CHAPTER 1 INTRODUCTION Basically, we can say that the production of this product is to solve the problem that occurred

to the users especially housewife. An example of this problem is in squeezing coconut milk. Basically, to get the coconut milk, we have to squeeze the coconut grated by using manpower (hand) for several times. Thus, this process will take a lot of times and also the users will be exhausted after this process. Although, we know there are available coconut milk wringer using hydraulic on the market, but the size is bigger and that not suitable to keep at home because this product are created for a large production of coconut milks. Thus, its seemed impossible to put that on your house because of the sizes. Besides that, this product is very expensive to be owned by housewife at the present and that will be a waste of money except we want a large production for coconut milks. Apart from that, hydraulic coconut milk wringer need more attention in their maintenance because it consist of hydraulics system that are easily broken with problems such as leaking and stuck and it needed maintenance by a professional workers. Thus, this will cause the usage of a lot of money to the owner. So, we like to come out with new solution for all the problems by producing a new innovation called Coconut Milk Wringer Machine. Generally, this product is created to solve the problems that occur to the housewife when they squeeze the coconut grated to coconut milk. There are several advantages of this product compared to another product that is available right now. Firstly, this machine is portable, easy to move from one point to another and doesnt need a large space to store it. Secondly, its not very expensive and it can be owned by all users especially housewife. Finally, the most important, this
1

product doesnt require lot manpower, easy to operate and easy to maintenance because did not consist of complex equipment or machine that will cause a lot of maintenances.

1.0 Objective There are several objectives that we have to achieve in order to successfully complete this project: a. To design a machine that can promote the green technology program in Malacca. b. To produce a green technology machine that can be used as a household appliance. c. To produce a machine that can improve a dailys lifes work. d. To apply the knowledge that gained in class into this project.

1.1 Literatures Review The coconut milk need to be squeezed from coconut already grated. The method coconut milk that is overall using today is squeeze coconut milk by using the electricity. Although there is coconut milk wringer available on the market where it was operate by hydraulics power, but that is too big and very expensive. Thus, it was difficult to be moved from one place to a place another. Besides that, coconut milk wringer is using hydraulic system and there will be a leaking problem that will occur after a period time. If oil in this machine leak and enter into coconut milk, it would affect cooking use stated coconut milk. Say stated coconut milk already corrupt

and would cause poisoning to state cooking or otherwise prompt it would affect in health long run. Thus we come out with new solution for all the problems by producing a new innovation that we call Coconut Milk Wringer Machine. In short, by doing this project, wecan help the house wife in squeezing work coconut milk with ease thus saves time since this coconut milk wringer will help them make the job much better. From our review at this project, it is an improvement from the other coconut milk wringer that is at the market. Furthermore, this coconut milk wringer machine has more advantage than other coconut milk wringer because it has a There are several advantages compare to another product that available right now. Firstly, this machine was portable, easy to move from one point to another and doesnt need a large space to store it. Secondly, its not very expensive and it can be owned by all users especially housewife. Finally, the most important, this product doesnt require electricity and overall using the human power, easy to operate and easy to maintenance because it did not consists of complex equipment or machine that will cause a lot of maintenances.

1.2 Background Product The coconut milk need to be squeezed from coconut already grated. The method coconut milk that is overall using today is squeeze coconut milk by using the electricity. Although there is coconut milk wringer available on the market where it was operate by hydraulics power, but that is too big and very expensive. Thus, it was difficult to be moved from one place to a place another. Besides that, coconut milk wringer is using hydraulic system and there will be a leaking problem that will occur after a period time. If oil in this machine leak and enter into coconut milk, it would affect the cooked food using that coconut milk. As the stated coconut milk are already tainted, so it would cause food poisoning in the cooking or otherwise gave affect in our health in a long run. From our review, this project was created to solve the problems that occurred to the housewife when squeezing the coconut grated. The main our focus in this project is save energy electric, so we propose a machine that will powered by human energy. In short, Most of customers wanted the machine to be moveable, easy to use, energy saving, corrosion resistance, reliability, high volume in one time and residual of coconut not mixed up with milk. Our decision to choose using material of Plain Carbon Steel 40C8 is because of its low cost compared the Alloy Steel and it is easy to clean every part in the machine especially at cage part for putting the coconut milk. This material had not given a bad implication at our customer because it is not rust material thus being a rust resistant machine. Each function is important to make sure the product is acceptable and satisfy the customer needs. Besides that, the function will determine either the overall system is working or not.

