: Life Cycle of the Phone Terminal

3.1 Quality Function Deployment (QFD) It is important to listen to customer requirements to obtain market needs and make them reflected on the product design. QFD is a method to collect vaguely expressed quality requirements (Voice of Customer: VOC) from the market and deploy them to actual design work.The roles of QFD include the analysis between trade-offs items for design and identification of their product‘s market competence through benchmarking processes. However, to make it simple, focus on creation of quality tables as they are the basic elements of this tool. (Keijiro, 2000) 3.1.1 Life Cycle Analysis Life cycle analysis is an objective analytical tool which organizations use to analyze the environmental costs and benefits associated with different design decisions. This process takes into account all factors which affect the environment throughout each phase of a product's life cycle. Such analysis may be considered the ultimate environmental evaluations tool in the green design process. (Hundal, 2000) 3.1.2 Life Cycle Assessment Life Cycle Assessment (LCA) is a method of checking the facts about the environmental burden of a product from its design through to production and then final disposal. An LCA can be used in the design of a new product or the evaluation of an existing product. LCA considers air, water and solid waste pollution generated when raw materials are extracted. It includes energy used in extraction of raw materials and pollution from manufacturing the product. Also, it accounts for environmental harm during distribution and use of product. LCA is a tool which is used to identify and measure the direct environmental, energy, and resource impacts, indirect environmental, energy, and resource impacts with a product, process or service. (Nowosielski, 2007) 3.1.3 Source Reduction These strategies attempt to reduce and eliminate waste and toxic by-products at their source by removing all or some of the material that initially creates them. This may entail dropping or combining product features, improving process controls and yields, or extending the product's life cycle 3.1.4 Waste Management The goal of these strategies is to design products that are easy to recycle, remanufacture, decompose and incinerate. The products must also be able to disassemble easily in order for the materials to be recycled and remanufactured.

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4.0 HYBRID / ELECTRIC CAR Nowadays, in day life people have to keep moving from one part to another part in order to reach their destination. That situation make the cars is a necessary to the people for transportation needed. The cars are sought out to be one of the best modes of transportation. But, with the rising economy, people tend to buy cars that have better mileage. But still we think of trading cars with something that is cheaper when we look at the rising petrol costs. Though we do not think much about the environmental effects, we must still consider the fact that cars are the major contributors to pollution. To an extent, hybrid cars can be a remedy to many of these problems. A lot of car manufacturers have started new plants to produce their own version of hybrid cars. Today's production hybrid cars are marketed by a singular benefit; increased fuel economy. Even though it is true that hybrid cars can save drivers a bundle on gasoline and even earn them a tax rebate the much more important benefit is the very significant reduction in emissions. Generally, hybrid cars produce 80% less harmful pollutants and greenhouse gases than comparable gasoline cars. This translates to less airborne pollutants, and a cleaner earth. 4.1 What Are Hybrid Cars? The word hybrid refers to anything that has a combination of two different ideas. When a car uses two different ideas to move, it is called a hybrid car. When gas and electricity were used in the combined mode, a better solution was made to the inefficiency and mileage. Apart from the mileage, the car has also proved to give a performance almost adequate to a conventional car. Due to its improved mileage and reduced pollution, the governments in most countries have been pleased and have helped in its promotion. 4.2 Parts Of A Hybrid Car There are mainly 5 essentials for a hybrid car. They are;

i. Conventional car engine – It can be a gasoline engine or also petrol or diesel respectively with greater efficiency and lesser emissions.

ii. Fuel Tank – For storing the fuel needed to rum the car engine. iii. Batteries – Batteries are needed to store and release energy as required by the car. iv. Electric Motor and generator – Though motors can act as generators, both of them are

needed for this car. A motor will be needed to take energy from the batteries and accelerate the car. Generators, on the other hand, are needed to produce the electrical power.

v. Transmission System – The entire transmissions that were performed in a conventional car will be done here as well, but in the hybrid manner.

4.3 How Hybrid Cars Work In a full hybrid car, the electrical energy is used while the car needs less power. The gasoline energy is used when the car needs less power. Thus at lower speeds the battery drives the vehicle and at higher speed the gasoline drives the vehicle. Since both electric motor and an engine are used simultaneously, the size of the engine will be considerably smaller than the usual ones. But they will be a lot more advanced than the usual ones. The motor, on the other hand is also used to give power for the air conditioner, power windows, water pump and also power steering. Figure 4 shows the actual working of the hybrid car. During the starting position, none of the system is working. After the car starts to move, it is in the normal driving mode. Thus the car will automatically change to the use of electric motor. Later when the car is accelerated and gains speed, it switches from the use motor to the use of engine. Thus the gasoline engine supplies the required power. This switching is carried out automatically, with the help of an on-board computer. Since the battery has lost some of its charge, it needs to be immediately recharged. This is also done automatically. When the car starts to go in a uniform speed or when it is descending a road, the generator starts charging the battery.

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Figure 4: Working of Hybrid Cars 4.4 Comparison between a Hybrid Car and A Gasoline Car Both of them are equally efficient. While a gasoline car has a bigger engine, the hybrid car has a smaller engine. Conventional cars have enough power to attain the required speed, and that too at the required time. In a hybrid car, as the engine is smaller, it is more efficient. It has lighter parts and reduced number of cylinder. The fuel required for smaller engines is lesser than the other ones. Since bigger engines have all the pistons in a bigger size, they need more energy when they make an up and down movement in the cylinder. Even if the car is not moving, the engine may be on. At this time also the big engine cylinders use fuel. If both the cars are moving equally the car with gas engine will use its whole single power to drive the car. The hybrid car will also need the same output power to drive the car. But, as it is smaller, it makes lesser power than the bigger one. This is when the electric motor comes into play. They provide the rest of the power from the battery to compensate the balance. 4.5 Advantages of Hybrid Cars

i) Very less pollution. ii) Better mileage. iii) More reliable and comfortable. iv) Very clean cars due to fewer emissions. v) Batteries need not be charged by an external source. vi) Warranties available for batteries as well as motors. vii) Less dependence on fuels.

4.6 Tips To Improve Fuel Efficiency

i) Most people buy tires that provide good traction for all weather conditions. Little do they look out for efficiency? If stiffer tires with higher pressure are used they reduce the friction by two times than the usual.

ii) For any car, as the weight and size of the car increases, the efficiency decreases. So remove the unwanted weight and thus increase efficiency. Make the body using lighter metals like aluminium and magnesium.

iii) Aerodynamics plays an important role in the fuel consumption of your car. For this you have to reduce the frontal area of the car, thereby reducing the air drag.

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iv) The energy wasted from your hybrid car includes the energy wasted as heat. If you could recycle that energy and reuse it, you can surely get more fuel efficiency. When you apply brakes, you are throwing out energy from the car. This energy can be stored in the battery through a process called regenerative braking. Instead of applying the brakes, the electric motor drives the hybrid to reduce the speed of the car. This way, the electric motor acts as a generator and charges the batteries while the car is slowing down.

5.0 DISCUSSION World Commission on Environment and Development, (WCED) defined sustainable development as; ―Sustainable development is development that meets the need of the present without compromising the ability of future generation to meet their own needs‖ (Giudice et al. 2006). It been discussed for many years. However, it is only when global climates begin to change drastically and effect the survival of human race with numerous calamities did it then gets the stronger international awareness on the importance of appreciating nature for future stability. There are 5 key factors in sustainable development and the role of environmental protection:

i) Establish environmental goals, regulation, incentives and standard ii) Make more effective use of economic instruments iii) Broaden environment assessment iv) Encourage action by industry v) Increase capacity to deal with industrial hazards vi) Strengthen international efforts to help developing countries.

Design for the Environment (DfE) interpreted the new idea. It is define as the methodology base on constantly evaluating the potential impacts implicated in the entire life cycle of the product, throughout the whole courses of the design process, and directed at the systematic reduction or elimination of these impacts. The most important benefit of DfE can only be obtained when the entire life cycle of the product is already taken into consideration at the very begin of stage. Base on product life cycle (PLC), there are five steps or phase that a product have to gone through for it entire life cycle:

i) Pre-production ii) Production iii) Distribution iv) Use/Utilisation v) Disposal

However, only with the systematic vision of the product over its life cycle, that can ensure that the design activities not only identifies the product‘s environmental criticalities, but also reduces them effectively and avoid simple transferring impacts from one arena to others. For a complete analysis directed at evaluating and reducing the environmental impact of the product, it is necessary to consider, together with the phases of development and production, those phase of use, recovery, and treatment of the entire product. 1Life Cycle Assessment (LCA) is an objective procedure use to evaluate environmental effect associated with product life cycle, through the quantitative determination of all the exchange flow between the product-system and the ecosphere in all the transformation processes involved, from cradle to the grave.

