Report Projek

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FIGURE LIST ` pg

Figure 2.1.1: Show the Boat Land after Netting Fish

Figure 2.1.3: Base example

Figure 4.1.1: Belting system

Figure 4.2.1: Structure of gear

Figure 4.3.1: Structure of polymer

Figure 4.4.1: Machine 1



Figure 6.1.1: Electrical Motor

Figure 6.2.1.1: Female Gear

Figure 6.2.2.2: Male Gear

Figure 6.3.1: Winch

Figure 6.4.1: Bearing

Figure 6.5.1: Shaft Holder

Figure 6.6.1: Worm gear holder

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Figure 6.7.1: Coupling

Figure 6.12.1: Basement

Figure 7.1.1: How to tight the base

Figure 7.4.1: How to hanging by cable

Figure 7.5.1: Process Drag the load

Figure 8.3.1: Product design (by using solid work)

Figure 8.3.2: Detail drawing

Figure 8.3.3: Part drawing

Figure 12.1.1: Assembly Drawing (Female Gear)

Figure 12.1.2: Assembly Drawing (Male Gear)

Figure 12.1.3: Assembly Drawing (Winch)

Figure 12.1.4: Assembly Drawing (Bearing)

Figure 12.1.5: Assembly Drawing (Shaft Holder)

Figure 12.1.6: Assembly Drawing (Worm gear holder)

Figure 12.1.7: Assembly Drawing (Coupling)

Figure 12.1.8: Assembly Drawing (Shaft)

Figure 12.1.9: Assembly Drawing (Bush)

Figure 12.1.10: Assembly Drawing (Basement)

TABLE LIST

Jadual 6.2.1 : Spesifikasi Am Enjin Proton Satria 1.3 (M) 19

Jadual 8.0.1: Senarai komponen yang digunakan 30

Jadual 8.2.1: Anggaran kos bahan 35

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LIST OF CONTENT

1.0 ABSRACT 7

2.0 INTRODUCTION 8

2.1 Problem Statement 8

2.2 Design Concept 10

3.0 OBJECTIVE 11

3.1 Overal Objective 11

3.2 Main Objective 11

4.0 LITERATURE REVIEW 12

4.1 Belt and Chain System 12

4.2 Gear System 13

4.3 Type of Material 16

4.4 Available Boat Winch at Pantai kundur and Pantai Puteri 18

5.0 IMPLEMENTATION METHOD 21

6.0 COMPONENT 22

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7.0 OPERATION METHOD 30

7.1 Basement 30

7.2 Position 30

7.3 Cable 31

7.4 Hanging Process 31

7.5 Drag 32

8.0 TECHNICAL SPECIFICATION 33

8.1 Product Cost 33

8.2 Product Specification 34

8.3 Product Design 35

9.0 DISCUSSION 37

10.0 CONCLUSION AND SUGGESTION 38

11.0 REFERENCES 39

12.0 APPENDIXES 40

1.0 ABSTRACT

First of all, this final project used to train us to become a knowledgeable and

matured in any field we attend, especially when we entered job environment after this.

Our design concept is according our problem statement. One of it, is to reduce the

machine cost at market but still effective. Then, the size of the machine must be smaller

than the product sold at market. From our literature review, we had recognized a few

types of gear that can transmit power from motor to a heavy load that not more than 1

tone. We add a few components like different gearbox from the available machine at

market. Our gearbox did not use oil, but only use grease to make it smooth. We also need

to draw the design using software to recognize the actual dimension before do the

machining process. The sketch for our design is our first idea before we find the really

effective design after our research from literature review and survey. After completing

our project at week 14, we still need more improvement for our product. What we mean

from the improvement phase is the aesthetic dimensional.

Pertama sekal tujuan projek ini adalah untuk merendahkan kos dan mengecilkan

saiz mesin. Berdasarkan kajian yang dijalankan terhadap produk yang sedia ada, terdapat

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pelbagai jenis gear yang digunakan. Namun keupayaannya berbeza-beza yang

membuatkan kumpulan kami terpaksa mendapat khidmat pakar dalam pemilihan gear.

Mesin kami dijangka boleh menarik beban tidak lebih dari satu tan. Kami juga ter paksa

membuat lukisan menggunakan solid work bagi mendapatkan dimensi sebenar dalam

memastikan tiada masalah semasa proses pemasangan. Setelah selesai projek mesin ini,

masih terdapat kelemahan yang perlu diperbaiki iaitu dari segi fizikal dan bentuk produk

tersebut.

