http://mariahudock.weebly.com/uploads/5/6/1/1/56118113/dp2_report_final2.pdf

INTRODUCTION TO ENGINEERING DESIGN

DESIGN PROJECT II:

AUTOMATIC DUMPLING MAKER

SUBMITTED BY:

Junghun Kim James Smith Dominick Forlenza

Nadine Geagea Maria Hudock

SUBMITTED TO: Dr. Xinli Wu

EDSGN 100

SECTION 204

TEAM 5

AUGUST 14, 2015

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ABSTRACT

This report discusses the design of a safe, easy to maintain, automatic dumpling maker that produces 10

dumplings per minute and manufactured with no more than $200, unless justified. Customer-needs assessment

and internet research helped determine ease-of-use and cost most important to consumers who are mainly

focused on home cooking.

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TABLE OF CONTENTS

COVER PAGE…………………………………………………………………….……………… . .….(Maria)

ABSTRACT ……………………………………………...……………………… . . . . .………... i i (Dominick)

3. INTRODUCTION

3.1 Issue Summary ….…………………....………………………………………1 (Nadine)

4. DESCRIPTION OF DESIGN TASK

4.1 Problem Statement………………………………..……………….….…...…1 (Maria)

4.2 Mission Statement …………………………………………………………...1 (Dominick)

4.3 Design Specifications………………………………..……………………….1 (Kim)

5. DESIGN APPROACH

5.1 Project Management (Gantt Chart)..…………………….….…………….......2 (Nadine)

5.2 Customer Needs Assessment ….………………………………………..……2-3 (James)

5.3 Concept Generation……….……………..……………………..…………….3-5 (James)

5.4 Design Selection Matrices………….…………………………….…………..5-6 (Nadine)

6. FINAL DESIGN AND PROTOTYPE

6.1 Assembly Drawing and BOM ...……...…..………………………….…......6 (Maria)

6.2 Multiview Drawings……...………….……..………………….…………7-9 (James, Kim)

6.3 Prototype Scale and Images………………………………………………9-11 (James)

6.3 Design Features…………....….……..……………………….….…….……11 (Maria)

6.4 Operation Instructions ….……..………………….….……………………..12 (Nadine)

7. ENGINEERING ANALYSIS

7.1 Working Mechanisms

Mechanism 1………………………………………………………………………12-13 (Kim)

Mechanism 2…………………………………………………………………………..13 (James)

Mechanism 3………………………………………………………………………13-14 (Maria)

Mechanism 4…………………………………………………………………………14 (Dominick)

Mechanism 5…………………………………………………………………………15 (Nadine)

7.2 Cost Analysis…………….……..………………….….…………………….15 (Dominick)

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8. CONCLUSION

8.1 Summary………….……..………………..……………………….…15-16 (James)

9. ACKNOWLEDGEMENTS ………………………………………………………....16 (Kim)

10. REFERENCES……………………………………………….....……………………………………..17(Dominick)

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3. INTRODUCTION

3.1 ISSUE SUMMARY

Dumplings are a crowd favorite dish. However, this popular dish can be quite manually intensive. From the

kneading of the dough to securing the filling, this dish requires many steps that need to be done in a particular

way for optimal results. Therefore, automating this process could drastically improve availability by reducing

the amount of time and energy needed for production of the dumplings.

4. DESCRIPTION OF DESIGN TASK

4.1 PROBLEM STATEMENT

Dumplings are a food enjoyed both as a staple in their native culture and as a cultural treat outside of it.

However, the labor-intensiveness of making dumplings means that they are not readily enjoyed on a frequent

basis. An affordable automatic or semiautomatic machine was needed to make this food more available in

household and larger settings.

4.2 MISSION STATEMENT

Traditionally, automatic dumpling makers were not easily accessible to the non-industrial consumers but

rather sold to restaurants or factories. In order to provide a more convenient way to produce dumplings, a

semi-automatic or automatic dumpling maker will be conceptually designed to give private consumers a new,

cost-efficient way to that makes a delicacy much more accessible.

4.3 DESIGN SPECIFICATIONS

The dumpling maker should work automatically or semi-automatically, produce more than 10

dumplings per minute, and cost less than $200 to produce. It should be safe for household use, easy to

maintain, and dishwasher safe.