Basically, this product is done by manually which is wringer modification human coconut milk to wringer coconut milk speed by rotate use the pedal at pulley. It does consist of several simple components and with different functions such as pulley, shaft, bearing and framework. Apart from that, this component can give more power and efficiency to get the milk from coconut.The part most important included the size of pulley because if largest diameter pulley,so the more little using human energy.

1.3 Scope Our scopes in this project are to decide the detailed functions and design requirements for the design. Then, we also should do conceptualize several approaches to our design. Besides that, we also assemble and do the detail drawings to show our design to others. We also build the model of Coconut Milk Wringer Machine that we have design. Before we choose this coconut milk wringer machine, we have design and sketch another coconut milk wringer machine. So, after we comparing the sketch, we look this coconut milk wringer machine has more advantage than other. Then, after Mr. Ir. Tan as our lecturer had accepted our proposal, we started doing this project.

1.4 Outline For Chapter 1 In this chapter we have mention about the introduction of coconut milk wringer machine. All about the coconut milk wringer machine we tell in this section. Then, we have told about the background of this product. After that, all problems that we have faced we told at this section. Lastly, for this chapter we have told about the scope, the objective and the outline for all chapters. For Chapter 2 For this chapter, we have mention about the design the problem formulation. We have done the customer survey and market study at area Melaka about the coconut milk wringer machine. Then, after done the survey and market study, we use the House of Quality Method (HOQ) , to determine raw score and the percentage of relative weight, the volume of cage take an important role in the design of coconut milk wringer machine we tell about the background that more focused on our project. The Engineering Design Specification (EDS) is a statement of what the product should be and should do. This is a constantly evolving document and subjected to change as the project progresses and as more information is learned.

For Chapter 3 For this chapter, we have told about the concept design phase. We also mention about the problem statement and show the Morphology Chart. After that, we mention about our initial sketching of conceptual design. Besides that, we have showed our five sketch design. From this five sketch design, we have choose one which have more advantage and easy to construct it. Then, in this section we also told more detail about our design and working mechanism. Then, the Weight Decision Matrix (WDM) is made to finalize the design of the coconut milk wringer used for this project. For Chapter 4 This chapter is made to discuss the configuration design concept of the Coconut Milk Wringer which involves the product specification, concept generation, and concept evaluation. At this level of design, it involves the sketch of each part with dimension and various design concepts with identification of gross requirement product. The base revenue from the sketch that is made, we decided to generate this product. We also study the functional decomposition in this chapter. For Chapter 5 This chapter will discuss about detail design drawing at each part and assembly the design. We also considered the BOM ( Bill Of Material) that we used for machine and make calculation to related between our project and our subject Mechanic Component Design.

For Chapter 6 All the result and discussion we told in this chapter. The results are including about the function all the part in our project such power screw, spring. This is last chapter in our report. This section includes about the conclusion and also recommendation of this project. 1.5 METHODOLOGY

START

Title selection, objectives and scope researh

Concept design development

Detail design

Design analysis

Succeed

NO

YES

Figure 1: Coconut Milk Wringer Process Operation Flow Chart

CHAPTER 2 DESIGN PROBLEM FORMULATION 2.0 CUSTOMER SURVEY SURVEY FORM The survey form was designed and distributed to consumer. The purpose of the survey is to gain information from customer about their needs toward our product. After getting the feedback from customer, an analysis was doing based on the survey form. The input or feedback that get will be evaluated to get the true need importance. 1) How much coconut milk you need to use for a month? < 20 coconuts 20 coconuts 30 coconuts > 30 coconuts

2) How much would you spend for a coconut wringer machine to assist you in extract coconut milk? Rm 50 Rm 80 Rm 100 > Rm 100

3) How much time you use for extracting coconut milk from one coconut? 5 minutes 10 minutes 20 minutes > 20 minutes

4) How do you feel if the coconut milk wringer machine is operated with motor but not manpower? Good satisfactory weak inadequate

5) In your opinion, give rating 1 to 5 for the most importance until least important? a. Cost e. Easy to clean b. moveable c. energy saving d. easy to use g. reliability

f. corrosion resistance

h. Not vibrate and making noise

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i. high volume in one time

j. Residual of coconut not mixed up with milk. 6) How much coconut that you expected can be saved after using the machine? 10% 30% 50% > 50%

7) How much coconut you wish to extract in one time by using this wringer machine? Half one one and half 2 or above

Table 2.0 Summary of responses from customer survey for coconut milk wringer machine for question number 5 Number of Responses Numbering a b c d e f g h I j with 5 rating 9 25 27 20 12 25 20 10 30 15 relative frequency 0.30 0.83 0.90 0.67 0.40 0.83 0.67 0.33 1.00 0.50

