University Malaya

Faculty of EngineeringDepartment of Engineering and Manufacture

KCEC 3171: Industrial ProjectGroup : 7Name of coordinator : Mr. Raja AriffinName of panels : Prof.Imtiaz and Mr. EdzrolDate of Submission : 14/Dec/2011Group members:

Name Matric Number Contact Number

Ching Han Leong KEP090006 010-2590982

Pang Sze Kuan KEC090026 017-6122818

Shamsinah Binti Shofian KEP090025 012-3275196

Nur Aribah Binti Abdullah KEC090022 019-6518747

Ummu Nazirah Binti Mohd Yassin KEP090030 013-3316595

CONTENT

1. Preface 1.1 Abstract------------------------------------------------------------- 3,41.2 Acknowledgement------------------------------------------------ 51.3 Project Team Structure------------------------------------------- 6

2. Introduction2.1 Project Title--------------------------------------------------------- 7

2.3 Literature Review-------------------------------------------------- 7-92.4 Problem Statement------------------------------------------------- 102.5 Objectives----------------------------------------------------------- 112.6 Project Risk--------------------------------------------------------- 11, 122.7 Project Benefit------------------------------------------------------ 12, 13

3. Project Planing3.1 Task and Time Planing-------------------------------------------- 14, 153.2 Activity Identification and Planing------------------------------ 16-18

4. Market Studies4.1 Market target-------------------------------------------------------- 19, 204.3 Market Analysis & Data Interpretation-------------------------- 20, 214.4 Technology Benchmarking---------------------------------------- 22-264.5 Product Benchmarking--------------------------------------------- 27

5. Design Requirement and Objectives

5.2 design target specification----------------------------------------- 285.3 list of metric needs-------------------------------------------------- 295.4 Quality Functional of Deployment (Phase 1) ------------------- 305.5 Model calculations-------------------------------------------------- 31-36

6. Concept Generation6.1 Defining Design Problem and Solution exploration------------ 376.2 Physical Decomposition-------------------------------------------- 38 6.3 Functional Decomposition----------------------------------------- 39 6.4 Morphological Box-------------------------------------------------- 406.5 Concept Sketch------------------------------------------------------- 41-48

7. Concept Selection7.1 Evaluation Matrix---------------------------------------------------- 49-507.2 Final Conceptual Design-------------------------------------------- 51, 52

8. Reference------------------------------------------------------------------------- 53

1. PREFACE

1.1 Abstract

Industrial Project is the way for us as cad/cam and manufacture engineering

student to learn and study how to produce a product from the conception to disposal

stage. From there, we can recognize the steps and processes of how to build a product

from an idea to a marketable product. In addition, this project can enhance our knowledge

and experience before we become an engineer.

Our project’s title is the loose fruit collection device for palm oil

plantation. Loose fruit is the ripest in the bunch and drop naturally to the ground.

Historically, loose fruit was not given much attention. They were deemed insignificant

compared to the Fresh Fruit Bunch which is larger in size. Hence the collection of loose

fruit was never taken seriously. Many of the fruit was left to rot.

Loose fruit contain 40% oil. Poor collection of loose fruit due to the tedious work

is therefore often the underlying cause of a low oil extraction rate among oil plantation in

South East Asia. Loose fruit are currently collected by way of raking or picked by hand.

Challenges in these operations are being identified and new approaches to the problem

and solutions are being considered. We need to invent or create the new product to pick

the loose fruit. Compared to a whole Fresh fruit bunches whose oil to weight ratio is

between 20% and 25%, loose fruit would have an oil-to-weight ratio of about 40%. This

basically means that if the weight of one loose fruit is about 10 grams, four grams of it

would be the weight of the oil.

One of this project expectation is a device can improve the collection of loose

fruits from the group efficiently. Besides that, this cost of the device should be less than

RM 2000 as motivate the small holder to collect the loose fruit. Other requirements from

the user and plantation environment are observed by doing research and interview.

Indeed, we know what customer needs from this device. Besides that, due to the needs of

the user, research and development is done to make the device easy to maneuver and suit

for all types of field condition around the bases of the palms. Hence, a device to collect

loose palm fruit is designed.

The benefits of our new invention can increase palm oil quality and reduce back

pain of the loose fruit collector because before this they are using hand to collect the palm

fruit. Besides that, it also can separate the loose fruit from debris.

