Table of Contents

LIST OF TABLE............................................................................................................ 2
LIST OF FIGURE........................................................................................................... 3
1.

Introduction.......................................................................................................... 4
1.1

Barbecue........................................................................................................ 4

1.2

Events and gathering..................................................................................... 4

1.3

Techniques..................................................................................................... 5

1.3.1

Smoking................................................................................................... 5

Smoking is the process of flavoring, cooking, or using preserving food by

exposing it to the smoke from burning or smoldering plant materials, most
often wood........................................................................................................... 5

2.

1.3.2

Baking..................................................................................................... 5

1.3.3

Braising................................................................................................... 6

1.4

Objective of the Product................................................................................ 6

1.5

MARKET OPPORTUNITIES............................................................................... 8

Problem Definition................................................................................................ 9
2.1

Purpose and Scope........................................................................................ 9

2.2

Problem analysis.......................................................................................... 10

2.3

Literature Review......................................................................................... 11

2.3.1

Kitchen Exhaust Ventilation Systems.....................................................11

2.3.2

Rotating Grill.......................................................................................... 12

2.3.3

Power motor as power supply................................................................13

2.4

Product Design Specifications......................................................................14

2.5

Mission Statements...................................................................................... 15

3.

Conceptual Designed......................................................................................... 17

4.

Optimization and analysis of the solutions.........................................................20

5.

4.1

Detail drawing.............................................................................................. 20

4.2

Critical part.................................................................................................. 44

4.3

Critical theory and analysis in engineering..................................................44

4.3

Analysis Conclusion..................................................................................... 52

Testing and Design Improvement.......................................................................53

1

5.1

Design Improvement.................................................................................... 55

6.

Construction....................................................................................................... 57

7.

Cost of the product............................................................................................. 64

8.

Solutions benefits to society..............................................................................66

9.

Ethical Issues..................................................................................................... 68

10.

Recommendations.......................................................................................... 69

11.

Conclusion....................................................................................................... 70

APPENDIX................................................................................................................. 71

LIST OF TABLE
Table 1: Recommendations for kitchen ventilation fans............................................................12
Table 2: Product Design Specification................................................................................. 14
Table 3: Mission Statements............................................................................................. 15
Table 4: Specification of power window DC motor.................................................................45
Table 5: Material analysis................................................................................................. 50
Table 6: Cost of product................................................................................................... 64
Table 7: Overhead cost.................................................................................................... 65

LIST OF FIGURE
Figure 1: Types of specification wanted by customer...........................................................10
Figure 2: Thomas and friends............................................................................................ 17
Figure 3: Various shape................................................................................................... 17
Figure 4: Hexagon shape.................................................................................................. 17
Figure 5: Smoke suction ................................................................................................. 18
Figure 6: Ferris wheel ride................................................................................................ 18
Figure 7: Classroom table................................................................................................. 19
Figure 8: Mechanical part................................................................................................. 44
Figure 9: Product leg...................................................................................................... 47
Figure 10: Stone henge.................................................................................................... 48
Figure 11: Partheon........................................................................................................ 48
Figure 12: Fans............................................................................................................. 51
Figure 13: Product leg..................................................................................................... 53
Figure 14: Electrical motor............................................................................................... 53
Figure 15: Product body.................................................................................................. 54
Figure 16: Mild steel plate................................................................................................ 54
Figure 17: Adjustable leg................................................................................................. 55
Figure 18: Body part....................................................................................................... 57
Figure 19: Charcoal drawer.............................................................................................. 58
Figure 20: Mechanical part............................................................................................... 59
Figure 21: Top part......................................................................................................... 59
Figure 22: Bending machine............................................................................................. 60

1.
1.1

Introduction
Barbecue

Barbeque is a method and apparatus for cooking food (generally meat). In the United States,
to grill is to cook meat relatively quickly using the direct heat imparted by
a charcoal or propane fire, while barbecue is a much slower method utilizing the indirect heat
imparted by the smoke of a wood-fueled fire (and tended to over an extended period of several
hours).
While there is a vast degree of variation and overlap in terminology and method surrounding this
form of cooking, the generally accepted difference between barbecue and grilling is in the
cooking time and the type of heat used, grilling is generally done "hot and fast" over direct heat
from low-smoke fuels (with the flame contacting the meat itself), while barbecuing is usually
done "low and slow" over indirect heat from high-smoke fuels (with the flame not contacting the
meat directly).
The term as a noun can refer to the meat or to the cooking apparatus itself (the "barbecue grill" or
simply "barbecue"). The term as an adjective can refer to foods cooked by this method. The term
is also used as a verb for the act of cooking food in this manner. Barbecue is usually done in an
outdoor environment by cooking and smoking the meat over wood or charcoal. Restaurant
barbecue may be cooked in large brick or metal ovens specially designed for that purpose.
Barbecue has numerous regional variations in many parts of the world.

1.2

Events and gathering

The word barbecue is also used to refer to a social gathering where food is served, usually
outdoors in the late afternoon or evening. In the southern United States, outdoor gatherings are
not typically called "barbecues" unless barbecue itself will actually be on the menu, instead
generally favoring the word "cookouts". The device used for cooking at a barbecue is commonly
referred to as a "barbecue", "barbecue grill", or "grill". In North Carolina, however, "barbecue" is
a noun primarily referring to the food and never used by native North Carolinians to describe the
act of cooking or the device on which the meat is cooked.
1.3

Techniques

Barbecuing encompasses four or five distinct types of cooking techniques. The original
technique is cooking using smoke at lower temperatures (usually around 240280 F or 115145
C) and significantly longer cooking times (several hours), known as smoking. Another
technique is baking, utilizing a masonry oven or any other type of baking oven, which uses
convection to cook meats and starches with moderate temperatures for an average cooking time
(about an hour plus a few extra minutes). Yet another technique is braising, which combines
direct dry heat charbroiling on a ribbed surface with a broth-filled pot for moist heat, cooking at
various speeds throughout the duration (starting fast, slowing down, then speeding up again,
lasting for a few hours). Finally, grilling is done over direct dry heat, usually over a hot fire (i.e.,
over 500 F (260 C)) for a short time (minutes). Grilling may be done over wood, charcoal, gas
(natural gas or propane), or electricity.