The purposes to develop a new design for a boat wicnh are to reduce machine cost

with machine easy to maintenance, easy to be used and can pull a heavy load. The

machine is design to improve the boat movement form the sea to the seashore at Pantai

Kundur. Survey conducted shows the existing machine consume high cost and limited

use where that machine cannot be shared with other fishermen

mesin tarik bot direkacipta untuk menarik bot di kawasan sekitart pantai kundur.

mesin yg telah sedia ada lebih tinggi kos dan tidak user friendly. ia juga terhad untuk

kemudian nelaya tertentu sahaja dan tidak dapat dikongsi dengna nelayan2 yg lain.

beberpa kajian telAH DILAKUKAN UNTUK MENCIPTA MESIN YG PALING

EFEKTIF DARI SEGI KPOS, PENYELEMNGGARAAN PEMASANSANGAN DAN

JUAG KEUPOYAAN. ANATAR YG TELAH DILAKUKAN ADALAH SURVEY

TERHADAP MOTOR, PENGGUNANN GEAR PEMASANGAN YANG RINGKAS

DAN JUAG KESELAMATN. MESIN YUG TELH BERJAYA DICIPTA DAPAT

MENARIK SEHIN NGA 500KG DENGAN KOS PEMBUATAN SEBANAYK

RM1663. BERBanding debgfab mesin yg sedia ada penjimatan jkos hampir 40 % daripad

harga di pasaran. mesin yg telah dicipta menaplikasikan gabungan motor dan gear utk

berfiungsi.

2.0 INTRODUCTION

2.1 Problem statement

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2.1.1 Most of fisherman at Pantai Kundur has problem while dragging their boat to

the land after netting fish. As we know boat is so heavy and beach sand give

only a bit help to pull it.

Figure 2.1.1: Show the Boat Land after Netting Fish

2.1.2 Only a few fishermen can afford to buy the previous machine because the

price is too high. It cost not less than RM 3000 per machine. The cost is

including motor, winch and gearbox, not with the cable cost. The cost for

3 phase wiring needs another RM 300.

2.1.3 The available machine can only can pull or drag one or two of boats that

really situated opposite of the machine because the available pole or

basement is fixed and cannot shift.

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Figure 2.1.3: Base example

2.1.4 The basement and the machine available at Pantai Kundur is too big which it

needs high cost and more space.

2.2 Design concept

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2.2.1 From the problem statement, the main focus of our product is to reduce cost

by design a product that used another application machine without giving

problems to the fisherman at Pantai Kundur.

2.2.2 The design concept will only need the fisherman to spend only half of the

cost of available machine. The estimation cost is around RM 1500

including motor, gearbox and winch. Our design concept might use

another type of gearbox. The gearbox named worm gear which transmit

more power, need small space, simple, more efficient and low of cost.

2.2.3 Our product would drag or pull the load or boat not only in front of the

machine but it can shift about 30 degree from the left or right of the

basement. This concept will help another fisherman boat which still

cannot afford to have the machine. This because our product need to

tightened to a pole using sling which it can shift according to the load

position.

2.2.4 A pole or basement of our machine only need half feet shaft and deeply

fixed in a surface to make it stronger.

3.0 OBJECTIVE

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3.1 Overall objective

3.1.1 To train and improve students creativity in producing a product which can

generate students idea.

3.1.2 Train the students how to do presentation and force their project design

while seminar session.

3.1.3 Apply how to write a technical report and how to take part in an exhibition.

3.1.4 Train the students how to handle any project with a minimum supervise.

3.1.5 Teach the students to become more innovative and competitive

3.2 Main objectives

In this project, we have our own objective where to get A in our final project and

also to support our mission to solve the fisher problem. The objective is:

To reduce machine cost

Design a machine easy to maintenance

Design a machine easy to use

Design a machine can pull heavy load

Design a machine more flexible

4.0 LITERATURE REVIEW

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Along this project, to design a good project, we had study many things from book,

internet and also from our analysis from customer comment, it like;

I. how to transfer the power from motor to winch

II. what is the efficient system for us to apply to our design

III. what the material we should be used

IV. how to reduce project cost

Every data collection we do analysis and discuss in group to make sure it really efficient

to apply or not. The data we collect is referring to the system what we want to used and is

it inside our mission where to reduce cost machine. The data is:

belt and chain system

gear system

type of material

4.1 Belt and Chain System

Belt and chain tensioners reduce belt or chain slack and transmit drive torque uniformly.