6.0 CONCLUSION All human being have their part in conserving the sustainable to the survival of the future generation. They are a lot of models and ideas develop in order to achieve the target of sustainable development and one of the important pieces of it is the DfE. DfE employs a variety of design approaches that attempt to reduce the overall human health and environmental

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impact of a product, process or service, where impacts are considered across its life cycle. Big multi global company should play the role of ‗go green‘ concept to educate their consumer by the implementation of ―green technology‖ and ―green concept‖ in their product.

7.0 BIBLIOGRAPHY

Calcott,P., et al.(2005) Waste, recycling, and “Design for Environment‖: Roles for markets and policy instruments. School of Economics and Finance. Victoria University of Wellington

Franklin, et al.(2004) "Life Cycle Inventory of Packaging Options for Shipment of Retail Mail-Order Soft Goods" [Online] Available at http://www.deq.state.or.us/lq/pubs/docs/sw/packaging/LifeCycleInventory.pdf [Accessed at 20 November 2014]

Giudice,F., et al. (2006) Product Design for the Environment. A Life Cycle Approach. Taylor and Francis Group. London

Hundal, M (2000) Life cycle assessment and design for the environment. International design conference - design 2000, 1-4.

Hauschild, M.Z, et at (2003) Design For Environment- Do We Get The Focus Right?. Concept Paper.

Macromill Inc., (2010) Survey of Consumer Awareness and Actual Behavior in Relation to Environmental Protection -Consumers Waiting for Chance to Contribute to Environmental Protection [online] Available at http://www.jri.co.jp/english/release/2010/100312/ [accessed at 20 November 2014]

Keijiro,M (2000) Development of a DfE methodology in japan. Quality Function Deployment For Environment , 1-8

Nowosielski, R. (2007) Methodology and tools of ecodesign. Journal of achievements in materials and manufacturing engineering , 1-4.

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THE DEVELOPMENT OF RICE WASHER MACHINE

Noor Sufiza Binti Ahmad Tel:+6013-9825060 Email: sufiza@psp.edu.my

Aswandi B. Yaakob

Tel:+6019-4766554 Email: aswandi@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic, Penang, Malaysia

Priyaraj Rajakumar, Marthininaidu Vasudiven, Nurmaisarah B. Nasir, Roslina Bt. Che Hasim

ABSTRACT

Rice Washing Machine is a design which focusing to solve the problem of washing rice. This machine is equipped with electric motor as the main source of propulsion to wash the rice and thus will reduce the time taken for washing the rice in large quantity. In addition, this machine requires only a single person to operate because of its size. The aim of this machine is to help the demand for caterers and restaurants. The whole machine is capable of being a tool that can help users because it is easy to maintain and easy to operate. Keywords: Development, Rice washing machine 1.0 INTRODUCTION Nowadays, there are few problems faced by school and college workers while washing rice. Through survey, many canteen workers have problems related such as time taken to wash rice in large quantity and using lot of energy for lifting the container fill with the rice while washing. Usually in the manual way for washing the rice in large quantity will take about five to seven minutes. Thus, it will result in loosing energy and time of the workers. These problem shows that a solution is needed to produce a small, portable rice washing machine. Moreover if it is easy to operate is really will help the school and canteen workers. In the designing stage, many aspects should be studied for producing a quality, effective and widely accepted product. There are many existing product of washing rice in market recently. All the machines have many advantages and disadvantages, different material and components used on existing products and machines. The existing products in market are expensive, high maintenance cost, heavy, not portable and not enough safety factor. The objectives to be achieved are to produce a washing machine that can wash rice in quantities of five to ten kilograms, saving time, portable and easy to operate. Therefore, these objectives are the key target for creation of the product. Based from the survey, the existing products have more disadvantages than advantages so it‘s will be the basic idea to design the ‗Rice washer machine‘. Therefore, Rice washer machine can overcome problems faced by small canteens or restaurants workers

2.0 METHODOLOGY After a research done, the development of the product was started with discussion about how to solve the problems, selection of materials and components to use. Analysis have been done to select the best design, materials for each parts and selecting the method for assembling the parts by using processes like welding, bending, grinding and drilling. 2.1 Designing and fabrication The rice washing machine uses ‗OFF‘ and ‗ON‘ switch and is connect to an AC motor which provides power to rotates the stirrer. The rotation speed is control by the speed control of 40:1 speed that connected to the motor. (William A Meyers). The base parts of the rice washing

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machine are stirrer, speed control, AC motor, valve and lock roller. A complete rice washing machine must meet safety requirement for the user and also able to complete and passed through repeated various tests.(Watson, Andrew 1983).The most suitable material chosen for the container is stainless steel because the strength and the mass of the material. According to the design, three different materials were used to fabricate the different parts of the machine.

Figure 1: Final Drawing for Rice Washing Machine

2.2 Parts of rice washing machine i) Basement The basement is the part that holds the container using the concept of stability. It has to hold strongly the container to make sure its stay in place during the washing process. Hollow iron was used to as the basement as it is known for its light weight property. Since the basement will hold tightly the container, this property is very crucial in material selection and consideration. The hollow iron was cut according to its measurement in (cm). For assemble process shielded metal arc welding (SMAW) method was used to join all shaft (Weman Klas, 2003).

Figure 2: Basement

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ii) Container The container is the main part of this machine. During the washing process, the rice and water were place in the container. Stainless steel was used to fabricate the container as it is known for its anti-corrosion property. Stainless steel rods were cut and bend according to mechanical drawing. For assemble, the tungsten inert gas (TIG) welding method was used for making the container. TIG is the best solution to make every different part connect together in line with the mechanical design. (Procedure Handbook of Arc Welding)

Figure 3: Container

iii) Stirrer The stirrer is an important part in the container used to rotate the rice while washing. It was control by an AC motor and speed controller for the speed rotation. It is made from aluminium and attached to a solid root bar stainless steel.

Figure 4: Stirrer

2.3 Testing The machine was tested three times for better washing process result. Firstly, quantity of rice (2kg-3kg) was tested. Secondly, medium quantity of rice (4kg-6kg) was tested and lastly large quantity of rice (6kg-8kg) was tested for the time taken compared to manually wash.

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3.0 RESULT AND DISCUSSION After all the testing was done, the results of washing rice by this machine are taken and compared by washing rice using by manually process. The data was shown below. Table below shows result for washing the rice:-

Description Quantity Time Taken

Manual 5 kg 5 Min 40 Second

Rice Washing Machine 5 kg 1 Min 17 Second

Table 1: Result of Testing

3.1 Functionality The ‗ON‘ button was switched on and this will make the stirrer to rotate. After that the container is filled with water and half packet of rice is put into the container. Therefore the washing process was start by rotating the stirrer, water and rice together. Next, the valve for water outlet was turned ‗ON‘ to release the water out. At the same time, the water was filled into the container. After the washing process done, the valve for water outlet was turned ‗OFF‘ and the besides valve was opened to let all the rice and water into the filter. Finally the cleanness of rice was checked and the cooking process can be started. 3.2 Safety Features Project i) Speed Control The speed of an AC motor is medium and was control by a speed controller. When the stirrer is spinning, it becomes very dangerous. Therefore, the speed can be controlled. Meanwhile washing is in progress. It is also to prevent the water from spitting out from the container. ii) The Push Button The push button function is not used as ‗ON/OFF‘ button but also function as an emergency button to stop the process whenever emergency or abnormal sound and behaviour of machine occurs. 3.4 Project cost Costing is important because it will affect the overall cost spend on the project. If the production cost can be reduced the potential for commercialization of projects can be higher. This is because the market is driven by extensive production costs and prices of goods sold. Project costs for Rice Washing Machine are RM850.39 only.

