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DESIGN AND FABRICATION OF ICE CRUSHER
Ramfauzan bin Ramlee
Bachelor of Engineering with Honours
(Mechanical Engineering and Manufacturing System)
2006
Faculty of Engineering
UNIVERSITY MALAYSIA SARAWAK
BORANG PENYERAHAN LAPORAN PROJEK TAHUN AKHIR
Judul: DESIGN AND FABRICATION OF ICE CRUSHER
SESI PENGAJIAN: 2005/2006
Saya, RAMFAUZAN BIN RAMLEE (HURUF BESAR)
mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik,
Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan untuk tujuan pengajian sahaja.
3. Membuat pendigitan untuk membanguankan Pangkalan Data Kandungan Tempatan.
4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
5. ** Sila tandakan (√) di kotak yang berkenaan.
SULIT (Mengandungi maklumat yand berdarjah keselamatan atau kepentingan Malaysia
seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di
mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
_______________________________ ________________________________
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap: No. 20 Kampung Perintah Gedong Dr. Mohd. Shahril b. Osman
94700 Serian
Sarawak
Tarikh: _____________ Tarikh: _________________
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda
** Jika tesis ini SULIT dan TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai
SULIT dan TERHAD.
APPROVAL SHEET
This project report attached here to, entitle “Design and Fabrication of Ice
Crusher” was prepared and submitted by RAMFAUZAN BIN RAMLEE - 9676 as
partial fulfilment of the requirement for the degree of Bachelor of Engineering with
Honours in Mechanical Engineering and Manufacturing System is hereby read and
approve by:
_____________________ __________________
Dr. Mohd. Shahril b. Osman Date
Supervisor
ii
ACKNOWLEDGEMENTS
Alhamdulillah, Thank God for all His blessing I was able to complete this
Final Year Project. First of all, I would like to thanks my supervisor, Dr. Mohd.
Shahril bin Osman for the patience, excellent supervision and encouragement to me
in completing my final year project successfully.
Apart from that, I would like to thank the technicians especially to Mr. Masri
who involved in guiding through fabricating session on this project. They do not
hesitate helping me solving the problems and difficulties which I faced during
fabricating my project.
Also special thanks to my family and my loved one for their moral support.
Finally, thanks to all my friends who have given me an advice and suggestion on
completing this project.
iii
ABSTRACT
In order to serve fast cold drink, the user just needs to add ice in their drink as
a simple alternative rather than using freezer. Ice crusher machine is the way to crush
the ice into the small texture. The smaller the ice’s texture the faster it cools the
drink. Ice crusher machine can be divided into two major types that are ice block
crusher machine and ice cube crusher machine. However, the existing ice crusher
machine still having problems in term of safety, mechanism of motion, texture of ice
produced and the maximum size of ice that it can be hold for producing ice flakes.
This project is focusing on redesigning and constructing a new block ice crusher
machine. Therefore, several of the problems of the existing machine need to be
reduced and eliminate. Several parameters are discussed and analysed in order to
build the new machine in term of cost, material selection and manufacturing
selection.
iv
ABSTRAK
Dalam penyediaan minuman sejuk segera, pengguna hanya perlu meletakkan
ais dalam minuman mereka sebagai pilihan mudah berbanding menyejukkan
minuman di dalam peti sejuk. Mesin pengisar ais menyediakan cara untuk mengisar
ais menjadi ketulan ais yang kecil bagi keperluan pengguna. Semakin kecil tekstur
ais semakin cepatlah ais menyejuk minuman. Mesin pengisar ais boleh dibahagikan
kepada dua jenis utama iaitu mesin pengisar bongkah ais dan mesin pengisar kiub
ais. Walaubagaimanapun, mesin pengisar ais terkini masih mempunyai masalah-
masalah yang berkaitan dengan keselamatan, mekanisma pergerakan, tekstur ais
yang dihasilkan dan saiz maksimum ais yang boleh dipegang dalam pemprosesan.