10

Bar Chart for Responses for question number 5

1.2 relative frequency 1 0.8 0.6 0.4 0.2 0 a b c d e option f g h i j 0.3 0.83 0.9 0.67 0.4 0.83 1 0.67 0.33 0.5

(a)

Pareto Plot
Relativee frequency of response, % 120 100 80 60 100 40 20 0 i c b f g option d j e h a 90 83 83 67 67

50

40

33

30

(b)

Figure 2.01

(a) Frequency of response plotted against option of question number 5 in conventional graph. (b) Frequency of response in percentage plotted against option of question number 5 as a Pareto diagram.
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ANALYSIS After getting the feedback from customer, an analysis was doing based on the survey form. The input or feedback that get will be evaluated to get the true need importance. Several questions were answered based on the customer survey to investigate the design problem. 1. Who is the customer or consumer? Housewife. 2. What product functions and or features does she / he want? Most of customers want the machine is moveable, easy to use, energy saving, corrosion resistance, reliability, high volume in one time and residual of coconut not mixed up with milk. 3. What will the operating condition be? The force needed to rotate the handle is not large and time taken is less to wringer the coconut milk. 4. How can each function be (quantitatively) measured? Identify each using engineering characteristics such as Force required to rotate

handle, Volume of cage, Toughness of material, Shape of machine, Power usage and Size of wringer. 5. How important is each function? Each function is important to make sure the product is acceptable and satisfy the customer needs. Besides that, the function will determine either the overall system is good working or not.

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6. What competitive products (or substitute products) exist? Coconut milk wringer machine that powered by motor. 7. How well do competitive products satisfy the customer? The machine can produce high volume of coconut milk with less time. 8. What features are missing from competitors products? There is using electrical as a power usage. But, we used human powered and the material that we used are made from non chemical substances. 9. How does customer satisfaction vary with each engineering characteristic? Depend on their needs that they think are the most important by giving and rating to each of customers need and engineering characteristic.

13

2.1 HOUSE OF QUALITY (HOQ) The important weight factor and rating that given in the HOQ was given based on the information from market study and bar chart for responses. Engineering characteristics Units N Force required to rotate handle mm mm W

Toughness of material

Customer requirements

Important weight factor

Shape of machine

Volume of cage

3 Cost Moveable 5 Easy to use 5 Easy to clean 4 Energy saving 5 Corrosion resistance 5 Reliability 5 Not vibrate and making noise 3 High volume in one time 5 Residual of coconut not mixed up with milk 5 Raw score Relative weight % Rank order

0.9 0.9

0.9 0.5 0.5 0.9 0.5 0.5

0.9

0.9 0.9 0.5 0.9 0.5 0.5 0.5 0.1 0.9 24.8 20.5 2

0.5 0.9 0.9 0.1 0.9 0.9 18.2 15.0 4

0.5 0.1 0.5 0.9 0.5 0.5 0.9 0.9 22.1 18.2 3

0.9 0.9 16.2 13.4 5

0.9 0.9 25.3 20.9 1

0.9 0.9 0.1 0.5 14.5 12.0 6

IMPORTANCE RATING 1Through 5 where 1-least important 5-most important

RELATIONSHIP MATRIX 0.9- strong 0.5-medium 0.1-weak Blank-none 14

Size of wringer

Power usage

FINDING / SUMMARY According to the HOQ method above, based on the raw score and the percentage of relative weight, the volume of cage take an important role in the design of coconut milk wringer machine. It ranks first position in engineering characteristics, and then follows by shape of machine, size of piston, power usage, force required, and then at last falls on the toughness of material characteristic. The volume of cage is the most important engineering characteristic that must be focused in choosing product concept and producing product. This is because this engineering characteristic has a large relationship with the customer requirement. By produce the large volume of cage, it is easy to be cleaned. Besides that, consumer can get the high volume of coconut milk in one time. As the result, they do not have to waste their energy to produce more value. The shapes of machine, size of piston and power usage are also very important. The shapes of machine must have a simple design. This is because, it will be easier for consumer to move, clean, and use it. In addition, the shape of machine must be stable so that there are no vibrations and noise will produce. The more vibration and noise produce the less reliability of the product. This engineering characteristic is also very important in order to make sure the customer requirement which is the residual of coconut not mixed up with milk is fulfill. The size of piston must approximately same with size of cage. If it not, the residual of coconut will mixed up with milk. Next is power usage. The customers want the machine that uses less power. In order to fulfill this requirement, we propose a machine that will powered by human energy. The last engineering characteristic is toughness of material. It seems like this not very important. The toughness of material that we need is not very large. This is because the machine is used to wring the coconut milk. So it not uses very high force. The impact that will be experienced by this machine is too low.