1.3.1 Smoking

Smoking is the process of flavoring, cooking, or using preserving food by

exposing it to the smoke from burning or smoldering plant materials, most
often wood

1.3.2 Baking

The masonry oven is similar to a smoke pit in that it allows for an open flame, but cooks much
faster, and uses convection to cook. Barbecue-baking can also be done in traditional stove-ovens.
It can be used to cook not only meats, but breads and other starches, and even
various casseroles and desserts. It uses both direct and indirect heat to surround the food with hot
air to cook, and can be basted much the same as grilled foods.

1.3.3 Braising

It is possible to braise meats and vegetables in a pot on top of a grill. A gas or electric charbroil
grill would be the best choices for what is known as barbecue-braising, or combining dry heat
charbroil-grilling directly on a ribbed surface and braising in a broth-filled pot for moist heat. To
braise, put a pot on top of the grill, cover it, and let it simmer for a few hours. There are two
advantages to barbecue-braising, the first is that this method now allows for browning the meat
directly on the grill before the braising, and the second is that it also allows for glazing the meat
with sauce and finishing it directly over the fire after the braising, effectively cooking the meat
three times, which results in a soft textured product that falls right off the bone. This method of
barbecue has a varying duration (depending on whether a slow cooker or pressure cooker is
used), and is generally slower than regular grilling or baking, but faster than pit-smoking.

1.4

Objective of the Product

This project objective is actually to see the market opportunities, its goal and the
resources to be included in this project. Firstly, a market is the set of all actual and potential
buyers of a product or service. Opportunities is a potentially favorable condition in which a
business can capitalize on a changing trend or an increasing demand for a product by a
demographic group that has yet to be recognized by its competitors. For a market opportunity to
exist, a company must be able to identify who its potential customers are, the specific needs that
need to be met, the size of the market, and its capacity to capture market share. Market goals are
the most advantageous segment which to offer a product. A product that already developed which
intends to sell prior to selecting the market versus choosing a market segment prior to product
development is what we call the goals. Market resources are factors of production that give
inputs to the product process. The most important thing to be solved in this design is the method
of the product to reduce human work on BBQ grill and also decrease the smoke produced by the
charcoal during BBQ process. Other problem to be solved in this project is to make the charcoal
easy to setup and remove, reduce the heat atmosphere around the BBQ grill and adding some
aesthetic value to the BBQ compared to current product in market today.

Market need is based on the product opportunity to be exploited in the market segment.
The product must be effective compare to the one in the market. The best way to determined
market need is to go through a checklist of the most common ways to market to consumers, and
then check them off according to what is missing in the current marketing plan. There are several
steps that can be used to determine market need. Firstly, do any research on how the competitors
market. Then, do market research. After that, identify the target customer base. Finally evaluate
product name, logo or motto follow by evaluation of materials should be used.
The product designed is based on the research done on current product. Current product
is identified to have most common problem which is smoke problem and charcoal setup and
remove problem. This two main problem is the work need to give solution implement
Stakeholder identification is the process of identifying the individuals or groups that are
likely to affect or be affected by a proposed action, and sorting them according to their impact on
the action and the impact the action will have on them. In simple word stakeholder are entities
that have an interest in the project. Theses stakeholders may be inside or outside an organization
which sponsor a project or have an interest or gain upon a successful completion project. For
example like customer, user group, project manager, development team and testers.
Resources are the means we use to achieve project objectives. The primary resource is
obviously people with applicable skills and competencies. The other main grouping of resources
we need include capital, facilities, equipment, material and information. There is usually a gap
between the investment reach of a project and the project demands. In order to ensure a cost
effective application of required resources we must perform a proper needs analysis in order to
define the project goals and objectives. The projects baseline that must be resourced will be
known after a requirement specification has been completed.

1.5

MARKET OPPORTUNITIES

In the context of product development, an opportunity is an idea for a new product. An

opportunity is a product description in embryonic form, a newly sensed need, a newly discovered
technology, or a rough match between a need and a possible solution. At the earliest stage of
development, uncertainty clouds the future, so an opportunity can be thought of as a hypothesis
about how value might be created.
They will be a long list of why people love to have barbeque. It is because barbeque will
not only give a good food but also leaves us with great memories. Barbeque has become of the
most family activity that people loved to do when they are home spending time with family. This
activity taught us to cooperate well among family member.
Some of people question that by having barbeque they will pollute the air. Basically its
depending on what type of barbeque grill that they are using. Users are eager to find barbeque
grill that are environmental- friendly. So there is still a wide market to sell barbeque grill.
Current barbeque grill has a lot of weaknesses. This opportunity opens up market for
barbeque manufacturer to sell their product. We can see that existing barbeque grill has too much
problem such as heavy, not multifunctional and not portable.
Basically barbeque grill food give different taste of food than gas type cooking food.
Sometime people might get bored eating food from gay-type cooker, so by having barbeque they
can taste a different taste of food.
Of all the benefits associated with barbeque grill, one always seems to get lost in the
shuffle because they're lots of fun. And also it because of they are safe and easy to operate, they
are great for families. In particular, kids love barbeque food. Barbeque grill come in a variety of
sizes, so their parents can join and share in with their own kids. So, due to this several
opportunities, the barbeque grill will have a potential to successfully sell throughout the world.

2.

Problem Definition
Although traditionally barbeque grills has been really beneficial to the users, a few

problem occur when using this device. A few parties such are really concerned about this
problem and wanted to fix this problem as soon as possible. For further explanations on this
problem, an investigation is carried out to discover the weakness of the existing barbeque grills.

2.1

Purpose and Scope

Thus, the main purpose of this report is to carry out a detailed research of the weakness of
the existing barbeque grills. Toward this end, we will come up with a solution that will help to
solve the problem or reduce the problem. The objectives of this research are to:
a. To identify the barbeque grill users perception on the existing barbeque grill.
b. To explore measures on the weaknesses of the existing barbeque grill and to make an
improvement in our project design.
c. To design a product that solve existing barbeque grill problem and satisfy user needs.