They also reduce noise and vibration; decrease sprocket, pulley, belt, and chain wear; and

increase the life of drive components. In drives, belts and chains are installed with

enough tension to create a level of friction that causes the belts or chains to grip the

pulleys and the pulleys to turn. Most belt drives consist of flat leather, rubber, or fabric

belts running on cylindrical pulleys, or belts with a V-shaped cross section running on

grooved pulleys. V-belts require less tension than flat belts because their greater surface

area creates more friction. Chain drives that use sprockets are reliable systems for long

running, continuous drive applications with limited shock and torque loads.

Belt and chain tensioners are available in a variety of sizes, styles, and materials. They

can handle different minimum and maximum loads as well as temperatures. With chain

drives, maximum chain pitch is an additional consideration. Belt and chain tensioners are

used in machinery and equipment, automobiles, bicycles, conveyor belts, and numerous

other applications

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Figure 4.1.1: Belting system

4.2 Gear System

In gear system, they have many aspects we have to see like there size, bill of tooth, the

material we used and more. The picture below show the basic structure of gear:

Figure 4.2.1: Structure of gear

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We also know, they have many type of gear in industry, where every type has their own

application and different function, but if we look it closely all of this gear has same

application where to transfer the rotation of movement. The main type of gear likes;

Table 4.2.2: Type of gear

No. Type of gear Picture

1. Helical

- In helical gear, the system if like spur

gear but the angle of tooth is not 90

degree.

- Basically used for transfer rotation in

heavy load; like car, bus and more

- Used the concept of gear ratio to

increase the power or system

- Used direct load from motor or supply

2. Hypoid

- this gear is used to change the angle of

rotation from vertical to horizontal


- Not efficient at heavy load

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3. Spur

- In spur gear, the system if like helical

gear but the angle of tooth is 90 degree

straight

- Basically used for transfer rotation at

light load; like bicycle, clock and more

- Used the concept of gear ratio to

increase the power or system


4. Worm

- the concept worm gear is like screw,

where it can reduce load and at the same

time can reduce speed of motor rotation

5. Bevels

- basically only to transfer the rotation

directly from motor or supply

- where if more speed we give the

rotation also increase like car coupling

and arm

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6. Rack and pinion

- basically used at conveyer system where

the gear cannot static when move

-

4.3 Type of Material

For convenience most engineering are divided into 3 main classes; metallic, polymer

(plastic), and ceramic materials. All of this we have to know their important mechanical,

electrical and physical properties. Where must choose it correctly to make sure it have all

specs that we wanted such as; strength, durability, hardness, and more that able to apply

base on applications. The basic materials are;

I. Metallic

- These materials are inorganic substance that are composed of one or more

metallic elements and may contain some nonmetallic elements.

- Metal and alloy are commonly divide into 2 classes; ferrous metals and

alloy that contain a large percentage of iron such as the steel and cast ion

and nonferrous metals and alloys that do not contain iron or contain only a

relatively small amount of iron

II. Ceramic

- Ceramic material is inorganic material that consists of metallic and non-

metallic element chemically bonded together.

- Ceramic material can be crystalline, non-crystalline or mixtures of both.

Most ceramic material have high hardness and high-temperature strength

but tend to be brittle.

III. Polymer

- Most polymer materials consist of organic (carbon

molecule chains or network.

- Structurally, most polymer material is no crystalline but some consist of

mixtures of crystalline and no crystalline regions. The strength and

ductility of polymer vary greatly

IV. Composite

- Composite are mixtures of two or more

of a selected filler or reinforcing material and a compatible resin binder to

obtain the specific characteristic and properties desired

- Composite can be of many types. Some of the predominant types are

fibrous(composite of

particles in a matrix)

V. Electronic

- Are not a major of material by volume but are an extremely important type

of material for advanced engineering technology.

- The most important electronic material is pure sil

various ways to change its electrical characteristic.

Most polymer materials consist of organic (carbon-containing) long

molecule chains or network.

most polymer material is no crystalline but some consist of


ductility of polymer vary greatly

Figure 4.3.1: Structure of polymer

Composite are mixtures of two or more material. Most composite consist


obtain the specific characteristic and properties desired

Composite can be of many types. Some of the predominant types are

fibrous(composite of fiber in a matrix) and particulate (composite of

particles in a matrix)

Are not a major of material by volume but are an extremely important type

of material for advanced engineering technology.

The most important electronic material is pure silicon that is modified in

various ways to change its electrical characteristic.