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2.2 ENGINEERING DESIGN SPECIFICATION (EDS) EDS can also be known as Product Design Specification (PDS). It is a single document that captures the whole teams understanding of the specific details of the design problem (Dieter, Dixon and Poli, Haik). In this document, it includes customer requirements, company requirements, engineering characteristics, constraints and customer satisfaction. The product design specification is a statement of what the product should be and should do. This is a constantly evolving document and subjected to change as the project progresses and as more information is learned. Detail is added as the design grows. The product design specification is driven by customer needs and the constraints imposed upon the system (such as operating environment and spatial environment). It is intended to show what you are trying to achieve, not what you will end up with. Table 2.21 NO 1. CRITERIA Volume of cage description of product DESCRIPTION By producing a large volume of cage, it is easy to be cleaned. Besides that, consumers can achieve a high volume of coconut milk at one time. So, energy is not wasted for producing more milk. 2. Shape of machine As the shape of machine having a simple design, it will be easier for consumer to move, clean, and use it. Even the shape of machine must be stable so that there are no vibrations and noise is produced.

16

3.

Size of wringer

The size of the wringer must approximately or if not nearly with the size of the cage. If not, the residual of coconut will mixed up with milk.

4.

Power usage

The customers want the machine that uses less power. In order to fulfill this requirement, we propose a machine that will powered by human energy. This way, the power usage is not so big.

5. 6.

Force required Material Toughness

The force required for our product is 54N. The toughness of material that we need is not very large. This is because the machine is used to wring the coconut milk. So it does not use very high force. The impact that will be experienced by this machine is too low.

7.

Movement

There are four wheels that are attached at the bottom of the frame of our machine. This way, you can set up this machine to any place that you want because it can be moved easily.

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CHAPTER 3 CONCEPT DESIGN PHASE 3.0 PROBLEM STATEMENT Nowadays, housewife use their own hand to wring the coconut milk. If they need a lot of coconut milk, they have to use more energy. Besides that, there are wringer machine that use electricity but it is consume a lot of electricity. Based on these situations, we would like to propose a new design for the coconut milk wringer machine that is powered by human energy. Since, this application no needs to use a lot of power. In this chapter, we will generate several design concepts by using morphology chart and choose the best concept by using weighted decision matrix.

18

3.1 MORPHOLOGY CHART

19

FINDING / ANALYSIS Based on the morphology chart above, there are several options of mechanism that used to perform the features for each of concept design. The first feature is housing. We are decided that not to include housing in our product design. This is because it is hard to clean the machine when there is housing. The second feature is handling. The design concept of handle is choosing based on the force required to work the machine. In this case, the force required to wringer the coconut milk is not large. Because of that our group was chose the option 4 for this feature. The design is simple and low cost. This type of handle did not have a pedal. Usually the pedal was design for comfortabality and safety for user. The pedal can prevent the users hand from any hurt. But, for this case, the force required to operate the machine is not large. So we think that it is not necessary to design a handle with pedal. Option 4 was chosen for the power transmission feature. The system for transmit power that chosen consist of horizontal and vertical threaded shaft. This system is the most efficient compared to the other options. For option 2 which is using gear is not efficient and need more energy to operate the system. In addition the cost is high. Same for option 1, the system needs a lot of force and energy to move the piston (wringer). Next feature is wringer. The shape of wringer chosen is circle or round. The reason for designing this shape is less of resistance in term of friction between the wringer (piston) and cage. This is because the size of wringer and cage are approximately same to avoid the residual of coconut not mixed up with milk. The circle or round shape is the best design to reduce the friction. For the cover cage, option 3 was chosen. This design is the most easier to be cleaned. For cage, option 1 is the best concept. This cage will screw fix with the cover cage compare to option 3, the cage is hang on the cover cage. This will cause vibration and motion during the operation. For the option 2, the shape is limiting the production of coconut milk only at the bottom half of cage. The last feature is body. The most suitable and stable design for body of machine is option 3.