2.2

Problem analysis
9

Nowadays people are getting more and more into having barbeque. Barbeque grill can easily buy
and there were various type of barbeque grill in the market. However, there is still some
dissatisfaction on the existing barbeque grill. As a solution, we conduct a survey involving the
specifications that user need in a barbeque grill.
14
12
10
8
6
4
2

Portable
Multifunctional
Cheap
Smokeless
adjustable height
Long-lasting burner
Faster burning griller
High Safety

Types of specification wanted by customer

Figure 1: Types of specification wanted by customer
Based on above chart we know that the most favourable specification wanted by customer is
multifunctional, smokeless and high safety. Multifunctional can be defined in many ways, plus
there are various functions that may be added in a barbeque grill. From this we can assume that
user getting boring with their barbeque grill and want something new with more features that can
benefit them. Second most wanted is smokeless. We can assume from here that user are having
difficulties on controlling the removal of smoke to the environment and we also can assume that
user nowadays are more concern on the effect of releasing large amount of smoke to the
environment. So they tend to have a smokeless barbeque grill. Third most wanted specifications
wanted by customer are high safety. As we all know, when having barbeque a lot of incident may
occur such as hand burns. From here we may assume that user want something that may risk
them to injuries or in other word user want a barbeque grill that reduce the use of their own hand.
These three specification lead us to the major problem that barbeque grill user had when having
barbeque.
10

2.3

Literature Review

Portable barbeque grill is a device to cook something by using charcoals. There are many
different types of griller sold in the market. Nowadays there are a few technologies applied to
barbeque grill. The technologies that we were like to implement on our product will be discussed
below.
2.3.1 Kitchen Exhaust Ventilation Systems
Indoor and human health is major housing issues related to cooking. Biological pollutants
such as molds are health threats. These pollutants require a moist environment. Regular use of
kitchen exhaust ventilation systems can help control excess moisture in the home. Moisture is
generated in a kitchen through cooking. Boiling or simmering of foods on a cook top is
particularly a problem (Pickett et al. 1986). The amount of moisture released in cooking will
vary, dependent on the type of food, whether or not the food is covered while cooking, and the
length and temperature of cooking. Kitchen ventilation systems are usually located over the cook
top, considered the primary source of odors, grease, and moisture. Most kitchen design experts
recommend a ventilation fan that is sized according to the recommendations of the Home
Ventilating Institute (HVI 2001) or the National Kitchen and Bath Association (McDonald,
Geragi, and Cheever 1996). The minimum recommendations of the Home Ventilating Institute
are comparable to that of the American Society of Heating, Refrigeration and Air-Conditioning
Engineers (ASHRAE) Standard 62 (ANSI/ASHRAE 1999). Although these requirements are
determined somewhat differently, the recommendations are similar (Table 2). Both the Home
Ventilating Institute (HVI 2001) and the National Kitchen and Bath Association (McDonald,
Geragi, and Cheever 1996) recommend that downdraft systems need larger fans to compensate
for the lack of a hood, but do not specify a size. The Home Ventilating Institute recommends
following the manufacturer's recommendation (HVI 2001).

11

Table 1: Recommendations for kitchen ventilation fans

Recommendation

Home
Ventilating
Institute

Hood placed
along a wall

Hood above
an island
or peninsula
(no wall)

National
Kitchen and Bath
Association

Hood placed
along a wall

Hood above
an island
or peninsula
(no wall)
Note: CFM is cubic per minute

Minimum:
40 CFM
per lineal foot
Recommended:
100 CFM
per lineal foot
Minimum:
50 CFM
per lineal foot
Recommended:
150 CFM
per lineal foot
50 to 70 CFM x the area
of the hood
in square feet
100 CFM x the area
of the hood
in square feet

Fan needed
for a typical
30-inch range
100 CFM

250 CFM

125 CFM

375 CFM

250 CFM to
350 CFM
500 CFM to
700 CFM

2.3.2 Rotating Grill

Most grill manufacturers will tell you that you don't really need to use a rotisserie because a grill
with a lid does the same thing, provides even roasting. The standard view of cooking is to move
the heat around the food, not the food around the heat. There are so many advantages to rotisserie
cooking. Meats are generally juicier, self-basted and slow roasted. Of course there are a few
differences between grilling and rotisserie cooking that you need to be aware of. The first place
to start is with the instruction manual for your particular grill, beyond that remember that while a
lot of grilling is done over a very hot fire you need a lot less heat for the rotisserie. Starting with
your equipment, you will need a Rotisserie attachment for your particular grill and a powerful
motor that will drive the rotating grill. Now the most important thing to remember in using a
rotisserie is balance and security. Place the meat on the middle of the rotisserie skewer and

12

fasten as firmly as you can. If you are cooking poultry remember to secure the wings
and legs in as tightly as possible.
2.3.3 Power motor as power supply

An electric motor is an electric machine that converts electrical energy into mechanical energy.
In normal motoring mode, most electric motors operate through the interaction between an
electric motor's magnetic field and winding currents to generate force within the motor. In certain
applications, such as in the transportation industry with traction motors, electric motors can
operate in both motoring and generating or braking modes to also produce electrical energy from
mechanical energy.
Found in applications as diverse as industrial fans, blowers and pumps, machine tools, household
appliances, power tools, and disk drives, electric motors can be powered by direct current
(DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating current
(AC) sources, such as from the power grid, inverters or generators. Small motors may be found
in electric watches. General-purpose motors with highly standardized dimensions and
characteristics provide convenient mechanical power for industrial use. The largest of electric
motors are used for ship propulsion, pipeline compression and pumped-storage applications with
ratings reaching 100 megawatts. Electric motors may be classified by electric power source type,
internal construction, application, type of motion output, and so on.
Devices such as magnetic solenoids and loudspeakers that convert electricity into motion but do
not generate usable mechanical power are respectively referred to as actuators and transducers.
Electric motors are used to produce linear force or torque (rotary).