Projek ini memfokuskan tentang merekacipta semula dan membina sebuah mesin
pengisar bongkah ais terbaru. Oleh itu, beberapa masalah-masalah yang terdapat
pada mesin pengisar ais terkini perlu dihapuskan dan dikurangkan. Beberapa
parameter dibincangkan dan dianalisa dalam membina mesin terbaru dari segi kos,
pemilihan bahan dan pemilihan pembuatan.
v
CONTENTS
ACKNOWLEDEMENT ii
ABSTRACT iii
ABSTRAK iv
CONTENTS v
LIST OF TABLES viii
LIST OF FIGURES ix
ABBREVIATION xii
CHAPTER 1 1
INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 2
1.3 Aim and Objective 3
CHAPTER 2 4
LITERATURE REVIEW 3
2.0 Introduction 4
2.1 Overview of Ice Form and Processing 4
2.2 Traditional Ice Block Crusher 6
2.3 Manual Ice Block Crusher 7
2.4 Motorised Ice Block Crusher 8
2.5 Summary 9
vi
CHAPTER 3 10
METHODOLOGY 10
3.0 Introduction 10
3.1 Basic Step in Designing 11
3.1.1 Study on Relevant Subject 11
3.1.2 Design the Ice Crusher Machine 12
3.2 Concept Generation 14
3.2.1 Brainstorming 14
3.2.2 Mind Map 15
3.2.3 TRIZ Approach in Problem Solving 16
3.3 Material Selection 21
3.3.1 Steel and other Material Selection 22
3.4 Manufacturing Selection 24
3.4.1 Equipment Selection 24
3.5 Shaft Analysis 26
3.5.1 Selection Procedure 27
3.6 Pulley Selection 28
CHAPTER 4 29
ICE CRUSHER DESIGN 29
4.0 Introduction 29
4.1 Existing Machine: Electric Ice Shaving 30
4.1.1 Specifications 31
4.1.2 Disadvantages of Electric Ice Shaving 31
4.1.3 Part that has to be improved 32
vii
4.1.4 Comparison between Existing Machine and New Redesign 33
4.1.5 Design Concept 34
4.2 Propose Design 36
4.2.1 Part Fabrication 36
4.3 Summary 41
CHAPTER 5 43
CONCLUSION AND RECOMMENDATION 43
5.1 Conclusion 43
5.2 Recommendation 44
REFERENCES 45
APPENDICES
APPENDIX A: Parts Features 46
APPENDIX B: Drawing 47
APPENDIX C: Figures 48
viii
LIST OF TABLES
Table 3.1 Basic Design consideration 12
Table 3.2 Design Consideration 13
Table 3.3 Engineering Parameter in TRIZ 18
Table 3.4 The Inventive of TRIZ 19
Table 3.5 General Properties of Steel 23
Table 3.6 Parts, Material and Processes 24
Table 4.1 Specification of Electric Ice Shaving 31
Table 4.2 Ice Block Crusher Comparison 33
ix
LIST OF FIGURES
Figure 2.1 Traditional Handmade Ice Crushing Machine 6
Figure 2.2 Manual Ice Crusher 7
Figure 2.3 Motorised Ice Shaving 8
Figure 3.1 Basic Steps in Design 10
Figure 3.2 Concept Map for Redesigning Ice Crusher Machine 15
Figure 3.3 General Problem Solving Model 20
Figure 3.4 Interrelations of Design, Materials and Proccesing 21
Figure 3.5 Shaft Parameters 27
Figure 3.6 First Pulley Diameters 28
Figure 4.1 A Block of Ice 29
Figure 4.2 Electric Ice Shaving 30
x
Figure 4.3 Concept 1 34
Figure 4.4 Concept 2 35
Figure 4.5 Concept 3 35
Figure 4.6 Blade Holder Frame 37
Figure 4.7 Blade Holder 37
Figure 4.8 Blade 38
Figure 4.9 Pulleys, Shaft and Joint 39
Figure 4.10 Ice Pusher Components 40
Figure 4.11 Body Frame 40
Figure 4.12 Propose Design 41
DESIGN AND FABRICATION OF ICE CRUSHER
RAMFAUZAN BIN RAMLEE
This report is submitted to Faculty of Engineering University Malaysia Sarawak
(UNIMAS) as to fulfil the requirements of Bachelor Degree Program
Mechanical Engineering and Manufacturing System
Faculty of Engineering
UNIVERSITI MALAYSIA SARAWAK
2006
xii
ABBREVIATION
ABC Air Batu Campur
QFD Quality Functional Deployment
PDS Product Design Specification
TRIZ Theory of Inventive Problem Solving
ARIZ The Algorithm of Inventive Problem Solving
Chapter 1 Introduction
1 Design and fabrication of ice crusher
CHAPTER 1
INTRODUCTION
1.0 Background
Almost every restaurants, cafés and others eating places, there will be menus
of cold drinks. The need of fast serving of cold drinks is essential in this field of
business. There are ways to quickly serve cold drink such as refrigeration or by
adding ice. Type of ice is categorized into 4 types which are ice tube, ice cube, ice
flake and ice block.