3.5 Comparison between Rice Washer Machine and Market Product

Rice Washing Machine Automatic Rice Washer RW-25 Machine

Cost RM 850.39

RM 1500.00 RM 1800.00

Advantages Save time Easy to move

Low cost Light weighted

Longer service life Easy to use

Reduce time & manpower

Easy to use Reducing work for rice washing

process Together with

filter

Disadvantages Height of the basement High cost Need bigger space for this

product

Not clean after used

No safety factor

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High maintenance cost Heavy

High cost

Table 2: Comparison

4.0 CONCLUSION This Rice Washing Machine‘s idea is created to overcome the problem facing by the small restaurants, school and college canteens in any condition where amount of rice between five to ten kg are needed to be washed before cooking using the rice cooker. Users just have to fill water and rice into the stainless steel container; switch ‗ON‘ the power to start the process of washing. The Rice Washing Machine reduced the time to wash the rice in 3 to 4 minutes or below for a quantity of 5 to 10 kg rice. Test run done to this machine proved its ability to achieved better efficiency compare with manual way for washing rice. This machine achieved all the objectives and also proved able to wash 5 to 10 kg of rice in shortest time and cheaper to produce compare with the other existing product from the same category.

5.0 BIBLOGRAPHY

Blalock, Thomas J., "The Frequency Changer Era: Interconnecting Systems of Varying Cycles". The history of various frequencies and interconversion schemes in the US at the beginning of the 20th century.

Cary, Howard B.; Helzer, Scott C. (2005), Modern Welding Technology, Upper Saddle

River, New Jersey: Pearson Education, ISBN 0-13-113029-3. Hiob, Eric, "An Application of Trigonometry and Vectors to Alternating Current". British

Columbia Institute of Technology, 2004.

Internship Report - Malaysia Polytechnics Seberang Perai Jeffus, Larry (1999), Welding: Principles and Applications (4th ed.), Albany, New York:

Thomson Delmar, ISBN 0-8273-8240-5 Lincoln Electric (1994), The Procedure Handbook of Arc Welding, Cleveland, Ohio: Lincoln

Electric, ISBN 99949-25-82-2 Los Alamos National Laboratory – Aluminum World Wide Words A history of the spelling of aluminium from a British viewpoint Oxford English Dictionary Entries "aluminum" and "aluminium", available by subscription Watson, Andrew (1983). Agricultural innovation in the early Islamic world. Cambridge University Press ISBN 0-521-06883-5 Weman, Klas (2003), Welding processes handbook, New York: CRC Press, ISBN 0-8493-1773-8

Willam A. Meyers, History and Reflections on the Way Things Were: Mill Creek Power Plant - Making History with AC, IEEE Power Engineering Review, February 1997, Pages 22-24

"Wind Energy Reference Manual Part 4: Electricity". Danish Wind Industry Association, 2003

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THE DESIGN AND DEVELOPMENT OF A NOZZLE TO SUIT LIQUID FUEL THRUST DEVICE

Ahmad Firdaus B. Zawawil Anwar

Tel: +6019-5535580 Email: firdauszawawil@gmail.com

Mechanical Engineering Department, Seberang Perai Polytechnic, Penang, Malaysia.

ABSTRACT

This project is a laboratory simulated small rocket engines system. The rocket engine is a relatively simple device in which the propellants are burned and the resulting high pressure gases are expanded through a specially shaped nozzle to produce thrust. Thrust is a mechanical force. It is generated through the reaction of accelerating a mass of gas. The gas is accelerated to the rear and the engine (and aircraft) is accelerated in the opposite direction. To accelerate the gas, we need some kind of propulsion system. Gas pressurized propellant tanks and simple propellant flow controls make operation of a small liquid fuel rocket engine as simple as operating an automobile engine. The combustion chamber and the nozzle form the main part of the engine, wherein the thrust is developed. The combustion chamber comprises the injector through which the propellants enter the vaporization, mixing and combustion zones and the restriction leading to the nozzle. The function of the nozzle is to convert the chemical thermal energy generated in the combustion chamber into kinetic energy. The nozzle converts the slow moving, high pressure, high temperature gas in the combustion chamber into high velocity gas of lower pressure and temperature. All the theories are based on the thermodynamics and fluid mechanics principle. Keywords: rocket engines, nozzle, thrust, combustion chamber

1.0 INTRODUCTION Nozzle is a relatively simple device, just a specially shaped tube through which hot gases flow. Rockets typically use a fixed convergent section followed by a fixed divergent section for the design of the nozzle. This nozzle configuration is called a convergent-divergent, or CD, nozzle. In a CD rocket nozzle, the hot exhaust leaves the combustion chamber and converges down to the minimum area, or throat, of the nozzle. The analysis of a rocket nozzle flow involves the study of steady one-dimensional compressible flow of an ideal gas. The actual flow differs somewhat from this simplified model particularly in regard to the presence of solid or liquid particles in the flow stream. The analysis of compressible flow involves four equation of particular interest continuity, momentum, energy and the equation of state. These equations are applied to design a nozzle with the objective of accelerating the combustion gases (and particles) to as high an exit velocity as possible. This is achieved by designing the necessary nozzle profile with the conditions that isentropic flow is to be aimed for. This necessitates minimizing frictional effect, flow disturbances and conditions which can lead to shock losses. As well, heat losses would have to be minimized. The nozzle represents a key part of a rocket motor. This component serves to accelerate a voluminous mass of stationary combustion gases to supersonic velocities within a very short distance, and in doing so, produces useful thrust. In accomplishing this remarkable feat, a nozzle is subjected to very high pressures, and rapid, dense gas flow at high temperatures. As such, a nozzle must be fabricated from a material that will be capable of withstanding such conditions of structural and thermal loading. As well, any restrictions to the free flow of gases must be minimized, which necessitates a smooth, suitably profiled flow surface. Considering the effort and time invested in making such a nozzle, multiple usages are obviously desired. Fortunately, stainless steel is well suited to this application, at least, for many popular amateur propellants. Stainless steel machines relatively well and tends to produce a better surface finish

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with less effort and produces less problematic chips. Stainless steel should be used with caution as this material may be less resistant to high temperatures than mild steel. Alloy steel should not be used, due to its lower melting point and difficulty in machining. Low melting point alloys such as aluminum and brass are not suitable for multi-usage nozzles, unless a high temperature resistant "throat inset" is used (which complicates the manufacturing). However, the more rational approach to rocket motor design and construction involves designing a nozzle to achieve a particular performance goal. This design process defines the nozzle shape and dimensions. Key design parameters for a standard conical de Laval nozzle are the convergent and divergent angles, and the diameters of the inlet, throat, and exit. As well, the exterior profile of the nozzle is sculpted to minimize the mass of the finished nozzle. A nozzle that does not have a sculpted exterior will work nearly as well. It is important to recognize that the more care and effort that is put into creating an accurate and detailed drawing, the less laborious the effort to fabricate the nozzle and combustion chamber and the less likelihood of making a mistake during machining which could relegate hours of effort to the scrap bin. CAD software programs (even basic ones) are ideal for producing a suitable nozzle and combustion chamber drawing. Machining of the nozzle is more difficult, complex shape and also need for accuracy aspects of lathe use, compare with combustion chamber. The combustion chamber should build as a one-piece unit. This arrangement, while more difficult from a machining point of view, eliminates the requirement for a joint of some kind between the two parts; this joint would be exposed to the hot combustion gases on one side and would, in all probability, fail. Building the combustion chamber and nozzle in one piece eliminates this potential failure point. Care must be exercised during the machining of the stainless steel chamber and nozzle to ensure constant wall thickness and the correct taper in the nozzle region. The bolts holding the two components together (and in this case also holding the assembly to the test mounts) must withstand this force with and adequate safety factor (typically a factor of two). The strength of these bolts, however, depends to some extent on the adequacy of the threads in tapped holes, the tapped material, and the bolt tightening procedure used in assembly.

2.0 METHODOLOGY The first stage of this project is about finding related information regarding on how to determine the thrust developed by designing and development of the nozzle to suit liquid fuel thrust device. The concept of the nozzle and system included the theoretical analysis has been studied. In doing this, information regarding this analysis is obtain from the text books and had been discussed with advisor. The important objective in the first stage is to obtain the measurable thermodynamics and fluid mechanics properties such as temperature, thrust, and pressure also flow rate. To achieve the objective, the device such as nozzle and the test stand are fabricated. Once the experimental and analysis is carried out, some improvements is suggested or recommended.