13

2.4

Product Design Specifications

Table 2: Product Design Specification

Specification

Description

1) Grill system

1) Consist of an automatic rotating griller so that user can have

the taste of roasted chicken
2) Consist of automatic net-griller to grill meat, fish and others.

2) Body material

Stainless steel and aluminium.

3) Product colour

Blue( Thomass colour)

4) Operating System

1)Use gear to rotate the roast chicken movement

2)Use switch to turn on and off the rotating grill

5) Target location to use the

product

At beach, camping site, flat places and homes

6) Target Market

Suitable for family uses

7) Storage

Place to store the charcoal

8) Time for cooked

1) Roasted chicken : 20 minute

2) Prawn : 3minute
3) Meat : 15 minute
4) Chicken : 10 minute
5) Sausage : 3 minute

9) Fuel use for cooked

Charcoals

10) Power sources

Supplies power for rotating griller and light

14

11) Product Warranty

2.5

1 year warranty. Depending on our target market and how often

they used we choose one year.

Mission Statements

Table 3: Mission Statements

Product

Portable multifunctional barbeque grill equipped with rotating grill

description

function, adjustable height function, proper lightning system and proper

smoke removal system.

Benefit proposition

First, table was added to build a place for users to eat after
having barbeque and to put their things. In this case user can
save a lot of space.
Second, this product was design to be at size of a luggage so
that user can bring this barbeque grill everywhere easily.
Third, this barbeque grill consists of 4 L.E.D light so that user
can use this grill at night. When users are having barbeque at
night, a few problems usually occur because of the lightning.
They cannot check whether the chickens are well-cooked or not.
Fourth, this product was equipped with fans that act as a smoke
suction. This can help to save our environment because its
release a very few amount of smoke.
Fifth, this product can be adjusted to a few level of height. This
certainly will make the user more comfortable because the
barbeque grill is appropriate with their height and they dont
have to bend so much.
Sixth, this product can last for longer time. This is because we
split the charcoal container with the drawer. We use a really
small holes type net so that it will not affect the barbeque grill
drawer.
Seventh, this product also equipped with rotating grills. This
15

function is specially made for those who love the taste of Ayam
Key businessgoal

Golek.
Environmental friendly (reduce smoke)
Customer satisfaction (investigate customer needs through
survey and interview)
Low manufacturing cost (investigate the most appropriate

Target market

Assumptions and
constrains

Stakeholders

3.

material with low cost)

High safety product
Chalets
Organization such as recreational club
Students
Hawker such as sate seller and otak-otak
Restaurants
All the product can be obtained from hardware in Malaysia
Product price can be minimized because parts are assembling by
our own.
Product can be improve and have a lot of interest from buyer
Purchasers and users

Conceptual Designed
16

Pop my barbeque design was inspired by a kid television program name Thomas and his
friends. Our target market is family who love to barbeque so we try to produce something that
could attract people with its shape and colour. In our design we also try to combine different kind
of shape such as hexagon (figure 5), hemisphere (figure 3), cylinder (figure 4), cone (figure 1)
and rectangular shape. This combination of shape will formed train shape. This is because
existing barbeque grill mostly are in rectangular or box shape, so we try to produce something
different that not only looks great when it is been used but also will looks great when user want
to store it at their home and in fact it might be one of their home decoration.

Figure 2: Thomas and friends

Figure
Figure4:3:Hexagon
Various Shapes
shape
In order to produce an environmental

friendly product we add a fan that is used to control the air flow inside the barbeque grill. The
barbeque grill top part will be closed when having barbeque so there are no rooms for smoke to
be released to the environment. Fan is added in order to suck the smoke and move the smoke to
the wet sponge. This functional operation is inspired from kitchen vent hood.

17

Figure 5: Smoke suction

By having this fan we can reduce the amount of smoke release to the environment and
maybe there will be no smoke release to the environment.
On the griller part, we try to produce something that will reduce the use of hand. As we
all know, when having barbeque we had to flip the meat we grill for a few times to avoid the
meat to be overcooked. In our product we try to produce something that can solve this problem.
The idea of the griller was inspired by the funfair amusement game name ferris wheel ride.

Figure 6: Ferris wheel ride

We are not copying the shape but we try to apply the mechanism into our griller. In ferris
wheel ride system only the wheel will rotate but in our system we will make the wheel and the
passenger seat rotate. This means that in our system motor will gives rotation to wheel and
passenger seat. So the meat inside the passenger seat will not overcook or just one sided
overcooked because the meat keeps rotating. Plus user also doesnt have to look at the meat and
flip the meat.
Next is the concept of the leg or bottom part. This leg is used to support or to hold the
barbeque grill. This leg will make the barbeque grill looks like a real train because the leg is
equipped with 4 wheels and a holder. So this barbeque grill can easily be moved from one place
to another. The leg also designs to be foldable just like a regular classroom table.
18

Figure 7: Classroom table

We also design the charcoal net to be differing from the existing product. There will be a
drawer for the charcoal to ease user changing the charcoal. The charcoal drawer also designs to
be long lasting drawer. We realize this by having a net on the top of the drawer. This means that
the drawer will not exposed to direct heat from the charcoal and the net will hold the charcoal.
The net is a small hole net which means that only dust from the charcoal will fall onto the
drawer. Overall, this design concept has a really unique concept and would be an interesting
concept when finish manufactured.

19

4.