However some cold beverages need ice in finer shapes, smaller than ice
flakes. ABC or ‘Air Batu Campur’ for instance, needs the finer ice to create rapid
cooling of the beverage thus making it colder than other cold drinks. This ice is
created by ice crusher machines from bigger form of ice such as ice tubes or ice
block.
Ice crusher machines are divided into two groups. There are tube ice crusher
machine and block ice crusher machine. Most mobile business use tube ice crushers
while most permanent business uses block ice crushers. Block ice crushers are
commonly much bulkier and heavier than the cube ice crusher counterparts. The ice
tube crusher machines are generally much more compact and take up far less space.
Chapter 1 Introduction
2 Design and fabrication of ice crusher
Before the ice crushing machines were invented, the crushing of ice was done
by utilizing the ice pick. The ice-pick resembles the shape of a tooth pick but bigger
in size and it is made out of stainless steel. This method required the operator to stab
the ice to induce crack that breaks the block of ice into smaller sizes. The
disadvantages of this method are the size of the ice is irregular, lack of safety and
very tiring to operators.
Other traditional method to crush the block ice is used by handmade ice block
machine. This machine body is made from wood and the blade is made from metal.
The ice holder also made from the wood. The ice is hold by using nails that being
punch through the ice holder.
New constructions of ice crusher machines are designed to ease the process.
There are various types of ice crusher machines which maybe manual and motorised.
There machines are constructed to crush the different shape of ice like ice cube or ice
tube, ice block and ice flake. Ice crusher machines sometimes call ice shaver
machine.
1.1 Problem Statement
There are several problems occur in the existing ice crusher machine. From
research and study that had been made referring to the existing machine, the main
problems are:
Chapter 1 Introduction
3 Design and fabrication of ice crusher
1. The ice produces is not fine, so the quality of the ice texture need to be
improves.
2. Lack of safety. The operator of the machine is exposed to the falling ice block
during rotating and the rotating ice block gripper that can cause injury to the
operator.
3. The limitation of ice block size that machine can hold before crushing.
Therefore, the quantity of ice produces is low because of the small size of ice
block that can be hold in a certain time.
1.2 Aim and Objective
The aim of this project is to design and construct a new ice block crusher
machine. The objective is to improve the existing machine problems.
Chapter 2 Literature Review
4 Design and fabrication of ice crusher
CHAPTER 2
LITERATURE REVIEW
2.0 Introduction
The purpose of this chapter is to study the parameters that are involved in
designing the ice crusher machine. The scope of the project is based on the objectives
that are stated in the first chapter. The relevant subjects are studied to be used as a
guide for this project. This chapter is also focus on the principle operation of ice
crusher machine. A few examples of the existing ice crusher machines will be studies
in order to design the ice crusher machine.
2.1 Overview of Ice Form and Processing
The forms of the ice commonly can be divided into three categories. Ice
block, ice tube and the ice flake. The purpose is to serve as cold drink and beverage
applications.
The traditional form of ice is the ice block. It is formed in the can which the
dimension and temperature is usually selected to give a freezing period of between 8
and 24 hours. Rapid freezing results in brittle ice. The weight can vary from 12 to
150 kg, depending on requirements. The thicker the block ice would result of longer
freezing time. Blocks ice of less than 150 mm thick are easily broken and a thickness
of 150 to 170 mm is preferable to prevent the block toppling. The size of the tank
required is related to the daily production. Block ice are still in use for many
Chapter 2 Literature Review
5 Design and fabrication of ice crusher
applications. With an appropriate ice crushing machine, the ice block can be reduced
to any particle size without the guarantee of uniformity in size. In some situations,
ice block may also be reduced in size by a manually picking the ice block using an
ice-pick.
Another shape of ice is the ice tube. It is formed on the inner surface of
vertical tubes and is produced in the form of small hollow cylinders of about 50 x 50
mm with a wall thickness of 10 to 12 mm. The ice tube plant arrangement is similar
to a shell. The condenser with water on the inside of the tubes and the refrigerant will
fill the space between the tubes. The machine is operated automatically on a time
cycle and the tubes of ice are released by a hot gas defrost process. As the ice drops
from the tubes a cutter chops the ice into suitable lengths, nominally 50 mm.