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Photo 1: Combustion Chamber and nozzle assembly

Photo 2: Ignition Attachment

3.0 RESULT AND DISCUSSION This project is considering the static tests because it only involving the engine system which is not including any aircraft used. In this project, the method to measure the thrust is by using a sensor that will convert input analogue signal to digital output signal in term of bit. That is why the calibration using conventional weight scale is needed before the data for thrust measurement is taken. During the force calibration process, the distance calibration is also takes place. This matter is important to determine the velocity and acceleration of the cart when the thrust is produce. By doing this calibration we can determine the real thrust force.

Barricade

Combustion

chamber

Injector

head

Nozzle

Rail

Ignition wire

Cart

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Figure 1.0: The Increment of Bit Due To Time Increment

Figure 2.0: The Increment of Mass Due to increment of Time

Figure 3.0: The Increment of Displacement Due To Time

By referring to the result (tables and graphs) that is obtained above, it is found that the initial displacement of the thrust device is given in the graph where it is displaced to 0.25 cm from rest condition in 0.6 second. So the initial velocity is given by;

t

SV

s

mV

6.0

0025.0 ;

smV 0042.0

Bit Vs Time

0

5

10

15

20

25

30

0

0.6

1.2

1.8

2.4 3

3.6

4.2

4.8

5.4 6

6.6

7.2

7.8

8.4 9

9.6

10

.2

Time (second)

Bit

Displacement Vs Time

0

0.2

0.40.6

0.8

1

1.2

1.4

1.61.8

2

2.2

2.4

0

0.6

1.2

1.8

2.4 3

3.6

4.2

4.8

5.4 6

6.6

7.2

7.8

8.4 9

9.6

10

.2

Time (Second)

Dis

pla

ce

me

nt (c

m)

Mass Vs Time

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0

0.6

1.2

1.8

2.4 3

3.6

4.2

4.8

5.4 6

6.6

7.2

7.8

8.4 9

9.6

10

.2

Time (second)

Mass (

kg)

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Then it is stopped for about 1.8 second where this condition is considered as no velocity condition. From that condition it displaced to 2.5 cm in 0.2 second. This condition can be considered as maximum thrust and the velocity at this condition is given by;

s

mV

2.0

019.0

smV 095.0

So from the velocity that is determined above, the acceleration can be obtained. The acceleration of the thrust device is given by;

t

UVa

; 25.0

sma

The thrust force is the product of mass of the thrust device and its acceleration and is given by;

maF

25.03s

mkgF

NF 5.1

Thrust of the combustor is related on how fast and how much hot gas exhausts passes through the nozzle. Since there are increase total amount of propellant, the propellant reaction also increase in terms of heat and pressure. Heat and pressure in the combustion chamber will affect the total mass flow rate at the nozzle. The theoretical relation state that, mass flow rates at the nozzle will produce net thrust of the combustor. From the result, it showed that the velocity of the propellant is proportional to the amount of flow rate and as mentioned above the propellant reaction is related to the amount of flow rate too. If the chemical reaction is increased the amount of hot exhaust that passes through the nozzle will also increase. The exit velocity that determined by the shape of the rocket nozzle is supersonic.

4.0 CONCLUSION This system is equivalent to the theoretical design where the thrust developed is equal to total mass flow rate of the propellant multiply by exit velocity. This can be proved by applying the following relation;

As the mass flow increase the thrust will also increase and due to the effect of heat and pressure inside the chamber. The fluid pressure that is related to the momentum of the gas molecule acts perpendicular to any boundary impose to it if there are net changes of pressure in the flow direction hence additional in momentum. The design of the nozzle will determine the exit velocity for a given pressure and temperature. The maximum flow through the nozzle is determined by the throat diameter due to the occurrence of choke.

5.0 BIBLIOGRAPHY

Dennis G. Shepherd, Fourth Edition (1989). Aerospace Propulsion. Elsevier Publishing Company.

Frank P. Incopera and David P. Dewitt, fifth edition (2002). ―Fundamentals of Heat and Mass Transfer‖. John Wiley & Sons, Inc.

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Gordon C. Oates, Third Edition (1997). Aerothermodynamics of Gas Turbine and Rocket Propulsion. AIIA Education Series.

George P.Sutton, Fifth Edition (1986). Rocket Propulsion Elements: ―An Introduction to

the Engineering of Rockets‖. John Wiley & Sons, Inc.

T D Eastop and A. McConkey, Fifth edition (1993). ―Applied Thermodynamics for Engineering Technologists‖. Addision Wesley Longman Limited.

Myer Kutz, Second Edition (1987). Handbook of Materials Selections. John Wiley &

Sons, Inc.

Yunus A. Cengel and Michael A. Boles, Third edition (1998). ―Thermodynamics: An Engineering Approach‖. McGraw-Hill Companies.

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THE DEVELOPMENT OF V- CLAMP PIPING MACHINE

Nurhasliza Binti Rosli Tel: +6012-5711303 Email: nurhasliza@psp.edu.my

Mechanical Department, Seberang Perai Polytechnic, Penang, Malaysia.

ABSTRACT Vehicle Air Conditioning Clamp Piping Machine (V-clamp piping machine) is a machine that works to clamp the pipe air vehicles. Specifically machine is only reserved in maintenance work on vehicles pipe connection system. Connection pipe has three elements, namely hoses, pipes aluminium and coil as a key component in this connection. Machine pipe clamp is purposed to clamp the coil at the pipe which is coated with aluminium on the inside of the pipe. V-clamp piping machine was developed as a user friendly clamp machine for maintaining air conditioning system in the vehicle. Time used to clamp the pipe in car air conditioning can be saved although it is manually operable and convenience in maintenance. The dimensions of the V-clamp piping machine are (425 x 310 x 260 mm). Due to the small size, then it saves storage space. The V-clamp piping machine is also portable and easy to assemble. This machine is also has removable snap-in dies and convenience maintenance. This, the V-clamp piping machine is manually operated with the help of hydraulic jack power.

Keywords: air-conditioning piping clamp machine, vehicle clamping machine, V-clamp piping machine

1.0 INTRODUCTION Vehicle air- conditioning piping clamp machine (also known as V-clamp piping machine) is a machine that was used to crimp the vehicle air conditioning hoses. A clamping device is

provided for clamping two or more articles together. The clamping device includes two or more members‘ movable between an unclamped position and a clamped position (Neil Dobston, 2007). The crimping assembly includes at least two moving-element subassemblies, each with a pair of moving elements. The moving elements having a first side and a second side joining at a tip (Arkady Kokish, 2007). According to Donald R. Gilbreath et al. (2013), a crimper system comprising a slide frame with a base, a movable head slid ably mounted on the slide frame and a drive mechanism adapted to pull the two elbows toward each other thereby driving the head toward base. However, the traditional clamp hose that were used in a hose clamping process before were not so tough and easier to rust. This will make the connection of the hoses not last longer and easy to leak. Due to a study, a machine designed to improve that were available in the market. It is because the workplace used for these machines occupied wide space. The objectives for this research are to develop a user friendly clamp piping machine for maintaining air conditioning system in the vehicle, to build a clamp piping machine which is smaller in dimensions and used less space. The last objective is to develop a V-clamp piping machine affordable to the owner in workshop. In addition, the machine shall be used to overcome the lack of a machine or device in small and medium industries (SMEs). The literature review covers various aspects in terms of observations and studies that have been conducted. Both observations and studies were very important as they became a reference and guideline in developing V-clamp piping machine. Throughout the review, there were many types of clamp piping machine being developed in the workshop such as hose crimping machine. The machine is a hose clamp machine that powerful enough to crimp any hose in the vehicle air conditioning system. Due to the wide opening, it can clamp the hose with a diameter of 1.5 inches to 2.5 inches with the use of electric power. The electric motor with the power of 5.5kW used to move the pump that will push the tool and clamp the hose within 7.8 seconds. The dimension of this machine is (751 x 505 x 814) mm and has a total weight of 270 kg. (Hose

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Crimping Machine, retrieved March 2, 2015). The hydraulic hose swaging machine is applicable to crimping processing for the resisting hose, fiber tube and plastic pipe assembly used in the industry of engineering machinery. This machine had an inside diameter of crimped rubber hose between 6 mm to 102 mm and the maximum crimping force is 1070T. DSG102/S used electric motor with the power of 5.5 kW. The maximum opening of die is 212 mm. This machine has a weight of 1500 kg with the overall dimension is 1050×700×1550 mm. (Alibaba.com., retrieved March 2, 2015). This Hydraulic Hose Crimper made in United State. It still uses electric power and drives the electric motor to run the hydraulic pump. This type of clamping machine uses hydraulic pumps to push the tool on which it will be smaller than the diameter of the tool as well as sleeve of hose clamp. Therefore, the hose will held with strong. It has 1 HP motor to driven 2 stages pump system with foot control. This machine is also included 6 sizes of tool to clamp the hose which is -4, -6, -8, -12, -16, and -20. The cost for this machine is $2250. Not all workshops capable to have it. (Coast to Coast Industrial: Tool & Equipment for all industry, retrieved March 7, 2015).