Optimization and

4.1

Detail drawing

analysis of the solutions

20

21

22

23

24

25

26

27

4.2

Critical part

Critical part in order to fabricate this product is mechanical part. This is because we need to
combine the rotating grill net to the motor power supply to make a rotating movement.
Other than that to make a stable leg whereby the leg can be folded. Skill in welding is needed to
make sure the leg strong and not easy to break.
4.3

Critical theory and analysis in engineering

1. Motor analysis and selection

28

Figure 8: Mechanical part

The weight of the grill and load = 500 g

3 grill within load, m = 500 x 3 = 1500 g @ 1.5 kg.
Assumption is to reach the desired speed = 6-4 RPM for roaster chicken and slice meat.
1-3 RPM for larger meat like whole goat.
Sample calculation
Formula for power

P=

(2 NT )
60

To find the mass moment of inertia

I=m

( R 2)
2
(1.52 )
= 1.6875 X 10^ (-4) kgm2
2

= (1.5)

To find the value of torque

T=I

29

v
= =
t

2 N /60
=0.0209 rad / s
30

= angular velocity
v = angular displacement
T = (1.6875 X 10^ (-4))(0.0209) = 3.526875 X 10^ (-4) N.m
This torque seems to be very huge. The torque increases as we
reduce the time required to reach 6-4 rpm i.e.
when we decrease time, acceleration increases and there by
torque increases. So we are assuming that we can take the machine to 6-4 rpm in 30 second which gives
lesser torque.
Substitute the all value into the formula of power

(2 NT ) ( 2 )( 6 )(3.526875 X 10 (4 ))
P=
=
=2.216( 104 ) Watt @ 2.9717 ( 104 ) HP
60
60

Specification of power window DC motor

Table 4: Specification of power window DC motor

Voltage Rating (v)

12

No. load
Speed (R.P.M)

Current (A)

85(+/-)25

<= 3

Load Rating
Torque
Speed
(kgf.cm) (R.P.M)
30
70(+/-)2
0

Current
(A)
<=7

2. To determine the resultant internal loading acting on the cross section at middle of road.

19.62
N

30

F(C) =19.62N@2KG (for 1 chicken)

To find the value of F (A) by using moment method = 0.
When x = 80cm@0.8m =F (A) =225N,

Free body diagram (FBD)

F (A) =
225N

F (C) =
225N

MA = 0
225 (0.1) 19.62
BY =

(0.4)+B(y)(0.8) = 0
A(y
B(y
18.315 N
)
)

O.1
m

O.4
mFy

O.4m

=0
-FA -F+ A(y) + B(y) = 0
AY = 226.305 N

MC
NC

=0
0

(<-)FX = 0
NC = 0
(^)FY
NC =

VC

18.315 VC =0
O.4
18.315
mVC = -18.315N
N
M = 0
MC-18.315(0.4) = 0,MC =7.326N.m

2. Leg part
In the table stand part, the most critical component is to build this flip joint. See figure below.

31

Figure 9: Product leg

This component required in table stand to flip the legs so that the table can be used as cart
for the BBQ train. The first tried to make this product mechanism failed due to limitation of
concept and structure differences based on the table stand idea is came from folding table. After
that, we found a product that has almost the same concept as this product that called L folder. It
has the same function like this part but have some disadvantages that required is to not be used as
the flip joint for the table stand. The disadvantages are it does not hold the legs perfectly, does
not have spring that could hold if legs were flipped, and its easy to bend because of the material
does not suitable to be used for complex work. Finally, we decided to use the same component
from folding table with additional part being weld to it.
The most challenging part is to determine the exact weight table stand can support. Based
on the product to be design and develop, critical theory used is free vibration under simple beam
theory. There are several examples for this theory.

Figure 10: Stone henge

Figure11: Partheon

32

Determining the natural frequency of a simple supported beam, we need to understand and
calculate the following parameters, stiffness and mass of the Simple Supported beam. We can
determine the stiffness of simply supported beam by a simple equation from strength of
materials.

Where

Assumptions made during modelling and analysis:

The mass (M) of the whole system is considered to be lumped at the middle of the beam

No energy consuming element (damping) is present in the system example like

undamped vibration.

The complex cross section and type of material of the real system has been simplified to
equate to a simply supported beam.

The fundamental natural frequency Wn, by definition as

Since the simply supported beam is undergoing free vibration, the governing differential
equation of the systemconsidering undamped free vibration can be given by

This calculation need to find the Young Modulus, E (Modulus of elasticity) of the material to be
compared with the E that the material can stand before change shape.

33

This product is made of stainless steel.

K = (15kg*9.81)/(0.8m)
= 183.93N/m
I = (bh^3)/12
= (0.8*0.1^3)/12
= 6.67x10^-5
L^3 = 0.65m^3
= 0.27m

183.93=

48 E(6.67 x 105)
0.27

E=15511.33 N/m 2

Young's modulus can be used to predict the elongation or compression of an object as

long as the stress is less than the yield strength of the material. Below is the parameter of young
modulus.

34

From the parameter above, it shows that the maximum E that stainless steel could stand is
180x10^9 N/m^2 higher that E that we obtain.
Result calculated give us the conclusion that the table stand can hold the weight of the
BBQ train up to 11millions times than the current weight. So the objective of table stand
achieved and we can use it for the BBQ process.

Material analysis

There are 3 type of material that used to make this part such as:

Table 5: Material analysis

Melting point

Zinc plated
: 787.2F (419.5C)

Stainless steel
2750 F (1510 C)

Mild steel
1425 - 1540 87.2F
(2600 - 2800 C)

Young's modulus

108 GPa

193 Gpa

200 GPa
35

Thermal expansion

(25 C)

(16.9 C)

(30C)

Resistance
to corrosion

Resistance
to corrosion

Corrosion

Fan specification
Catia

Figure 12: fans

Actual

Voltage: 12v (DC)

Speed: 3500-5300 RPM
Power: 62.40 W
Air Volume: 417.00 CFM
Material: Aluminium

Sponge

36

This system doesnt need a high suction volume fan because our product is fully closed when the
charcoal burn. So this fan is needed only to ensure that smoke will flow to the sponge. This wet
sponge will change the smoke into moisture.

4.3

Analysis Conclusion

In order to fabricate barbeque product, analysis of the part is need to do. It to make sure that the
fabricate product can working perfectly. A little mistake in calculation can be neglect.
Calculation our product in order to fabricate mechanical part is successfully because rotating
grill can be rotate as we needed but unfortunately in leg calculation have a mistake because it
cannot 100% support the product body weight.

5.

Testing and Design Improvement

I.

Product Leg

Figure 13: Product leg

37

When designed and fabricate the product leg, we just focused to the leg whereby only strong to
support the body weight. So it is not suitable for customer who has different height. First our
testing after product finish to fabricate, the wheel at the product leg it small in size, so it is not
suitable because product body have a big size and weight in 15 kg. Other than that our product
leg cannot be adjustable, so it not suitable for someone who have different size.