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containing) long

most polymer material is no crystalline but some consist of


material. Most composite consist


Composite can be of many types. Some of the predominant types are

fiber in a matrix) and particulate (composite of

Are not a major of material by volume but are an extremely important type

icon that is modified in

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4.4 Available boat winch at Pantai Kundur and Pantai Puteri

This entire machine we get it from our survey at Pantai Kundur and Pantai Puteri.

There have 3 machines still function like figure below:


High cost of machine( more than RM 3000.00)

The cable not arrange correctly

Used motor 4 Hp

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Difficult to find the spare part

Difficult to maintenance (high cost)

Used motor 7 Hp

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Used bigger space to put the machine

Difficult to maintenance (high cost)

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5.0 IMPLEMENTATION METHOD

Table 5.0: Gantt chart for our scheduled project

NO. Activity W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

1 Title selection #

2 Idea of design concept #

3 Sketching #

4 Searching information #

5 Motor survey #

6 Worm gear survey #

7 Book worm gear/bush/motor #

8 Buy parts #

9 Design winch #

10 Design shaft #

11 Design 4 pieces holder # #

12 Design base #

13 Product assemble #

14 Product testing #

15 Presentation and seminar #

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6.0 COMPONENTS

6.1 Motor (custom made)

Figure 6.1.1: Electrical Motor

2 horsepower

3 phase

1500rpm

20 ampere

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6.2 Worm gear (custom made)

The main system that used in our product is worm gear, where we have to order from

supplier because it difficult to make it, figure below show the worm gear we used:

6.2.1 Female

Figure 6.2.1.1: Female Gear

Hardened brass

Have 32 teeth

4 holes for screw

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6.2.2 Male

Figure 6.2.2.2: Male Gear

Hardened mild steel

Have 4 teeth

Has key way

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6.3 Winch

Figure 6.3.1: Winch

The material is from mild steel

Have 4 holes for screw

Tightened with cable

The with is about 5 times of cable diameter

Welding and grinding

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6.4 Bearing (custom made)

Figure 6.4.1: Bearing

High speed steel

3 pieces

Inner diameter is 1 inch

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6.5 Shaft holder

Figure 6.5.1: Shaft Holder


Use milling process

2 pieces

6.6 Worm gear holder

Figure 6.6.1: Worm gear holder


Use milling, chamfering, drilling and threading process

4 pieces

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6.7 Coupling

Figure 6.7.1: Coupling


Has key way

2 Key jam holes

2 shaft jam holes

6.8 Key


Milling process

1 pieces

6.9 Shaft


Using lathe process

1 pieces

6.10 Hook (custom made)


Adjustable

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6.11 Bush (custom made)


6.12 Basement

Figure 6.12.1: Basement


6.13 Key jam


5mm screw

6.14 Bolls


10mm screw

12 pieces

6.4.15 Cam starter (custom made)

Model QS5

AC.500V50-60Hz

6.4.16 Cable (custom made)

Alloy

Long - 10 meter

Maximum load 450 kg

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7.0 OPERATION METHOD

7.1 Basement

First of all, the machine need to join to any base or pole for holding the machine

while pulling the load such as boat. The joining process we done are using to test

our product or machine is using sling. The sling can used to hang a load not more

than 4 ton. But, for the real testing at Pantai Kundur we need to join our machine

basement with the basement that ready for the previous machine using bolls and

nuts. The fasteners for the sling and our machine must be tidy.

Figure 7.1.1: How to tight the base

7.2 Position

The position of the machine might in any position. The motor is either at the

upside or down side. As long as the winch of this machine is opposite of the load

that were pulled.

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7.3 Cable

Before any process started, the cable need to be release as far as the load from the

machine was tighten with the basement. To release the cable we need to connect

the socket to the power supply. Then, switch on the power supply switch. Next,

push on the cam starter forward and the motor part will move the shaft which

connected to the worm fear and the winch. All the parts will move backward to

release the cable. The distance for the cable to release is according to the boat or

load situated.

7.4 Hanging process

At the end of the cable, we had tightened the cable with a hook. The hook that

joins with the cable needs to entwine about two times at the boat head or the load.

For our test we entwine the hook two times around the load and for the last

entwine we put the hook back with the cable to make it firmly fixed.

Figure 7.4.1: How to hanging by cable

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7.5 Drag

After tighten the cable with the load we start to drag the load. To drag the load we

just push the cam starter backward which will move the motor and the parts

related backward together.