2.0 METHODOLOGY Before the V-clamp piping machine entering design and fabricating process, the feasibility study was conducted with the owners of a car‘s workshop around Permatang Pauh, Penang. The methods in conducting the studies were through a survey and interview. A survey conducted to seek views and opinions about the project that will be developed.

2.1 Component of V-Clamp Piping Machine The tool that be used is diameter 41 mm top and tapers down along 250 mm while the diameter below is 37 mm. In one embodiment, an apparatus for shaping an article may comprise a plurality of movable dies arranged to form a chamber whose size may be varied by moving the dies. Each of the dies may have a contacting surface for contacting the article to be shaped (Jan Weber and Tracee Eidenschink, 2013). There were four rod pushers used by 545 mm long in V-clamp piping machine. The rod pushers were made of mild steel bar with a diameter of 20 mm. This should be large because it will cover the load incurred during the process of clamping. The rod pushers are used to stabilize the position of a machine. It is because, used as a booster to transfer power from hydraulic jack to a generator. The upper and lower rod along 150 mm was threaded. The rod pushers push the tool into the part of the outer block to obtain uniformity force. The function of the pusher is to press the upper part of the tool to enter the block-shaped tapered off. It is mounted on top of the rod pusher. The pusher will move downward together with the rod pushers and pressing the tool. The outer and inner diameter is 95 mm and 65 mm respectively. The thickness of the pusher is 75 mm. There were 3 pusher plates that being used to develop V-clamp piping machine. Every pusher plate has a thickness of 10 mm and was used on the upper part of the frame, in the frame structure and placed under hydraulic respectively. The dimension of the pusher plate is 220 x 180 mm. The 4 holes formed on the plate with the diameter 20 mm each. The upper plate used to hold the outer block so it doesn‘t move if force is applied. The second plate has to be strong so it could withstand the repulsive force of the hydraulic and as a support for the rod pusher during the clamping process. The distance between the first plate and the second plate is 100 mm. The last plate placed at the bottom of hydraulic and used to hold the rod pusher. For the safety purpose, the 100 mm plate also used to cover the whole frame. Four angle iron used on a diagonal angle with the dimension of 310 x 260 mm. It is connected with the plate which is around the frame using a method of welding. The height of the frame is 452 mm and has the thickness of the base frame is 37 mm. The width of frame for the V-clamp piping machine is 310 mm. Besides the main components, spring also used to push again the pusher plate when the hydraulic jack is released. Materials that were used in fabricated the V-clamp piping machine is mild steel. To assemble as shown in Figure 3.1, the components it starts with hydraulic jack. It is placed in the frame structure with overlaid the plate. The second plate is placed on the hydraulic jack. The, the die was inserted into the upper plate. Next, the

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pusher is placed on the top and connected with the rod pusher. The nuts are used to tighten the rod pusher with the pusher.

Figure 2.1: Part of V-clamp Piping Machine

Item Quantity Component

1 1 Angle iron 2 4 Rod pusher 3 1 plate 4 1 plate 5 4 nut 6 4 rod pusher 7 1 pusher 8 4 spring 9 8 nut

10 1 block 11 1 plate 12 1 die

Table 2.1: Part List of V-clamp Piping Machine

Generally, the hose will be connected will have three aspects in which it uses aluminium pipe, hose connector and a device called cooler. Usually, piping system is available in the vehicle air conditioning system where the pipe is located on the cooling coil to the air compressor. The process of clamping starts with the hydraulic jacks will be pumped up and the plate on the base will be down. Next, the rod pusher will be pulled and causes the upper part of the pusher plate that is connected together with rod pusher will be down. This causes the die that presses into the outer block to clamp the hose. Hydraulic jack bottle used in v-clamp piping machine due to cost, can be used without regular maintenance and high level of durability. The characteristic of V-clamp piping machine are small volume, light weight, rapid opening of die, easy in operation and convenience in maintenance.

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2.2 FABRICATING V-CLAMP PIPING MACHINE In designing the project, there are some factors to be considered such as lower cost in maintenance, user friendly, safety features and durability. Computer aided design (CAD) software was used to design the V-clamp piping machine. The opinion collected during survey being analysed and studied in designing the machine. In fabricating, starting with measuring and getting raw materials such as mild steel, angle iron, iron rod, nuts, spray tin and steel plate. After that, process in cutting and machining the material with accurate dimension had been done. To make the outer frame, mild steel plate had been used. Iron pipe with diameter of 2cm and 10 cm also cut. Next is to make the hole of the tool around the block of 6 holes measuring 1cm x 3cm. EDM wire cut is used to produce stainless steel tools. After that, the process of drilling 3 holes on the plate mounted on top of the framework of the project. Hence the process of welding been used in completing the tool block, site sections, side and top of the framework of the V-clamp piping machine. Lastly, the process of assemble the spring, a supporter and actuator plate at the top of the framework. Tapping and threaded process also been carried out. For safety purpose, grinding process was conducted on sharp edges. Painting process is done to give attractions to V-clamp piping machine.

Figure 2.2: V-clamp Piping Machine

4.0 RESULT AND DISCUSSION Data were analysed using Microsoft Excel and are presented in a pie chart. The objective for this research is to build a clamp piping machine which is smaller in dimensions and used less space. According to Figure 4.1, the V-clamp piping machine is 57% smaller than the other two products on the market. The dimensions of the V-clamp piping machine are (425 x 310 x 260 mm). Therefore, it only requires little storage space. This machine is also portable because it is not so heavy to carry out. The V-clamp piping machine that fabricated is affordable.

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Figure 4.1: Pie Chart Percentages Of Sizes

The cost in fabricated only requires RM 959. Figure 4.2 show that the cost for V-clamp piping machine is 81% cheaper compare with product A and Product B. Thus, the owner of the workshop for small and medium-sized industry was able to have it. Moreover, the machine that is developed convenience and lower cost in maintenance.

Figure 4.1: Pie Chart Percentages Of Cost

The differences between V-clamp piping machines compared with the two products on the market are shown in table 4.1.

Table 4.1: Comparison of Products

Name Product A Product B V-Clamp Piping Machine

Cost RM 7600 RM 8850 RM 959 Size (1050 x 700 x1550 )

mm (751 x 505 x 814) mm (425 x 310 x 260) mm

Operation Powered

Electric Motor Electric Motor hydraulic jacks

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The die means movably mounted at the front portion of said inner member to close and open. So that, the tool used can be adjusted according as required. Therefore, it is user-friendly. Hence, the objective achieved in maintaining air conditioning system in the vehicle.

5.0 CONCLUSION The V-clamp piping machine that developed can be commercial to the owners of workshop in small and medium industries. It is because the machine is cheaper compare with the machine on the market. That‘s why, the owners of workshop affordable to own it. Due to the small size, then it saves storage space. Moreover, time used to clamp the pipe in car air conditioning can be saved although it is manually operable. The V-clamp machine is has removable snap-in dies, hydraulically powered and convenience maintenance.

6.0 BIBLIOGRAPHY

Arkady Kokish (2007). Method for compressing an intraluminal device. Advanced Cardiovascular Systems, Inc.