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3.2 SKETCHING OF CONCEPT DESIGN

Figure 3.2.1 first concept

Figure 3.2.2 second concept

21

Figure 3.2.3 third concept

Figure 3.3.4 forth concept

22

Figure 3.2.5 fifth concept

23

3.3 WORKING MECHANISM AND PRODUCT FUNCTION FIRST CONCEPT The working mechanism of this concept is based on the human energy which transfers through rotating of handle. When we rotate the handle power screw, it will produce a force that moves the stem thread to go downward thus gives a force to move the wringer or piston downward and upward about the cage to get the coconut milk. As the wringer move down, the milk of the coconut is extracted from the coconut kernel. Next, using the handle, the power screw will move the wringer upward for the kernel to be taken out from the cage. SECOND CONCEPT For this concept design, it is quite different to any of other concept. One of it is that, its position is in horizontal. Another one is that, it has a cover attached to it and also, the wringer of the machine is not attached to the shaft. The working mechanism of this machine is just like the working mechanism of a screw. Put the handle into the hole of the wringer and then rotate it clockwise. When it has been attached to the wringer, it will push the wringer downwards to squeeze the milk out of the coconut. THIRD CONCEPT For the third concept, this design is quite simple compared to the other concept. The unique of this design is having adding feature which is housing. The housing is used to prevent anything that inclusion not gets into the machine. The machine will be operated by rotate the handle and then the threaded shaft that connected with it will moved the wringer or piston downward and upward about the cage to get the coconut milk.

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FORTH CONCEPT This concept used the spur gear system to transfer energy from handle to the wringer. By rotating the handle, the vertical shaft will rotate also, it will then lowering down the wringer. The wringer is then compressing the grated coconut. By using this working mechanism, it provides more power. Besides, it produces least noise when it is in operation. FIFTH CONCEPT As for the fourth concept, the design is made to maximize the quantity of milk to separate from the coconut kernel by having a funnel under the wringer. The machine uses the pulley system to move the power shaft thus moving the wringer upward or downward to extract the milk of the coconut from the coconut kernel. This will maximize the power used to move the wringer and save power used to move the handle.

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3.4 WEIGHTED DECISSION MATRIX (WDM) Concept 5 70 138.68 Plain carbon steel (40C8) 163.25 4.5 Concept 3 67 154.09 Plain carbon steel (40C8) 168.00 5 Concept 4 62 77.05 Steel Alloy (50 MPa) 151.72 2.5 Concept 2 58 61.64 Plain carbon steel (40C8) 150.27 2 Concept 1 54 95.46 Plain carbon steel (40C8) 153.94 3

Force required (N) Power usage (W) Toughness of material Size of wringer ( ) Shape of machine (n/a) Volume of cage (kg)

Hierarchical Objective Tree

Coconut Milk Wringer (1.0)

Performance (0.6)

Reliability (0.4)

Force required (0.4)

Toughness of material (0.3)

Size of wringer (0.4)

Shape of machine (0.2)

Power usage (0.3)

Volume of cage (0.4)

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Characteristic Force required Power usage Toughness of material Size of wringer Volume of cage Shape of machine

Parameter N W

Calculation 0.6 0.6 0.6 0.4 1.0 0.3 1.0 0.3 1.0 0.4 1.0 0.4 1.0 0.2 1.0

Weight factor 0.24 0.18 0.18 0.16 0.16 0.08

n/a kg n/a

0.4 0.4 0.4

The Score
Excellent 5 points Good Fair Bad 4 points 3 points 2 points

Very Bad 1 points

Based on the Weighted Decision Method (WDM) above, it is achieved that from the five designs made and the characteristic made, the best design for our product is design 5 with the raw score of 4.00. In second place is design 4 with the raw score of 3.40 followed by design 2 with raw score of 3.32. Fourth is design 3 with 3.04 and last is design 1 with 2.86. For the first characteristic that is the force required for the machine to work, design 5 achieves the highest score with 5 as its force used to work the machine is 54 N. It gets the highest score as the forces required to move the handle is the lowest thus making it easier to move the wringer and the power shaft for extracting the milk from the coconut kernel.
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Design 4 having the second lowest force required to move the wringer followed by design 3 with 62, design 2 with 67 and finally design 1 using the highest force. Then, the design required needs to use less power to move the wringer. So, design 4 has the highest score with 5 by having a power usage of 61.64 W. Second is design 3 with power usage of 77.05 W followed by design 3 with 95.06 W, design 1 using power of 138.68 W and in the end, design 2 uses the highest amount of power using 154.09 W. The toughness of the material is essential as the toughness that we need is not too high. The reason is because the machine is used in wringing the coconut milk. So it does not use very high force. This will make the impact that is experienced by this machine to become too low. So, the design 1, design 2, design 4 and design 5 uses plain carbon steel (40C8) as the toughness is not too high thus having the best score with 5. Only design 3 uses steel alloy for the material of gear as it is a strong material to withstand the forces made to move the wringer using the handle. For the size of the wringer, by having a bigger wringer, it will maximize the quantity of milk extracted from the coconut kernel. So, design 2 gets the highest score of 5 by having the biggest size of wringer with 168.00 . Next is design 1 having a size of wringer of 163.25 . Third .

is design 5 with the size of wringer of 153.94

followed by design 3 with size of 151.72 .