II.

Electrical motor 24 volt.

Figure 14: electrical motor

We have made a testing by using motor 24 volt, we found that the power rotates the rotating grill
net so fast and it is not suitable to use it.
III.

Big size of product body

Figure 15: Product Body

38

Body of our product is too big in size, so it will make a burden to customer although it complete
with the wheel to bring it.

IV.

Use mild steel to fabricate product.

Figure 16: Mild steel plate

We use mild steel plate because it have already prepared at the manufacturing workshop level 2
faculty of engineering mechanical Shah Alam. It can help decrease our cost on material.

5.1

I.

Design Improvement

Changed the product leg from forded leg to the adjustable leg.

39

Figure 17: Adjustable leg

In order to improve the product, change the forded leg to the adjustable height, so it will suitable
for customer who has different height. Just adjust the height with the customer height by make it
up and down condition. It also good in ergonomic because customer no need to bend his body
when want to use it.

II.

Changed the 24 volts motor to 12 volts motor

24 volts power motor it not suitable to use because the rotation is too fast, so we changed it to 12
volts power motor. The 12 volts power motor is more suitable to use because the rotation
produce from the motor is lower and the combustion will be more uniform.

III.

Design product body with small in size

For our future, the other designed that needs to improve is about size of our product. Small in
size will give more easier to the user or to the customer in order to bring It although it has wheel.

40

IV.

The last improvement is to use stainless steel as a part body.

Between mild steel and mild steel stainless steel is better, stainless steel Headers can be repaired,
or modified at any time in their lifespan due to the simple fact that they do not rust and do not
need a Thermal coating. Mild Steel Headers are very tough to repair or modify due to Thermal
Coatings and rust.
It is believed that due to Stainless Steel Thermal characteristics, the high exhaust temperature is
retained inside the primary tubes and can increase the exhaust speed in the header, which in a
Competition Racing Header sometimes is an important goal. Due to the simple fact that there is
no rust generated, the inside of each primary tube will stay smooth and flow accordingly.

6.

Construction

My Pop Barbeque product is divided into four separated part whereby the parts are body part,
mechanical part, top part and leg part.
A. Body Part Constructions

41

i.

Body part

Figure 18: Body part

Body construction Process

1. To construct about the body process the first step is must to fabricate the body structure.
Body structure is build by cutting the hollow square mild steel and then attaches them
together.
2. Attaching the hollow square mild steel by using drill process to build a hole to put the
screw.
3. Use welding process at the end of the screw to make sure the attachment between the
screw and the hollow square mild steel is strong.
4. After the structure of the body done, the process is continued by the bending process.
Mild steel plate is used as a cover of the body. Bend the mild steel plate using bending
machines and follow the shape of the body structure. Then drill the hole and tighten with
the screw.
5. The body part is done.
ii.

Drawer Part Construction

42

Figure 19: Charcoal drawer

1. The special about this drawer is it has a charcoal cover whereby its to protect the hot
charcoal contact directly with the drawer, so the drawer has long life.
2. The cover is doing by using zinc material.
3. To construct the drawer is using bending process by build the box shape and follow the
dimension. Also use drill process to build hole for tighten and attach process.
4. Wood use as the drawer holder and the welding process is done to attach the holder
drawer to the drawer.
5. The process of charcoal drawer is done.

B.

Mechanical part

43

Figure 20: Mechanical part

In order to fabricate mechanical part manufacturing such as searing process, bending process,
cutting process, hydraulic process, drilling process and lathe process needed.

C.

Top Part

Figure 21: Top part

44

Figure 22: Bending machine

There are several process involve to fabricate this part. Every material that we used come in large
dimension and needs to undergo shearing process to obtained desired dimension. We joined
every single part in the top part using either screw joint or welding. When using screw joint we
need to drill a few holes before the screw and nut can be insert. For the welding joint we used
two types of welding that is arc welding and gas welding.
For the cylinder part, we used rolling machine. We roll it according to our desired radius in the
rolling machine. Then for the cone part we use rolling and bending. Next, for the hemisphere
shape we shear the mild steel and then we roll it into rolling machine with radius of 20cm. After
that we proceed to the fan holder part. This part was made using bending magnabend bending
machine. Then we joined the part altogether and become the top part. Lastly we put a holder on
top of the fan holder part.

45

D.

leg part

No

Drawing

Description

A 5x2.5cm rectangular stainless

steel is cut using Metal cut-off saw
into 4 pieces each 40cm long and
another 2 pieces more with 30cm

and 35cm meter long.

2.5x2.5cm square stainless steel
cut using the same machine with 4
pieces each 65m long and hole
with diameter 6.8mm is drill at tip
of it each part. Another pieces with
30cm 2 pieces and 35cm 2 pieces

been cut.
1.5x1.5cm square stainless steel
cut using the same machine with 2
pieces each 17cm

8.5x8.5cm 4 plates of mild steel is

prepared and bend to get U shape
using the bending machine to get

3x2.5x3cm
Then the part is drill at bottom side

using 6.8mm tool drill

All parts welding together using
gas-shielded metal arc welding
(GMAW) and part which got hole
will be tight using nut and bolt.

46

For the handle part, this shape of

part been produced 2 pieces using
manual metal shear, bending
machine and drilled with 2 holes

6.8mm and 4mm

Then, a 20cm diameter with 39cm
long is cut and welding with 2
pieces of 1.5x1.5cm square rod
that already been drilled holes with
6.8mm at tip of it to connect with

the part above.

This part welded to the top of table

stand.
This part from mild steel and bend
using bending machine to get this
shape and also cut to get curve
shape using manual metal shear to
get 12cmx2.5cmx5cm and drilled
with 10.7mm tool drill to insert

trust for the wheel.

This wheel welded to body of table
stands legs 1.5cm below the place
where legs and U shape were

tightened.
This part welded to the 2.5x2.5cm
square rod of 30cm and 35cm to
support the folding table.

47

A 39cm long and 9cm width of

aluminum sheet metal is cut and
rivet on the 1.5x1.5cm square rod.