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5. DESIGN APPROACH

5.1 PROJECT MANAGEMENT

TABLE 1. GANTT CHART

5.2 CUSTOMER NEEDS ASSESSMENT

A questionnaire was utilized in order to evaluate and understand customer needs prior to

brainstorming to give the customer the product that fits their needs most. Below are summarized results from

the survey.

Customers desire a simple product that is easy to use

Most customers made dumplings a few times a year

The dumplings produced varied from 20 to as large as 300

Customers were generally willing to pay an average of $101-$300

Customers preferred automatic over semi-automatic however, when price adjusting the consensus was a cheaper model with a semi-automatic design

Note** - Customer needs were filled out by individual households, product is geared towards the

individual home-owner as oppose to a restaurant/business.

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Average scores for qualities rated on a scale of 1-5 (5 being most important)

TABLE 2. AVERAGE DESIGN FEATURE SCORES AND SURVEY FEEDBACK

Ease of use: 4.8 Other Consumer Concerns:

Ease of cleaning

Small size

Attractive to store in kitchen

Durability: 4.8

Weight capacity: 4.3

Collapsibility: 4.2

Cost: 4.0

Weight of cart: 4.0

Safety: 3.8

Attractiveness: 2.2

These results were used to drive creative design features and to determine and factor importance for

the weighted design matrix. The initial six designs inspired by this feedback follow.

5.3 CONCEPT GENERATION

Sorting through the Customer Needs Assessment allowed the group to create a variety of initial

designs that were further broken down in the design matrix to truly see which one satisfies the most customer

needs. The concept generation consists of six initial ideas and how they

operated.

DESIGN A: COOKIE CUTTER

This design was initially produced to be semi-automatic

however could easily produce the dough given an extra attachment;

consumer would incur an additional price. There is a dough

compartment and feeder compartment. The dough compartment will

be rolled onto a conveyer belt, and then there will be a timed

mechanism that will cut the dough into the shape of the circle. Once

cut the excess dough will fall to the sides given the way it is orientated,

which can be utilized again later for re-use. Continuing along the

conveyer belt it will then be filled and brought together by a shell

mechanism.

DESIGN B: CANON

One of the most unique designs, it has a large compartment

for dough and filling. Moves through a conveyor belt and is filled

utilizing a filling wheel much like the waterwheel design. Once filled it

will be folded in the “canon” which will be a shell.

FIGURE 1: DESIGN A

FIGURE 2: DESIGN B

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FIGURE 3 DESIGN C

DESIGN C: CRANK PRESS

Automatic Design where flour and water is entered

and then combined to create the dough, this dough is then

inputted into a separate compartment where it will undergo

two stages of rolling to ensure the dough is properly flattened.

Once flatted, it will arrive onto a conveyer belt and be moved

along until the filling is then inputted, timed correctly in order

to fill the correct amount through the filling station. Once filled

it will then be cut and brought together by a coupling

mechanism where the final product being an uncooked,

perfectly wrapped dumpling.

FIGURE 4. DESIGN D

DESIGN D: DOUGHGEA

There are two separate compartments for the filling

and dough. Dough is inputted onto a conveyer belt through

the compartment, with the use of a cutting mechanism it is

shaped and sized. Using the stop-and-go timing mechanisms

will allow for filling and cutting to occur simultaneously

however there will be a slight delay due to that. Once filled it

will continue along and then be brought together by a

combining shell, leaving with the final uncooked product,

ready to be eaten.

DESIGN E: WATERWHEEL:

The unique portion about this is that the feeding

mechanism is timed, however it can feed multiple

dumpling sets at once due to the multi-stage conveyor belt

and multi-stage feeding wheel. Multi-stage feeding wheel

looks exactly like a waterwheel, which will continually turn

feeding the dough that is being moved on the conveyer

belt. Much like the other designs all the other operations

remain the same.

FIGURE 5. DESIGN E

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DESIGN F: TIME MACHINE

The standard cookie cutter could be used with a

semi-automatic or automatic design this would just be an

extra charge if it were automatic. The dough would be

inputted into a large cylinder from this cylinder be

pressurized to push it through a hole the size of the dough

sheets that we would like and cut on the aft end, timed just

perfectly to cut the correct thickness. Once cut it would land

on a conveyer belt, while moving it would be filled with filling

through a second storage unit. Portioned just right to not

have excess dough or filling. Once it reaches the end of the

conveyer belt it shall be clamped and then dropped into the

“finished dumpling basket”. From there dumplings are ready

to be steamed/fried or any other method of cooking.