In last place is design 4 with the size of wringer of 150.27

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The volume of the cage is also important as by having a large volume of cage, it will be easier for the users to clean the machine. Moreover, even they can accumulate a high amount of coconut milk at one moment. Thus, energy is not wasted for producing more milk. The design with the biggest volume of cage is design 2 with 5.0 kg followed by design 1 with 4.5 kg. In third place is design 5 with the volume of 3.0 kg. Design 3 having a volume of cage of 2.5 came in fourth and design 4 came last with 2.0 kg. By the shape of machine having a simple yet elegant design, it will be easy for users in moving, cleaning, and using the coconut milk wringer. The shape of machine must be stable so that no vibrations and noise are produced from the machine. Design 5 came in first having the most favorable shape of machine with design 4 came in second. Third is design 3 followed by design 2. The least favorable design is design 1 as it is known to be too complicated as it has the large amount of component for assembly. In conclusion, the best design that achieved the targeted concept is the design 5 as it is the best concept among the five concept made.

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W e i g h t Characteristic f a c t o r 0 . 2 4 0 . 1 8 0 . 1 8 0 . 1 6 0 . 1 6 0 . 0 8

Design 1

Design 2

Design 3

Design 4

Design 5

Factor unit

Magnitude

S c o r e

Rate

Magnitude

S c o r e

Rate

Magnitude

S c o r e

Rate

Magnitude

S c o Rate r e

Magnitude

S c o r e

Rate

Force required

70

0.24

67

0.48

62

0.72

58

0.96

54

1.20

Power usage

138.68
Plain carbon steel (40C8)

0.36

154.09
Plain carbon steel (40C8)

0.18

77.05
Steel alloy ( 50 MPa)

0.72

61.64

0.90

95.06
Plain carbon steel (40C8)

0.54

Toughness of material

n/a

0.90

0.90

0.72

Plain carbon steel (40C8)

0.90

0.9

Size of wringer

163.25

0.64

168.00

0.80

151.72

0.32

150.27

0.16

153.94

0.48

Volume of cage

kg

4.5

0.64

5.0

0.80

2.5

0.32

2.0

0.16

3.0 Excellent

0.40

Shape of machine

n/a

Very Bad
2.86 5

0.08

Bad

2 3.32 3

0.16

Fair
3.04 4

0.24

Good
3.40 2

0.32

5 4.00 1

0.40

Raw score Rating

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CHAPTER 4 CONFIGURATION DESIGN 4.0 PART DESCRIPTION After doing analysis in concept design phase, concept design number one was chosen as our product design concept. The concepts having 9 basic parts which are cage, cover cage, wringer, center shaft, horizontal shaft, disc, handle, bearing and frame. In this chapter, in order to design this machine, the dimension of each basic part must determine.

COMPONENTS 1.Cylinder cage

DESCRIPTION Use to filter coconut cake by its drilled hole and place to transmit coconut milk that has been squeezed.

2. Casing

A temporary container used to cover the finish filtered coconut milk from the cylinder cage to the container.

31

3. Wringer

Use as a compressor to compress the grated coconut to wring out coconut milk.

4. Center shaft

Rotated by the horizontal shaft to move down the wringer to compress grated coconut milk.

5. Horizontal shaft

Transmits work from the handle to the center shaft by rotating the center shaft with its rotating thread.

6. Disc

Connect between the handle and the horizontal shaft.

32

7. Handle

Handled by human to rotate the horizontal shaft to control the movement of wringer either up or down.

8. Frame

Use to place all the component parts and act as a body to move the whole machine.

9. Shaft Support

Use to launch movement and support the horizontal shaft.

33

10. Roller

Connected to the frame legs to move the machine by rolling.

34

4.1 BASIC DIMENSION All dimensions are in millimeter (mm)

35

36

4.2 FUNCTIONAL DECOMPOSITION Functional decomposition is the second type of representation strategy usually in early stages of concept generation. It emphasis on identifying the functions and sub functions which are required to achieve the overall behavior defined by the PDS. For the coconut milk wringer machine, its functional decomposition can be represented as below:

Coconut Milk Wringer Machine

Cylinder Cage

Casing

Frame

Roller

Wringer

Handle

Center shaft

Horizontal Shaft

Disc

Shaft support

37

CHAPTER 5 DETAIL DESIGN 5.0 DRAFT SOLID MODEL

38

5.1 TECHNICAL DRAWING 5.1.1 DETAIL DRAWING AND BOM

39

5.1.2 CYLINDER CAGE

40

5.1.3 WRINGER

41

5.1.4 CENTER SHAFT

42

5.1.5 HORIZONTAL SHAFT

43

5.1.6 DISC

44

5.1.7 HANDLE

45

5.1.8 FRAME

46

5.1.9 SHAFT SUPPORT

47

5.1.10 ROLLER

48

5.1.11 ASSEMBLY DRAWING

The operation sequences of the coconut milk wringer machine are listed below: 1. Lift the wringer up by rotates the handle. 2. Pour the grated coconut into the cylinder cage. 3. Set the wringer back to its original place at the center shaft. 4. Before rotates the handle, place a container under the outlet of the casing. 5. Rotates the handle, the handle will then rotate the disc in which it will also rotates the horizontal shaft. 6. The threaded horizontal shaft will then mate with the center horizontal shaft. 7. The rotation of the horizontal shaft will then move the center shaft in vertical direction. 8. The wringer is then moving down to compress the grated coconut.

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9. Coconut milk is then squeeze out by the compression of the wringer and flow out to the casing from the cylinder cage. 10. The residual of grated coconut remains in the cylinder cage. 11. Collect the coconut milk with container. 5.2 DESIGN ANALYSIS AND CALCULATION 5.2.1 Maximum capacity for load 3 kg for grated coconut = 12 of coconuts Where, we can get 1 liter of coconut milk from 1 kg of grated coconut. So, from 3 kg grated coconut, we can get 3 liter of coconut milk. We assume that, that maximum capacity load for this machine is only 3 kg per cycle. F = mg = (3+0.5) (9.81) = 34.335 N

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5.2.2 Static load analysis Figure shows a crank located by a force F= 1000 N that cause twisting and bending of a 20 mm diameter shaft fixed to a support at the origin of the references system. In actuality, the support may be an inertia that we wish to rotate, but the purpose of the stress analysis we can consider this as static problems. As suggested in theoretical, the steps to analysis this handle part will follow those steps. i. ii. iii. iv. Sketching of a free-body diagram. Identify the kind of analysis to be performed( in this case, we consider as static) List all data and assumptions. Write formulas to be used in symbol form, indicating the values and units of variables involved.

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Free Body Diagram BC

F = 1000 N

Tc

C Y 130 mm

B T2 Z M2 Y

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Free Body Diagram AB

MA TA A F = 1000 N B 140 mm F = 1000 N M2 T2 Z

Analysis From the analysis problem, we firstly list down all the information that we have. 1 = 20 mm L1 = 140 mm L3 = 130 mm 2 = 20 mm L2 = 100 mm F = 1000 N

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At end C of arm BC Force components: F, TC F = -1000j N TC = F x L2 = (-1000 N) x (100 mm) = -100 kN.mm At end B of arm BC Force components: F = 1000j N M1= F x L3 = 1000 N x 130 mm = 130i kN.mm T1 = F x L2 = 1000 N x 100 mm = 100k kN.mm

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At end B of shaft AB Force components: F, T2, M2 F = -1000j N T2 = F x L3 = (-1000 N) x 130 mm = - 130i kN.mm M2 = F x L2 = (-1000 N) x 100 mm = -100k kN.mm At end A of shaft AB Force components: F, MA, TA F= 1000j N TA = F x L3 = (1000 N) x 130 mm = 130j kN.mm MA = 312 k kN.mm

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For arm BC, the bending moment will reach a maximum near the shaft at B. If we assume that is 130 kN.mm, then the loading stress for a rectangular section will be:

Of course, this is not exactly correct, because at B the moment is actually being transferred into the shaft, probably through a weldment. For the torsional stress, we are use equation as below to compute the value. Thus we have;

This stress occurs at the middle of the BC component. For element at A, the bending stress (x direction) is tensile (xy direction) and;

and the torsional stree is (xy direction) ;

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Where the reader should verify that the negative sign accounts for the direction of xz. Point A is in a state of plane stress where the stresses are in the xz plane. Thus the principle stresses is obtain by using the below formula. The maximum normal stress is then given by:

= 664.08 MPa

The maximum shear stress at A occurs in surfaces different than the surfaces containing the principle stresses or the surface containing the bending and torsional shear stresses. The maximum shear stress is given by below Equation:

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5.2.3 Shaft Shaft description: Plain carbon steel 40C8 D = 20 mm L = 400 mm Syt = 380 MPa max = Mb = 850 N.m Mt = 0

max = max =

Ssy = 0.5 Sut = 0.5 ( 380 ) = 190 N/mm F.S = Ssy max =

= 0.35
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5.2.4 Power screw analysis