Figure 7.5.1: Process Drag the load

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8.0 TECHNICAL SPECIFICATION

Table 8.0.1 Product cost

Component Price/unit Quantity Price(RM)

3 phase 2 hp motor RM 300 1 250.00

Coupling RM 300 1 250.00

Key RM 5.00 2 10.00

Jam screw RM 0.50 4 2.00

Male worm gear RM300 1 250.00

Female worm gear RM300 1 280.00

Bearing RM 10 3 30.00

Female worm gear shaft and acc RM 80 1 80.00

Bush RM 50 1 50.00

Winch and acc RM 50 1 40.00

Worm gear holder RM 50 4 200.00

Cable RM 3 20 m 60.00

Hook and acc RM 5 1 5.00

Base RM 20 1 20.00

Bolls RM 0.50 12 6.00

Wiring acc RM130 1SET 130.00

TOTAL RM 1663.00

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8.2 Product specification

Table 8.2.1 product for production

Parameter Specification

Length 480 mm

Width 205 mm

Height 170 mm

Weight 30 kg

Type of gear box Worm gear

Material used:-

Holder/shaft/ winch/base/coupling

Male worm gear

Female worm gear

Mild steel

Hardened mild steel

Hardened brass

Motor type 3 phase

Motor speed 1500 rpm

Motor volt 450 V

Motor current 20 A

Motor torque 2 hp

Cable type Alloy

Color Black and green

Capacity load Below 1 tan

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8.3 Product Design

Figure 8.3.1: Product design (by using solid work)

Figure 8.3.2 Part drawing

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Figure 8.3.3: Detail Drawing

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9.0 DISCUSSION

For along 14 weeks designing this project, we faced many problems. At the first

week until third week we cannot find the type of gear should be used. Is it the bigger ratio

is more powerful or type of material will make it different from each other? At last we

find Mr. Saifuddin at Muar Johor to make decision because he is an expert for custom

made product. He said for pulling a load the most powerful gearbox is using worm gear.

The other problems are selection of 3-phase and single phase motor. The available

machines at Pantai Kundur are using 3-phase motor. But the phase motor need 420volt

power supply, not as usual at Malaysia. The power supply is 240volt. Using 3-phase

motor need special wiring that need an application from Tenaga Nasional Berhad (TNB)

for that type of wiring. For 420 watt, it usually used at factory field or lab as at KUTKM

fasa B laboratory. 3 phase motor socket or plug also different. The single phase motor

plug is same as our home accessories. It is 3 pin plugs.

This subject is the most difficult subject which needs full concentration and

calculation from start until end. At last, we solve those problems with Mr. Saifuddin, our

gearbox expert.

We also difficult to find the raw material according to the size we want. To solve

this problem, we use a second hand part and rubbish material from mild steel which find

by our expert Mr. Saifuddin.

Capabilities of machine.

Problem of mounting

Cable

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10.0 CONCLUSION & SUGGESTION

As a conclusion, our project was successfully done to reduce the available

machine cost. The cost we had reduced is more than half prize from the market price but

with same product efficient. The cost at market is not less that RM 3000 and our product

costs RM 1663 only. The price should be less because the price is including try and error

price. Our machines also ease and low cost to maintenance because its use open gearbox

which no need to use gear box oil. Those types of oil will the increase the maintenance

cost. Our machine can pull not more than 1tonne load and very useful for those low

income fisherman. Lastly, this machine is design with high flexibility which it can shift

according the boat coordinate because its only needs a sling with a tough pole as a

basement. The available machine need a high, big and really tough basement to install the

machine before can use it. Finally our product is successfully done and gives more

satisfaction to the buyer from the available product.

For our improvement and suggestion, we need to use thicker cable as a safety

because the diameter for our cable is 5mm. its maximum stress is 800 kg. it might

fracture when more than 1 tone load given. We need about 10mm diameter of cable to

make this machine confident to pull load not more than 1 tone.

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11.0 REFERENCES

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12.0 APPENDIXES

12.1 Assembly Drawing

Female gear

Figure 12.1.1: Assembly Drawing (Female Gear)

Male gear

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Figure 12.1.2: Assembly Drawing (Male Gear)

Winch

Figure 12.1.3: Assembly Drawing (Winch)

Bearing

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Figure 12.1.4: Assembly Drawing (Bearing)

Shaft holder

Figure 12.1.5: Assembly Drawing (Shaft Holder)

Worm gear holder

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Figure 12.1.6: Assembly Drawing (Worm gear holder)

Coupling

Figure 12.1.7: Assembly Drawing (Coupling)

Shaft

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Figure 12.1.8: Assembly Drawing (Shaft)

6.11 Bush (custom made)

Figure 12.1.9: Assembly Drawing (Bush)

6.12 Basement

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Figure 12.1.10: Assembly Drawing (Basement)

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