This industry project provide us with the opportunity for a conducting background

investigation and analysis of the way to collect the loose palm fruit currently, detailed

design work and component selection, manufacture and assembly, and practical

examination and communication of the outcome. We also have the chance to work in a

real environment, follow a disciplined process and learn to deal with the problems that

arise. We also will discover and familiarize the common practices followed in the

industry.

We strongly believe that our product will be able to compete and get place in the

market especially in Malaysia because the device to collect loose palm fruit is still new in

industry.In summary, we hope that our project will be successful.

1.2 Acknowledgement

We would like to acknowledge and extend our heartfelt gratitude to the following persons

who made the completion of this Industrial Report possible.

Our coordinator, Mr. Raja Ariffin bin Raja Ghazilla, for his understanding and helpful

that gave us good comments and great ideas. Without your guidance we probably could

not make our project successful.

We also would like to thank the panels, Professor Dr. Imtiaz Ahmed Choudhury and Mr.

Edzrol Niza bin Mohamad, for the excellent cooperation in giving comments needed for

completing this project. This also goes to the rest of the class which we all care and love

for giving their cooperation in giving information more about the project. Everyone is

being very helpful and having good sense of understanding between each other.

Last but not least a special thanks to our group members especially our group leader Mr.

Ching Han Leong and the rest of the group members, Miss Pang Sze Kuan, Miss

Shamsinah binti Shofian, Miss Nur Aribah binti Abdullah and Miss Ummu Nadzirah

binti Mohd Yassin for the great support, wonderful effort and cooperation of completing

this project. Without the good communication and understanding among us we probably

would not complete the project on time and successfully.

And to God, who made all things possible. Thank you very much.

1.3 Project Team Structure

Project Leader

Ching Han Leong

KEP090006

Panels: Professor Dr. Imtiaz Ahmed Choudhury and Mr. Edzrol Niza bin Mohamad

Group members:

Name Matric Number Contact Number

Ching Han Leong KEP090006 010-2590982

Pang Sze Kuan KEC090026 017-6122818

Shamsinah Binti Shofian KEP090025 012-3275196

Nur Aribah Binti Abdullah KEC090022 019-6518747

Ummu Nazirah Binti Mohd Yassin KEP090030 013-3316595

Product Development Organisation Chart

2. INTRODUCTION

Panel

Mr. Edzrol Niza Bin Mohamad

Panel

Prof. Dr. Imtiaz Ahmed Choudhury

Project Assistant

Pang Sze Kuan

KEC090026

Project Secretary

Shamsinah Binti

Shofian

KEP090025

Project Treasurer

Nur Aribah Binti

Abdullah

KEC090022

Project Runner

Ummu Nazirah Binti

Mohd Yassin

KEP090030

2.1 Project Title

Design and fabrication of a prototype loose fruit collection device for palm oil plantation

2.3Literature Reviews

Palm oil extraction has been declining over the years due to the incomplete collection of

loose palm oil fruits. Sime Darby (2008) stated how important the collection of loose

fruits at the plantation. The Vice President II of Sime Darby R&D Centre’s Technology

Centre & Advisory, En.JamaluddinNasir, has been quoted to say that loose fruit has the

highest oil to weight ratio due to them being the ripest. The article continued to highlight

the loss in benefit from the uncollectable loose fruits, quoting that the company would

make an extra RM30 million in net profit if estate workers collect six loose fruit per

tree.We consider the facts presented by this article important and crucial in our product

development since Sime Darby has been established as one of the major player in the

palm oil industry.

The main factor for the low collection rate is believed to be caused by labour

shortage.MohdSolahDeraman, Abd Rahim Shuib and MohdSallehJaafar (2009), stated

that labour shortage is the main factor to poor harvesting practices which in turn leads to

longer harvesting intervals and higher quantities of loose fruits left uncollected. The

current methods used to collect these loose fruits are raking and manual method. They are

said to be not only labour-intensive and time-consuming but also tedious and laborious.

This article is published for the MPOB’s research archive for the purpose of developing a

roller picker to solve the problem at hand. Therefore we have decided to follow close to

this particular product as our benchmark and improvise the design of the roller picker.

There is also another popular method in loose fruit collecting that is suction method.