However, the size can be adjustable. Ice tube is usually stored in the form it is
harvested, but the particle size is rather large and unsuitable for use with fish. The
discharge system from the plant therefore incorporates an ice crusher which can be
adjusted to give an ice particle size to suit the customer's requirement.
Ice flake is formed on one face of a refrigerated vertical plate and released by
running water on the other face to defrost it. The optimum ice thickness is usually 10
to 12 mm and the particle size is variable. An ice breaker is required to break the ice
into a suitable size for storage and use.
Chapter 2 Literature Review
6 Design and fabrication of ice crusher
2.2 Traditional Ice Block Crusher
The traditional method to crush the block ice is shown in Figure 2.1. The
body is made from wood and the blade is made from metal. The ice block holder also
made from the wood. The ice is hold by using nails that being punch through the ice
holder. The operator pushes the ice block on the machine body where the blade is
located at an angle direction and the ice block is sliced to produce ice flakes. The
blade is adjusted by using hammer. However, the size of the ice block must be
adjusted to fit the width of the ice holder.
Figure 2.1: Traditional Handmade Ice Crushing Machine
Chapter 2 Literature Review
7 Design and fabrication of ice crusher
2.3 Manual Ice Block Crusher
The ice block crusher machine as in Figure 2.2 is popular for home use and
small businesses. The body is made from cast steel. For crushing the ice block, a
single blade is positioned at the copper holder. The blade is fixed in angle position
and can be adjusted manually. Gears are fixed within the body to transfer the motion
from the rotation of spindle by user to the ice holder. The ice holder is in vertically
position and is rotated in counter clockwise to give some force to the ice block. The
blade then crushes the rotation of the ice block and reduces it into small particle ice.
Figure 2.2: Manual Ice Crusher
Chapter 2 Literature Review
8 Design and fabrication of ice crusher
2.4 Motorised Ice Block Crusher
The development of the manual ice block crusher machine produced a new
method of the same concepts that is a motorised one. Two pulleys are fixed in the
shafts of the ice holder and the electric motor. Production of the small particles of the
ice becomes much faster and the quantity of the ice flakes is increased. Therefore, it
becomes popular for the medium size business and shows in Figure 2.3.
Figure 2.3: Motorised Ice Shaving
Chapter 2 Literature Review
9 Design and fabrication of ice crusher
2.5 Summary
The important subject in this project is the forms of the ice that is going to be
crushed. The scope of the project is to redesign the ice block crusher, all parameters
of the ice block is studied. The parameters are the weight of ice block, size, length
and other characteristic.
Traditional ice crusher to existing ice crushers are studied in part. For the
purpose of study, the study and design in order to redesign the ice crusher is focused
on the selected machines that will be used as references.
The existing ice crusher needs to be redesigned due to improve the quality of
ice textures produces, quantity of the ice produce in a certain period and safety. The
limitation of existing ice crusher is the maximum ice block size that can be hold
before crushing it into ice flakes. From the study, the maximum of ice block size is
about 6” x 6” x 5”. With the limitation of size, the operator only can produce a small
quantity of ice flake at a time. Therefore, the operator needs to crush the ice again in
order to increase the quantity of ice flakes. Other limitation is the texture of ice
produced. The ice texture is not fine enough due to using a single blade that static on
the copper blade holder. The single blade is easy to be dull and needs adjustments
frequently in order to make sure the blade cut the ice block during processing.
Chapter 3 Methodology
10 Design and fabrication of ice crusher
CHAPTER 3
METHODOLOGY
3.0 Introduction
This chapter described about the method in order to achieve the objective to
redesign new ice block crusher. Figure 3.1 shows the basic steps in design that will
be discussed in this chapter [1]. Some calculations for the analysis purposes are also
discussed.
Figure 3.1: Basic Steps in Design [Dieter, 1986]
Gather
Information
Internet
Patents
Trade
literature
Concept
Generation
Brainstorming
Functional
decomposition
Morphological
chart
Define Problem
Problem Statement
Benchmarking
QFD
PDS
Project planning
Evaluation of
Concept
Pugh concept
selection
Decision
matrices
Configuration
Design
Preliminary selection
materials and
manufacturing
Modeling and sizing
of parts
Parametric
Design
Robust design
Final
dimensions
Tolerances
DFM
Detail
Drawing
Detail
drawings and
specifications
Product
Architecture
Arrangement
of physical
elements to
carry out
function