Alibaba.com.(2006).Retrieved March 2, 2015, from

http://hyjxgs.en.alibaba.com/product/195188846850426703/CE_standard_multi_functional_hose_crimping_machine_Hydraulic_hose_swaging_machine_Hose_crimper.html

Crimpers & Equipment. (n.d.). Retrieved March 1, 2015, from http://www.gates.com/products/industrial/industrial-hydraulics/crimpers-and-equipment

Coast to Coast Industrial: Tool & Equipment for all industry. (n.d.). Retrieved March 7, 2015, from http://www.c2cindustrial.com/

Donald R. Gilbreath, Martin Bauer, Marvin Miller, Micheal H. Ellis, Tomothy James

Dean, (2013). Crimper System. The Gates Corporation. Hose Crimping Machine (FY-330). (n.d.). Retrieved March 2, 2015, from

http://www.made-in-china.com/showroom/hdfuye/product-detailyofnZMBJbTUe/China-Hose-Crimping-Machine-FY-330-.html

Jan Weber and Tracee Eidenschink (2013). Crimper. Boston Scientific Scimed, Inc.

Mark D. Morrison (2004). Hose and Clamp Assembly. Mpdi.

Neil Dobson (2007). Clamping Device. Teconnex Ltd. http://www.directindustry.com/prod/op/manual-crimping-machines-hose-air-conditioning-

17876-434334.html

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SIMPLE HARMONIC MOTION KIT (SHM KIT)

Kamarul Hisyam B. Hj. Osman @ Othman Tel :+6019-4572036 Email: kamarul@psp.edu.my

Nik Abdullah B. Nik Hassan Tel :+6012-4202109 Email: nikab@psp.edu.my

Tan Chin Chai

Tel: +6012-5505975 Email:cctan@psp.edu.my

Mechanical Department, Politeknik Seberang Perai,

Penang, Malaysia.

ABSTRACT

The Simple Harmonic Motion Kit (SHM Kit) was developed at engineering workshop of Mechanical Engineering Department, Politeknik Seberang Perai (PSP) on 2014. The objective of this product is to help lecturers in their teaching process and at the same time to help students in their learning process towards the understanding on the simple harmonic motion movement. It operates by using mass-spring concept in order to prove the existence of the harmonic motion. The process begins by the mass will be hanged at the spring which attach to the equilibrium marking plate and to be pulled down from its equilibrium position to the experiment distance, x with due to Hooke‟s Law concept. Since the presence of the restoring force in the spring, the simple harmonic motion will occur once it is released. Simultaneously, the sketching paper that driven by shaft will horizontally rotates when the electric motor is switch on. By attaching the marking pen in the marker pen housing on the equilibrium marking plate, the graph of the simple harmonic motion will be marked on the sketching paper due to the vertical movement of the mass-spring and the horizontal movement of the sketching paper. Lastly the mass-spring will continuously oscillates in the present of the spring restoring force and respect to the gravitational force while the marking pen keep on sketching the oscillation cycle on the sketching paper until it is stopped. As for the safety and the effectiveness purposes, testing of the final product has been conducted and the results show its satisfaction to the objective and the user needs. SHM-KIT is able to solve the lecturers and students problems in dealing with the simple harmonic motion.

Keywords: Simple Harmonic Motion, Mass, Spring, Equilibrium, Hooke‟s Law, Force, Graph.

1.0 INTRODUCTION Simple harmonic motion is wisely related to our daily lives such as in auto suspension bounces, bridges sway, musical instruments vibrate, radio circuits resonate or clocks use a pendulum. However, during the learning process in a classroom, students and lecturers facing problems on understanding the simple harmonic motion since there are no special tool in dealing with it. The present invention relates to the study of simple harmonic motion by using mass-spring system as described by Hooke‘s Law. The Hooke‘s law applies not only to the ―ideal‖ springs found in the physics books, but too many other situations as well (Nicholas Giordano, 2012).

The motion of the spring-mass system is described by equation (1) and (2) above. The properties of a periodic motion will be studied by using a mass suspended on a spring. The

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mass is pulled off from the equilibrium position and it will oscillate up and down around the equilibrium position. In elementary mechanics the elasticity for a spring is expressed by Hooke‘s law, which says that the amount a spring is stretched or compressed beyond its relaxed length is proportional to the force acting on it (B.Lautrup, 2011). Therefore, it can be described that this motion undergoes the equation of simple harmonic motion since the present of the Newton Second Law concept could be applied. For details, the parameters in the purposes of studying the simple harmonic motion such as the restoring force in the spring, the period of motion, the amplitude of the motion, the spring constant and the natural frequency of the system could be measured. In many cases this condition is satisfied if the displacement from equilibrium is small. The angular frequency, frequency and period in SHM do not depend on the amplitude, but only on the mass, m and force constant, k (Satyajit Deb, 2013) as in the equation (1). The result of the oscillation in the system can be represented in the graph of displacement versus time and its help user to more understand and visualized the concept of simple harmonic motion. Many oscillating systems can be represented by a displacement-time graph (David Sang, Graham Jones, 2014). Alternatively the data gain from this kit can be used in the existing formulas in order to understand the theory better. In addition, the users will have benefit from this innovation. Therefore, a learning tool need to be invented in order to help lecturers and students gain and understand the basic parameters in dealing with simple harmonic motion.

2.0 METHODS There are four phases of development process that include the conceptual design of the SHM-KIT which are design, built, final product and data‘s survey. In addition, the sketching of the final product and technical drawing with the complete measurement for all three main components are included. Secondly, the process of build the SHM-KIT starts from the selections of the raw material, sheet metal fabrication works, components assembly, electrical and finishing works. Thus, the outcome design of SHM-KIT is ready to be tested. Next, the final works is to complete the invention and the user needs in terms of output of the final product. Some parameters such as the ergonomics factor, the present of friction, force and the vibration effect are generally being finalized. Finally, the data‘s survey helps the inventor to overcome and to improve the qualities of the final product in the some factors such as design, equilibrium position, the electrical motor and the effectiveness of the oscillation on the sketching paper before finalized the SHM-KIT as a new product invention. 2.1 Design For the invention to be more fully understood, one embodiment will now be described by way of

example with reference to the drawings.

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Figure 1: Conceptual design of Simple Harmonic Motion Kit (Isometric View)

Figure 1 illustrates the isometric view of Simple Harmonic Motion Kit. This kit includes three compartments which are equilibrium marking plate (1), sketching paper shaft (2) and marker pen housing (3). The sketching paper shaft (2) has been tied together with bushing and coupling and attached to the structure of the kit and is powered by an electric motor. The graph of the oscillation will be sketched on the paper due to the rotational of this shaft.

1

3 2

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2.2 Built

Figure 2: The actual Simple Harmonic Motion Kit Figure 2 above shows the final product of Simple Harmonic Motion Kit (SHM-KIT). This actual educational kit can produce the supportive data on the oscillation measurements such as the amplitude, frequency, period and spring constant for the various mass-spring combinations.

3.0 RESULT This testing has been carried out in order to ensure the effectiveness and the efficiency of the final product. These include: 3.1 The period of motion, T 3.2 The amplitude of the motion, a 3.3 The spring constant, k 3.4 The natural frequency,

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Figure 3: Result from Simple Harmonic Motion Kit

From figure 3, the concept of this kit is to produce collections of data such as the amplitude, frequency and period from the graft obtained by the oscillation of the mass-spring.

4.0 DISCUSSION 4.1 Design The Figure 1 shows that the marking plate is easily moved up and down by the helps of gravitational and restoring forces. The rotation of the sketching paper shaft is also smooth. 4.2 Mass-Spring The testing result in Figure 3 for mass and spring used in this learning kit shows that the various weights of mass are matched with the spring constant. There is no presence on critical-damp ratio found in the experiment and the oscillation is still in the range of under-damp ratio. 4.3 Electrical Motor This kit can works above 3 hours without cut off in power supply. The forward and backward mechanisms are very useful to rotate the sketching paper shaft. The revolution per minutes of the motor is fixed and in a standard range of speed. 4.4 Equilibrium Marking Plate During testing, the plate shown that it could work smoothly without stack or jam. This plate has been attached together with spring and testing data shown this attachment can generate the restoring force and simultaneously oscillate this plate with the present of mass hang up on the system.