Power screw specification: Major diameter, d = 20 mm Mean diameter, dm = 17 mm Pitch, P = 10 mm Thread depth, = 3mm Thread width = 3mm Minor diameter dr = 14 mm

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Lead, l = 8mm Coefficient of friction, = 0.08

Torque produced when raising the wringer,

TR =

++

= 13.60 +7.68 = 21.28 N.m Torque produced when lowering the wringer,

TL =

++

= 0.276+7.68 = 7.956 N.m

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5.2.5 Spring analysis d = 2 mm OD = 20 mm D = 18 mm Ls = d Nt = (2) (10) = 20 mm From table 10-4, we find that A= 2211 MPa.mmm Sut = A Dm = 2211 2(0.145) = 1999.58 MPa Ssy = (x) (Sut) = (0.45) (1999.58) = 899.81 MPa m= 0.145 plain ground ends, Nt = 10 coils music wire material

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Fsy =

.Ssy 8Kb.D

Kb =

C=

=9

Kb =

= 1.152 Fsy = (899.81) 8(1.152) (18) = 136.32 N 5.2.7 Permanent Joint- Welding Torsion From Table 9-1, A=1.414hr = 1.414(10)(10) = 444.22 mm2 Ju = 2r3 = 2(10)3 = 6283.19 mm3
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 = V/A = (1k)/(444.22) =2.251 MPa = Mr/J M = P.x = (1k)(80) = 80kNmm r = 10mm J =0.707hJu = 0.707(10)(6283.19) = 44422.15 mm4 = (80k)(10) / (44422.15) = 18.01MPa max = = = 18.15MPa FS = Ssy / max
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Ssy = 0.577Sut Sut for a steel AISI 1018 = 341MPa Ssy = 0.577(341) = 196.76MPa FS = 196.76/18.15 = 10.84 Bending From Table 9-2, A=1.414h (b+d) = 1.414(20)(78+52) = 3676.4 mm2 Iu = (d2/6) (3b+d) = (522/6) (3(78) +52) = 128890.67 mm3 = P/A = 5k/ 3676.4 = 1.36 MPa

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 = Mc/I M = P.x = (5K)(56) = 280kNmm c = 26mm I =0.707hIu = 0.707(20)(128890.67) = 1822514.07 mm4 = (280k)(26) / (1822514.07) = 3.99MPa max = = = 4.21MPa

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CHAPTER 6 CONCLUSION AND RECOMMENDATION In short, we have design a product called coconut wringer machine. Our coconut wringer machine used a pulley to operate the wringer to squeeze the milk from the grated coconut. Thus, this machine is an environmental friendly machine where as this machine only uses human power. By producing this machine, we have successfully produced a machine that can promote the green technology program in Malacca. This machine also can be used as household appliances where as the user of this machine are the housewives. Also, this machine can improve the dailys lifes work of the housewives because rather than squeezing the coconut milk using their own hands, instead they can use this machine and can produce the coconut milk in a large quantity. By doing this project, all of our knowledge that we have gained during class can be applied to it. The used of HOQ and EDS that we learned in class, we have applied to this project and we have shown it in Chapter 2 Design Problem Formulation. Besides that we can nurture our soft skills in terms of working in group. Without good communication with other group members, we cannot successfully finish this project. For the recommendation, we can substitute the used of manpower with the used of an electric motor. This way it will be much more convenient for the consumer and also, it is still an environmental technology machine because it only uses electric power. We can also use recyclable material to produce this coconut wringer machine so that we can cut the cost. Another feature that we can add to this machine is a device that can supply water automatically for cleaning purpose after this machine has been used.
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REFERENCES

1. http://ms.wikipedia.org/wiki/Santan 2. http://www.bio-asli.com/minyak_kelapa_dara.asp 3. http://www.engineersedge.com/spring_comp_calc.htm 4. http://en.wikipedia.org/wiki/Sustainable_design 5. desaku@streamyx.com 6. Roslan Abdul Rahman, Che Abas Che Ismail dan Mohd Yunus Abdullah, 2003, Mekanik mesin, Penerbit UTM, Johor. 7. Richard G. Budynas, J. Keith Nisbett, Shigleys Mechanical Engineering Design, Eighth Edition in SI units, Mc Graw Hill 8. Amarasiri WA, Dissanayake AS (June 2006). "Coconut fats". Ceylon Med J 51 (2): 4751. 9. Abercrombie, Stanley (1995). George Nelson: The Design of Modern Design. MIT
Press

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