FIGURE 6. DESIGN F

5.4 DESIGN SELECTION MATRICES

After initial concept generation, the six concepts above were evaluated in a simple design matrix using

Design A as the standard.

TABLE 3. SIMPLE DESIGN MATRIX

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TABLE 4. WEIGHTED DESIGN MATRIX

6. FINAL DESIGN AND PROTOTYPE

6.1 ASSEMBLY DRAWING AND BOM

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6.2 DETAIL DRAWINGS

FIGURE 7. DETAIL 5 – SEALING WHEEL ASSEMBLY

FIGURE 8. DETAIL OF TOWER FROM 4 – ROLLER ASSEMBLY

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FIGURE 9. DETAIL OF CROSSBAR FROM 4 – ROLLER ASSEMBLY

FIGURE 10. DETAIL OF BAR FOR DOUGH ROLLER FROM 4 – ROLLER ASSEMBLY

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FIGURE 11. DETAIL OF DOUGH ROLLER FROM 4 –ROLLER ASSEMBLY

6.3 PROTOTYPE SCALE AND IMAGES

FIGURE 12. PROTOTYPE

SCALE: 1:2

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FIGURE 13. SOLIDWORKS MODEL

FIGURES 14A-D. ADDITIONAL VIEWS OF PROTOTYPE COMPONENTS

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6.3 DESIGN FEATURES

This dumpling maker is ideally suited to its purpose of bringing quick, easy manufacture of dumplings

to consumers at a reasonable cost, while keeping aesthetic in mind.

To begin, the machine is almost fully automatic – the only steps that the user must take (after loading

the basic ingredients) are to simply invert the dough chamber and reattach the convenient, hand-sized

movable motor head when the dough is finished mixing. After that, dumpling manufacture is purely automatic.

Production is quick, too: once the dough is moving through the second stage, the machine will produce

dumplings in sets of 2 at an estimated rate of up to 60 dumplings per minute.

Cost to the consumer is reduced by using effectively sourced materials, while also providing for

attractiveness. All components are food-safe and FDA approved. The machine’s main frame, designed from

metal originally purposed for a food splash plate, is sturdy, safe, and attractive (in white and almond finishes).

Additional stainless steel shim, wooden and polyethylene rolling components, a cleanly packaged motor head,

and a white food-grade conveyor belt are the safe and thematic components of the machine.

Finally, this compact machine is easy and safe to use and maintain. With overall dimensions of 2’H x

2.5’W x 1’D, it won’t be a hassle for consumers to set up in home kitchen areas. An open front face makes it

easy to access any part of this machine during use. No sharp edges, save for on plastic turn wheels, pose any

threat to any operator. A removable dough chamber, filling chamber, and set of conveyor belts can be placed

in the dishwasher for easy cleaning. Other surfaces simply need to be wiped down.

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6.4 OPERATION INSTRUCTIONS

1. The ingredients (water, flour) are loaded into the inverted dough chamber. The motor head attached

to the first gear rod (then lower) mixes the dough.

2. The dough chamber is then flipped over and placed onto the apparatus. The motor head, attached to

the second (new lower) rod, extrudes the dough.

3. Dough drops down and is rolled through the two stage roller.

4. Once the dough is rolled, it drops onto the conveyor belt assembly.

5. Once on the conveyor belt assembly, it slowly begins to be folded (due to the placement of the

conveyor belt).

6. As it nears the end of the conveyor belt, meat drops from the meat box onto the dough.

7. It then reaches the cutting wheel, which cuts the dough with filling into a 2 inch high and 3 inch wide

dumpling.

7. ENGINEERING ANALYSIS

7.1 WORKING MECHANISMS

WORKING MECHANISM 1

FIGURE 15A. CUTTING WHEEL TOP VIEW

Gears are designed to fit in to each other. When angled dough approach to the gear, Gear clamps onto

each other sealing the top part of the though with the filling inside.

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FIGURE 15B. CUTTING WHEEL FRONT VIEW

Pockets in the gear are designed to fit to each other. Dumpling shaped pockets come together shaping

the dough into dumpling (2 inches high, 3 inches wide) with the filling in, cutting the dough.

FIGURE: 16

WORKING MECHANISM 2: MULTI-STAGE DOUGH ROLLERS

Dough will enter through the top and through then be

dropped down and rolled through the two-stage mechanism. Once

completed it will then exit through the bottom and be on the conveyor

belt assembly.