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5.0 CONCLUSIONS This Simple Harmonic Motion Kit (SHM-KIT) now used by lecturers and engineering students at PSP. The SHM-KIT now is in line of new categories in an educational kit based product. It is considerably recognized as a green technology product. This learning kit helps students to understand much better the simple harmonic motion based on mass-spring concept. Moreover its application is much more easy to use. The advantages of this kit are more effective in terms of design and size. SHM-KIT is a kit that easily operated by lecturers. Alternatively this learning kit can guide the lecturers to gain the parameters that usually used to resolve the problem that relates in their teaching and also to enhance their finding and data collections in such experiment. Thus, it fulfills the needs of the educational organization by the use of the technologies. In the other hand, this innovation also benefits students to learn in effective way since this kit was developed due to a reasonable objective.

6.0 BIBLIOGRAPHY

B.Lautrup (2011). Physics of Continuous Matter : Exotic and Everyday Phenomena in the Macroscopic World. CRC Press, Broken Sound Parkway, Boca Raton, Florida, USA.

David Sang, Graham Jones, Gurinder Chadha, Richard Woodside, Will Stark, Aidan Gill (2014). Cambrige International AS and A Level Physisc Coursebook with CD-ROM. Cambrige University Press, United Kingdom, England.

Nicholas Giordano (2012). Collage Physics: Reasoning and Relationships. Cengage Learning, Boston, Massachusetts, USA

Satyajit Deb (2013). Fundamental Of Physics. Pearson Education Inc., San Francisco, California, USA.

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BATIK FIXATION THROUGH INFRARED

Muhammad Nasir B. Marzuki Tel: +604-538 3322 Email: nasir@psp.edu.my

Surianis Bt. Dalimin

Tel: +604-538 3322 Email: surianis@psp.edu.my

Norhafizah Akmal Bt. Sukri Tel: +604-538 3322 Email: hafizah@psp.edu.my

Mechanical Engineering Department, Politeknik Seberang Perai,

Penang, Malaysia.

ABSTRACT

In this paper, infrared is used in order to fix dye onto the fabrics for batik making. Traditionally, sodium silicate is used as a medium in achieving the fixation of dye. However the use of sodium silicate contribute to environmental issue and using a large volume of water. The purpose of this study is to prove that infrared can be used as batik fixation and to overcome the environmental issue from the batik industries. The study was done on batik cotton fabric by canting technique.The fabric has been exposed to the infrared ranging from 1 to 5 minutes for different samples. All the samples have been tested with Rotawash Colourfastness Tester and then examined using colour matching cabinet. It shows that the exposure of the infrared for 5 minutes gave the most identical result compared with the sodium silicate method. “Batik Fixation through Infrared” proven that there is other media, which is suitable to replace sodium silicate during batik fixation. Keywords: infrared, batik, canting, sodium silicate, batik fixation

1.0 INTRODUCTION Batik was mentioned in the 17th century Malay Annals. The word is first recorded in English in the Encyclopædia Britannica of 1880, in which it is spelled battik. It is attested in the Indonesian Archipelago during the Dutch colonial period in various forms: mbatek, mbatik, batek and batik [Blust,1989]. The word batik is Javanese in origin. It may either come from the Javanese word amba (to write) and titik (dot), or may derive from a hypothetical Proto-Austronesian root *beCík (to tattoo). Batik is a technique of manual wax-resist dyeing applied to whole cloth, or cloth made using this technique. Batik is made either by drawing dots and lines of the resist with a spouted tool called a canting (tjanting), or by printing the resist with a copper stamp called cap. The applied wax resists dyes and therefore allows the artisan to colour selectively by soaking the cloth in one colour, removing the wax with boiling water, and repeating if multiple colours are desired. A tradition of making batik is found in various countries, including Indonesia, Nigeria, China, India, Malaysia, Philippines and Sri Lanka (Sumarsono et al., 2013). The method of Malaysian batik making is different from those of Indonesian Javanese batik, the pattern being larger and simpler with only occasional use of the canting to create intricate patterns. It relies heavily on brush painting to apply colours to fabrics. The colours also tend to be lighter and more vibrant than deep coloured Javanese batik. The most popular motive are leaves and flowers. Malaysian batik often displays plants and flowers to avoid the interpretation of human and animal images as idolatry, in accordance with local Islamic doctrine. However, the butterfly theme is a common exception. The batik of Indonesia, however, is the most well-known. Indonesian batik made in the island of Java has a long history of acculturation, with diverse patterns influenced by a variety of cultures, and is the most developed in terms of

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pattern, technique, and the quality of workmanship. On October 2009, UNESCO designated Indonesian batik as a Masterpiece of Oral and Intangible Heritage of Humanity (Indonesian Batik, 2009). Sodium silicate is the common name for compounds with the formula Na2(SiO2) O. A well known member of this series is sodium meta silicate, Na2SiO3. Also known as water glass or liquid glass, these materials are available in aqueous solution and in solid form. The pure compositions are colour less or white, but commercial samples are often greenish or bluish owing to the presence of iron-containing impurities. They are used in cements, passive fire protection, textile and lumber processing, refractories, and automobiles. Sodium carbonate and silicon dioxide react when molten to form sodium silicate and carbon dioxide (Greenwood et al,. 1997). The used of sodium silicate for the colour fixation was widely used since long time ago. It‘s due to the effectiveness for the colour fixation on fabric. In hand dyeing process, sodium silicate solution is used as a fixative for with reactive dyes that require a high pH in order to react with the textile fiber. After the dye is being applied to a cellulose-based fabric, such as cotton or rayon, or onto silk, it is allowed to dry. After that the sodium silicate is painted onto the dyed fabric, covered with plastic to retain moisture. Left for reaction for an hour at room temperature (Burch, 2010). Most of the small industries using this method because of it easy to get and one can recycle it for a few times. Besides that, the cost of this material is very low compare to the other method. By using sodium silicate, the process took at least 8 hours for the fixation process, need more operators, end up a messy workshop and chemical effect to human. This is due to the water pollution and the environmental effect. Infrared (IR) is invisible radiant energy, electromagnetic radiation with longer wavelengths than those of visible light, extending from the nominal red edge of the visible spectrum at 700 nanometers (frequency 430 THz) to 1 mm (300 GHz) (Liew, 2007) (although people can see infrared up to at least 1050 nm in experiments) (Sliney et al., 1976). Most of the thermal radiation emitted by objects near room temperature is infrared. Infrared radiation was discovered in 1800 by astronomer William Herschel, who discovered a type of invisible radiation in the spectrum beyond red light, by means of its effect upon a thermometer (Michael, 2013). Slightly more than half of the total energy from the Sun was eventually found to arrive on Earth in the form of infrared. The balance between absorbed and emitted infrared radiation has a critical effect on Earth's climate. Infrared energy is emitted or absorbed by molecules when they change their rotational-vibrational movements. Infrared energy elicits vibrational modes in a molecule through a change in the dipole moment, making it a useful frequency range for study of these energy states for molecules of the proper symmetry. Infrared spectroscopy examines absorption and transmission of photons in the infrared energy range (Reusch,1999). Infrared radiation is used in industrial, scientific, and medical applications. Night-vision devices using active near-infrared illumination allow people or animals to be observed without the observer being detected. Infrared astronomy uses sensor-equipped telescopes to penetrate dusty regions of space, such as molecular clouds; detect objects such as planets, and to view highly red-shifted objects from the early days of the universe. Infrared thermal-imaging cameras are used to detect heat loss in insulated systems, to observe changing blood flow in the skin, and to detect overheating of electrical apparatus. Thermal-infrared imaging is used extensively for military and civilian purposes. Military applications include target acquisition, surveillance,night vision, homing and tracking. Humans at normal body temperature radiate chiefly at wavelengths around 10 μm (micrometers). Non-military uses include thermal efficiency analysis, environmental monitoring, industrial facility inspections, remote temperature sensing, short-ranged wireless communication, spectroscopy, and weather forecasting. Infrared radiation extends from the nominal red edge of the visible spectrum at 700 nanometers (nm) to 1 mm. This range of wavelengths corresponds to a frequency range of approximately 430 THz down to 300 GHz. Below infrared is the microwave portion of the electromagnetic spectrum.