Finally, all part sprayed to black

colour with 3 layers.

7.

Cost of the product

Table 6: Cost of product

No
1

Type of material/Part
Mild steel

2
3
4
5

Zinc plated
Stainless steel
Aluminum
Screw

Bearing

Size (cm)
0.2 X 100
2.5 X 2.5 X 100
2 X 1.8 X 50
0.2 X 100
l2.5 X 5 X 100
0.2 X 30
M6X0.45
M6X0.35
2.8 (outer)

Quantity
7
6
2
3
2
2
30
20
6

Unit/RM
20.00
15.00
12.00
15.00
20.00
10.00
0.35
0.25
3.00

RM
140.00
90.00
24.00
45.00
40.00
20.00
10.50
5.00
18.00
48

 2.1 (inner)
4 (outer)
7

Hinge

8
9
10
11
12

Clip part
Spray
Wire
Switch
Battery

13
14
15
16

Wheel
Angle flip
Bolt and nut
DC motor

2 (inner)
8X6
5X3
2X2

3 volt
12 volt
7
15 X 15 X 17.5
0.4
12 Volt

4.00

8.00

2
8
3
5
1
1
1
1
4
2
4
1

2.00
1.50
6.00
6.00
2.00
2.00
7.00
20.00
4.50
10.00
1.00
30.00

4.00
12.00
18.00
30.00
2.00
2.00
7.00
20.00
18.00
20.00
4.00
30.00

TOTAL

567.50

Overhead cost
Table 7: Overhead cost
Overhead cost
Transportation
Welding
Labor
Electricity
Communication
Wiring
Total

PRICE(RM)
10
15
50
8
10
12
105

Overall productions cost = material cost + overhead cost

= RM 567.50+ RM 105
= RM 672.50

49

8.

Solutions benefits to society

Environment
To make sure that our product is good to the environment. We design our product complete with
the fan and the span to make it function as a smoke suction. The smoke suction part we do it at
the top part. When we use the barbeque product, all the smoke will be up to the top part and the
span function is to suck the smoke. It is design not for 100% environment friendly but its design
to reduce plus minus in arrange 50% the environmental problem. It is because barbeque product
in market now produces more to the functional without thinking about the environmental
problem.
Society
Pure barbecue lovers quite often prefer barbecue grill with charcoal burner for its authentic taste
and richly infused smoky flavor meat. Steaks, thin slices of meat like bacons, bratwurst, brisket,
salmon and other fish dishes also retain their moisture and tenderness due to slow smokecooking process that is usually enclosed within charcoal smoking unit.
During this long cooking session, (typically between two hours to even one or two days), fat and
unhealthy grease also get their chance to drip out of barbecue a process which can also be
referred to as "meat sweating". So while preserving moisture and vital nutrition, such as
50

vitamins, charcoal barbecue grill also helps to reduce fat intake and avoid many high cholesterol
level related illnesses such as heart decease.

Public health and safety

While many purists would say that charcoal is the best pick to fully experience outdoor barbecue
grilling, there are also environmental and health concerns related to barbeque grills and smokers.
Because charcoal requires burning of wood, it creates hydrocarbon and carbon monoxides
which pollute the air. In addition, in 2003, scientists from Rice University after some study
found that poly-unsaturated fatty acids as the result of burning charcoals also contributed to the
atmosphere pollution in Houston.
Another impact on health is the risk of cancer. Grilling meat from charcoal barbeque grills can
potentially

produce

hazardous

carcinogenic

compounds,

called

polycyclic

aromatic

hydrocarbons (PAHs) and heterocyclic aromatic amines (HAA). These chemicals are created
when fat dripped from meat come into contact with burning charcoal, then they evaporate in
form of smoke and get deposited back into charred parts of barbecue meat. The hotter the
cooking temperature is and the longer the smoking session lasts, the higher the risk of food
poisoning. This phenomenon can actually happen when you broil and pan-fry meat as well.
In order to make charcoal grilling healthier, the first solution is to use natural charcoals instead
of commercially processed charcoals that are pre-soaked with poisonous chemicals and
petroleum bases. Whether you burn lumps or briquettes, they are still the same
51

You can also raise your own awareness of food safety and learn how to recognize the warning
signs usually used in the food industry. A site called Food-Safety-and-You.com has a great
resource of all things related to the safety of food and cooking to help you avoid buying toxic
products.
Many experienced barbecue lovers and experts advise us to cook charcoal barbeque grills on low
temperature and reduce the cooking time to minimal as possible.

9.

Ethical Issues

Before we have done fabricate our barbeque product, the roasted stick and rotating grill net
supposedly can put together on the product for cook process unfortunately have a dimension
mistaken during measurement process, so both of them need to separate when want to do
barbeque and roasted process.
In order during product fabrication process, tools such a hand drilling tool, hand grinding tool
have not enough this is because other than our class member have another mechanical class
doing project for Design 2 and they keep the tools for themselves. We need to postpone
manufacturing process until they return the tools back.
Although have a problems in order to complete our barbeque product, with team members good
cooperation and critical thinking solve the problem coming we lastly can finish our product on
time successfully.

52

10.

Recommendations

Add table to the product. The function of the table is to put a food or items such as spoon,
glass and others.

To use the barbeque product in the dark, lighting function must add to the product. In
market nowadays also not already have yet barbeque product with the lighting function.

In order to make sure that we know when the cooking time arrived, we need to add a
timer. Referring to our product specification to cooked prawn need 3 minutes, meat 15
minutes, chicken 10 minutes, sausage 3 minutes and to roasted chickens need 20 minutes.
After we enter minute number to the timer, the timer will produce a sound when the
cooking time arrive and its function just a like timer at microwave.

To make sure it more effective to the customer, need to add slots to the product for easy
to assemble and dissembles.

In order to make sure customer no need to carry a food using hand for do barbeque, small
storage can be add , so just need to put the food in the storage. It more effective and easy
for the customer.

53

11.