WORKING MECHANISM 3: REVERSIBLE DOUGH MIXER/PRESS

This mechanism operates based on a detachable motor head that operates a rod to first mix

ingredients, then extrude dough.

FIGURES 17A-B: CHAMBER OVERVIEW AND MOVEABLE MOTOR HEAD

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FIGURE 17C. MIXING STAGE 1

In Stage 1, the user inserts dough ingredients into the inverted

chamber by removing the conical lid. The motor head is then attached to

the lower gear rod, which spins the dough mixing blade. Shown here is the

inverted chamber (chamber walls suppressed) and the rotation of the

mixing blade.

In Stage 2, the user turns the dough chamber so that the conical

lid faces downward over the dough rollers. The motor head is attached to

the new bottom gear rod, which interacts with the mixing rod threads to

push the rod, and attached chamber base, downward. This presses the

dough out through the hole in the conical lid. The flexible silicone lid

bends to fit into the conical lid and force out all dough.

FIGURE 17D. DOUGH EXTRUSION

WORKING MECHANISM 4: FIGURE:18

The Meat Wheel

This mechanism is timed perfectly to distribute meat to each dumpling. Attached to the meat box, the meat wheel uses a timed gear motor system to drop meat from a low clearance into each dough piece moving across a horizontal conveyor belt below. The mechanism uses gravity to dispense the meat from the meat box before cutting occurs. The meat wheel is made of food grade steel and can be removed for cleaning.

FIGURES 18A-B. MEAT WHEEL INTERIOR AND UPPER VIEWS

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WORKING MECHANISM 5

Four conveyor belts with support bars attached

to the apparatus frame are angled to face a single other

conveyor belt to create two V-shaped paths. Once the

dough is dropped between two of the conveyor belts, it

will start to shape the dough into the appropriate shape.

As the conveyor belt moves the dough forward, it will

eventually reach the point where the meat will drop and

the dough and filling are cut into the dumplings.

FIGURE 19. PAIRED ANGLED CONVEYORS

7.2 COST ANALYSIS

Customers needed a home based dumpling maker, hence a product built with FDA approved materials was needed to keep our customers safe and healthy. The dumpling maker consisted of many removable, cleanable parts included wood dough rollers, and food grade steel for the mechanisms and parts that came in contact with the food items. By using food grade steel the total manufacturing price of approximately $197. 27 is justified, customers will avoid foodborne illness and own a very durable product. Mechanisms for distributing meat, shaping dough, cutting dough and forming the dough will always be costly. Although if produced in mass, the dumpling maker could be more cost effective and bring a larger profit.

8. CONCLUSION

8.1 SUMMARY

When comparing projects one with project two, the difficulty level was much higher. However, the

team utilized all of the experience gained from the previous project to produce a better product at a faster

rate. The first project was inefficient and the team didn’t perform adequate time management. Adversely

during the second project the team was anything but inefficient, with the time crunch of slightly more than a

week to produce the product the team had to find a way to work smartly. Tasks were delegated appropriately

to ensure maximum efficiency, to give an example, three members worked on the solid model prototype, while

one completed the PowerPoint, all while another member was completing the solid works prototype model.

During the first design project there wasn’t much integration of ideas, there were five initial designs

and the team produced one of the ideas. Throughout the second design project the team developed six initial

ideas, which were then revised to take the most attractive portions of each design to truly create the best

possible product for the consumer.

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Despite the poor experiences in the first project, there are no major or minor experiences within the design

team for project two. There was a definite time crunch due to unforeseen circumstances, which only made the

team stronger. Having worked together once already, it was simple to work the details out.

Some suggestions for future classes would be to possibly have more defined guidelines in order for the class to

perform phenomenally. For example, even though the Professor explicitly stated what would be required of us

on the PowerPoint, it would have been nice if there was a sheet that adequately defined it or if possible to see

a past-classes example.

Above all, the team members had an amazing experience. The project itself provided many adverse tasks

through which the team grew. All members participated at the highest level, which allowed the product to

ultimately be astounding. Much like the first project, there was constructive criticism and parallel thinking

which allowed the revision of ideas.

9. ACKNOWLEDGEMENTS

The team would like to thank Dr. Xinli Wu, Jake, Nick for their assistance and contribution to

this project, and also The Pennsylvania State University’s SEDTAPP in the College of

Engineering.

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