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Table 1: Infrared in relation to Electromagnetic spectrum

In general, objects emit infrared radiation across a spectrum of wavelengths, but sometimes only a limited region of the spectrum is of interest because sensors usually collect radiation only within a specific bandwidth. Thermal infrared radiation also has a maximum emission wavelength, which is inversely proportional to the absolute temperature of object, in accordance with Wien's displacement law. Therefore, the infrared band is often subdivided into smaller sections. The International Commission on Illumination (CIE) recommended the division of infrared radiation into the following three bands:

i. IR-A: 700 nm – 1400 nm (0.7 µm – 1.4 µm, 215 THz – 430 THz) ii. IR-B: 1400 nm – 3000 nm (1.4 µm – 3 µm, 100 THz – 215 THz) iii. IR-C: 3000 nm – 1 mm (3 µm – 1000 µm, 300 GHz – 100 THz)

Therefore, a new technique used to prove that infrared can be used as batik fixation and to overcome the environmental issue from the batik industries. This research is focusing on the canting process as it is widely used in Malaysia batik industries. Besides that the material used in this research is cotton fabric only because of the setting for temperature and dyestuffs used are depending on material. For example, polyester, by using the man-made fabric, disperses dye need to be used and the temperature for the process even higher. It‘s very hard to get the best result as well as to control the process.

2.0 BATIK TECHNIQUES There are a few ways of making batik. Either canting technique or stamping technique. For this research, we concentrate of the canting technique since it widely use in Malaysia. Below are the flow process of making batik by canting technique.

Light comparison[8]

Name Wavelength Frequency (Hz)

Photon Energy

(eV)

Gamma ray

less than 0.01 nm

more than 30 EHz

124 keV – 300+ GeV

X-Ray 0.01 nm – 10 nm

30 EHz – 30 PHz

124 eV – 124 keV

Ultraviolet 10 nm – 380 nm

30 PHz – 790 THz

3.3 eV – 124 eV

Visible 380 nm–700 nm

790 THz – 430 THz

1.7 eV – 3.3 eV

Infrared 700 nm – 1 mm

430 THz – 300 GHz

1.24 meV – 1.7 eV

Microwave 1 mm – 1 meter

300 GHz – 300 MHz

1.24 µeV –

1.24 meV Radio 1 mm –

100,000 km 300 GHz –

3 Hz 12.4 feV

– 1.24 meV

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Figure 1: Flow chart process of batik making using canting technique

According to Figure 1, batik making using canting technique starts with melting the wax and resin in 50%-50% ratio in a bowl with heater. Once it is melting, fill the canting with the mixture of wax and resin. Draw the wax on a white fabric. The fabric can be cotton or silk. The process has to be fast and accurate because the wax will cool faster and cannot be corrected once it is being applied. By using the colour brush, artist paint the enclosed area with the needed colours. Sometimes, clean water is used to produce shading effect. Again, the choice of colour is limited only to the creativity of artist. When the colour is dry completely, apply a layer of sodium silicate on the fabric to fix the colour. Leave it for at least 4 hours to dry. The colours will be durable and will not fade easily. Put some soda in the water and boil the fabric for few minutes. The wax will come off of the fabric. Hang and dry the fabric. A piece of batik was created.

3.0 METHODOLOGY 3.1 Design Concept There are a few design been sketch. Each design comes with its own advantages and disadvantages. The final design is as in the diagram below.

Figure 2: Assembly drawing of the project design

wax melting wax drawing painting

drying boiling applying sodium silicate

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Figure 3: Cover part of the project design

1. Frame work 2. Wheel holder 3. Screw 4. Nut 5. Wheel 6. Batik box machine 7. Screw 8. Nut 9. Screw 10. Nut 11. Holder to reject 12. Rod station 13. Rod station 14. Rod station 15. Rod station 16. Rod station 17. Rod station

18. Cicle holder 19. Screw 20. Nut 21. Holder gear 22. Bearing 23. Motor 24. Screw 25. Nut 26. Rod 27. Gear chain 28. Nut 29. Bearing gear 30. Bush 31. Screw 32. Infrared cover 33. Infrared Mirror

Figure 4: Detail of the project design

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3.2 Material Selection Material which have been selected are based on certain criteria;

i. Cost of the materials ii. Durability of the materials and the function ability. iii. Ease of supply. iv. Easy to assemble.

3.2.1 Components of the project i. ―Infrared‖ light bulb – the main component of the project. ii. ―Stainless Steel‖ - all the frame is made of stainless steel. iii. Motor – for the conveyor and chain movement. iv. ―C Channel‖ – as a chains track. v. Temperature meter – indicate the temperature in the machine and auto stop the

thermostat for the temperature controlling. vi. Shaft - hold the components. vii. Sprocket – to move the chain. viii. Screw and nut – joining the parts of this ―Infrared Fixation Batik Machine‖

4.0 RESULT All the sample fabrics have been tested with Rotawash Colourfastness Tester by following the AATCC method 61-1980 Test No IIA. From the washing test result, all the samples have been examined using colour matching cabinet. The results are as follows:

Time / Gray scale grade Result

1 minute Gray scale: 3

2 minutes Gray scale: 3/4

3 minutes Gray scale: 4

4 minutes Gray scale: 4

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Table 2: Colourfastness result according to exposure period

According to Table 2, all of the samples were exposed to the infrared for different time periods ranging from one minute to five minutes. The sample that was treated with sodium silicate was used as control sample. The samples were graded by using gray scale indicator. It shows that the exposure of the infrared for 5 minutes gave the most identical result compare with the sodium silicate method. It has been graded as 4/5 using the gray scale indicator.

5.0 CONCLUSION As a conclusion, ―Batik Fixation through Infrared‖ proved that there is other media, which are suitable to replace sodium silicate during batik fixation. Overall, this infrared fixation concept could help batik producers to replace sodium silicate in their production. Furthermore, it could save the production time, large amount volume of water deductible and as a result, protect the environment from water pollution caused by the batik industries.

6.0 BIBLIOGRAPHY

Blust, Robert (Winter 1989). "Austronesian Etymologies - IV". Oceanic Linguistics 28(2): 111–180. doi:10.2307/3623057 Burch, Paula (2010). "Sodium silicate as a fixative for dyeing". Retrieved March 22, 2010.

Dash, Madhab Chandra; Dash, Satya Prakash (2009).‖Fundamentals Of Ecology 3E”. Tata McGraw-Hill Education. p. 213. ISBN 978-1-259-08109-5.

Greenwood, Norman N.; Earnshaw, Alan (1997). Chemistry of the Elements (2nd ed.). Butterworth-Heinemann.ISBN 0080379419.

"Indonesian Batik", Inscribed in 2009 on the Representative List of the Intangible Cultural Heritage of Humanity". UNESCO. Retrieved 10 October 2014.

Liew, S. C. "Electromagnetic Waves”. (2007). Centre for Remote Imaging, Sensing and Processing. Retrieved 2006-10-27.

Lynch, David K.; Livingston, William Charles (2001). Color and Light in Nature (2nd ed.). Cambridge, UK: Cambridge University Press. p. 231. ISBN 978-0-521-77504-5.

Michael Rowan-Robinson (2013). "Night Vision: Exploring the Infrared Universe". p. 23. Cambridge University Press.

Reusch, William (1999). "Infrared Spectroscopy". Michigan State University. Retrieved 2006-10-27.

Sliney, David H.; Wangemann, Robert T.; Franks, James K.; Wolbarsht, Myron L.

(1976). "Visual sensitivity of the eye to infrared laser radiation". Journal of the Optical Society of America 66 (4): 339–341. doi:10.1364/JOSA.66.000339

5 minutes Gray scale: 4/5

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Sumarsono, Hartono; Ishwara, Helen; Yahya, L.R. Supriyapto; Moeis, Xenia (2013). Benang Raja: Menyimpul Keelokan Batik Pesisir. Jakarta: Kepustakaan Populer Gramedia. ISBN 978-979-9106-01-8.

Saidman, Jean (15 May 1933). "Sur la visibilité de l'ultraviolet jusqu'à la longueur d'onde

3130" [The visibility of the ultraviolet to the wave length of 3130]. Comptes rendus de l'Académie des sciences (in French) 196: 1537–9.