Conclusion

We can conclude that our product is successful to fabricate and function. In order to construct our
product we use manufacturing process such as rolling, bending, welding, drilling, shearing,
grinding and coating. The design of the product is totally different from the previous semester.
Product that we fabricate now is more concentrated on aesthetic value. We choose train as our
conceptual design because trains full with various shapes such as cylindrical shape, combination
of hexagon shape and half hemisphere shape.
This product is successfully produced in the period time given. Many things that we learn in
order to finish the project, especially is skill in team work was the important part, our group have
given 100% percent commitment and time in order to finished the interesting designed and to
finished the prototype. In order to finished the designed we always do a meeting and change the
idea until we get the perfect designed for our product.
Before our group making the decision about the designed and concept that we need to
apply in our product, we define the customer market by doing the survey. From the survey we
know what the customer want and need when they want to buy or choose the product.
We are success to achieve the objective of this project. We are able to identify the
barbeque grill users perception on the existing barbeque grill by do a survey to the public. We
are able to investigate on the weakness of the existing barbeque grills by do a surveyor from the
internet and the get the opinion from the public. We also created improvement on our product for
Design 2 to get the best final design.

54

Finally, we hope that with our BBQ portable product will fulfill people satisfaction and
help them to do activity with family and friends and more easier to them in order using our BBQ
portable product in the future.

APPENDIX

MY POP BARBEQUE COMPLETE PRODUCT

55

Gantt chart Design 2

56

Data retrieval via survey

57

A number of people from diverse professions were involved in obtaining responses from public
regarding the weaknesses of existing barbeque grills. Questionnaires were distributed to users
that have used the barbeque grills in order to know what their feedback is after using it. Below
here is the sample of questionnaire that we distributed.

An investigation study of the current barbeque grill

QUESTIONNAIRE
We are Mechanical Engineering students at UITM Shah Alam. As part of the fulfilment of the
MEM531 (design) course, we have to complete a research and produce a product that fulfil and
satisfy customer needs. This study is to conduct a thorough investigation on the weakness of the
current barbeque grill. The following questionnaire is designed to obtain information of the user
perception about the weaknesses of the barbeque grill and suggestion to improve the barbeque
grill. Your cooperation throughout this survey is very much appreciated. Thank you.
Kindly tick

in the box provided and write in the space to indicate your response to each

question.
SECTION A: Personal Information
Gender:

Male
Female

Age

: 20-29
30-39
58

40-49
50-70
Profession

: ____________

Signature:

SECTION B:
1. Have you used a barbeque set before this?
Yes
No
2. What time usually you prefer to have barbeque?
Midnight
Morning
Afternoon
Evening
3. Do you agree that by having barbeque, we may pollute our environment?
Yes

No

4. Where usually you have your barbeque?

Home
Beach
Recreational Park
Others
5. Do you own a barbeque set?
Yes
No
6. If you want to buy a new set of barbeque grill, which are the specifications that you are
looking for? (You may tick more than one answer).
Portable
Gas-type griller
Multifunctional
Long lasting griller
Cheap
Faster burning griller
Smokeless
High safety
Adjustable height

59

SECTION C: Possible problem that occur when using barbeque grill.

Statement
7. Release a lot of smoke
8. Injuries might occur when changing the charcoal
The height of the barbeque grill cannot be adjusted and sometime
9.
causing muscle to cramp
10. The lifetime of the barbeque grill are too short
11. Barbeque grill use too much charcoal
12. Barbeque grill are too big and too heavy
The gas-type barbeque grill cannot produce the same result as
13.
charcoal-type.
14. Difficulties in changing or control the charcoal
15. Limited function

Agree

Disagree

16. Do you think that improvement have to be made to current barbeque grill? State your
reasons.
Yes

No

Metal melting point

Metal

Melting Point
o

( C)

(oF)

Admiralty Brass

900 - 940

1650 - 1720

Aluminum

660

1220

Aluminum Alloy

463 - 671

865 - 1240

Aluminum Bronze

600 - 655

1190 - 1215

Antimony

630

1170

Babbitt

249

480

Beryllium

1285

2345

Beryllium Copper

865 - 955

1587 - 1750

Bismuth

271.4

520.5

60

Metal

Melting Point
o

( C)

(oF)

Brass, Red

1000

1832

Brass, Yellow

930

1710

Cadmium

321

610

Chromium

1860

3380

Cobalt

1495

2723

Copper

1084

1983

Cupronickel

1170 - 1240

2140 - 2260

Gold, 24K Pure

1063

1945

Hastelloy C

1320 - 1350

2410 - 2460

Inconel

1390 - 1425

2540 - 2600

Incoloy

1390 - 1425

2540 - 2600

Iridium

2450

4440

Iron, Wrought

1482 - 1593

2700 - 2900

Iron, Gray Cast

1127 - 1204

2060 - 2200

Iron, Ductile

1149

2100

Lead

327.5

621

Magnesium

650

1200

Magnesium Alloy

349 - 649

660 - 1200

Manganese

1244

2271

Manganese bronze

865 - 890

1590 - 1630

Mercury

-38.86

-37.95

Molybdenum

2620

4750

Monel

1300 - 1350

2370 - 2460

Nickel

1453

2647

Niobium (Columbium)

2470

4473

Osmium

3025

5477

Palladium

1555

2831

Phosphorus

44

111

Platinum

1770

3220

Plutonium

640

1180

Potassium

63.3

146

Red Brass

990 - 1025

1810 - 1880

Rhenium

3186

5767

Rhodium

1965

3569

Ruthenium

2482

4500

Selenium

217

423

Silicon

1411

2572

Silver, Coin

879

1615

61

Metal

Melting Point
o

( C)

(oF)

Silver, Pure

961

1761

Silver, Sterling

893

1640

Sodium

97.83

208

Steel, Carbon

1425 - 1540

2600 - 2800

Steel, Stainless

1510

2750

Tantalum

2980

5400

Thorium

1750

3180

Tin

232

449.4

Titanium

1670

3040

Tungsten

3400

6150

Uranium

1132

2070

Vanadium

1900

3450

Yellow Brass

905 - 932

1660 - 1710

Zinc

419.5

787

Zirconium

1854

3369

62