According to Abdul-Shukor Abdullah (2006), a group of student fabricated a suction

device that uses Teflon nozzle that was said to provide an efficient suction power by

creating high velocity of air flow – in the region of 22.2 m/s – to carry the loose seeds

until they reach the collecting bag. However, based on the findings from the test session,

the suction power is still inadequate when the fruit seeds are stuck in mud. Besides that,

the weight of the device is also a major problem. The article later continued to state how

the device can be improved which is by conducting a thermodynamic test and reducing

the product weight by using DFA technique. We decided not to pursue the design in this

direction since we have stronger core in mechanical grounds. Other than that, based on

this article, the testing appeared to have only touched the suction power and the

ergonomic aspect of the product but not the overall experience of the user. The weight of

the loose fruits collected also has to be taken in to account.

The followings are the extracts from the articles mentioned above:

“… Findings of the test sessions are summarised as follows:

1. The suction power is poor when the fruit seeds stuck in mud.2. Suction power is inadequate when the seeds are more than 20 mm from the tip of the nozzle.3. The worker has indicated that the weight of the machine is manageable.4. Collection time using the machine is reduced considerably.5. Further design improvement must be done to reduce the noise level. 6. The machine minimises the worker’s chances of getting injured or back pain. …”

“… Poor suction power and weight are two criticaldesign factors which required furtherinvestigation. The former can be furtherevaluated and improved if the team canconduct a thermodynamic test and a furtherweight reduction can be achieved if theproduct can be assessed using DFA technique. …”

- Abdul-Shukor Abdullah., (2006) Collaborative Learning Analysis In MechanicalEngineering Design Project.Unisel, Malaysia.

358

“The decline in the rate of palm oil extraction is due to a great extent to the incomplete collection of loose oil palm fruits. This has worsened with labour shortages, which have been repeatedly mentioned as the most critical factor in ensuring all bunches and loose fruits are harvested and collected. Labour shortage continues to pose greatest challenge for the oil palm industry. Such shortages will lead to poor harvesting practices resulting in longer harvesting intervals and higher quantities of loose fruits left uncollected. Uncollected loose fruits account for about 3%-5% of bunch weight. Consequently, prolonged failure to collect and process these loose fruits will contribute to further reductions in oil extraction rate and profits.

Loose fruits are currently collected by way of raking and or picked by hand. These techniques are not only labour-intensive and time-consuming but also tedious and laborious. Besides, the debris content when raking is practised can be as high as 60% by weight.

A study was thus carried out on the approaches of collecting and separating loose fruits and to design a cost-effective device for loose collection. …”

“… The benefits in using the Roller Picker are:

The task is less strenuous and reduces back pain of the loose fruit collector; It results in debris-free collected loose fruits; and Increased palm oil quality is achieved at the mill …”

“… The capital investment of the Roller Picker is considered attractive with a payback period of one year. The investment is economically feasible as it is expected to yield a benefit-cost ratio (B:C) of 2.14, a net present value (NPV) of RM892.35 and an internal rate of returns (IRR) of 46%.”

- MohdSolahDeraman,Abd Rahim Shuib,MohdSallehJaafar.,(2009)Roller-Type Oil Palm Loose Fruit Picker. MPOB Information Series. ISSN 1511-7871.

“… However, loose fruit is not only the concern of the estate management but the company’s top management including the President and Group Chief Executive Dato’ Seri Ahmad ZubirMurshid who had touched on this matter during the townhall meetings. He had also been quoted in Business Times in November last year that the company would make an extra RM30 million in net profit if estate workers collect six loose fruit per tree. Such is the impact of the loose fruit. …”

- Sime Darby., (2008) Seedlink : Loose Fruits vs Lost Income, Vol 2/6., Sime Darby Plantation.

2.4 Problem Statement

Current harvesting process of palm fruits often leads to loose fruits scattered on the

ground from the fruits bunch, although loose contain about 40% of palm oil.

After the team meeting with MPOB officer, we summary the reason why most of the

plantation owner does not buy a loose fruit collector and why the worker do not want to

carry up the loose fruits.

a. Time Consuming

The workers lazy to pick up the small divided loose fruit from the ground, this is

because the amount is too big and not easy see where is the loose fruit from the

grass. Besides that, the worker have to pick up one by one of the loose fruit from

the group, it is totally wasting their time and lower their productivity.

b. Lead back pain to workers

Once the worker goes to pick the loose fruit from the ground, they have to bend

down their body and pick the fruit. If this action keeps continuous, this may lead

the back pain to the worker, the owner has to pay responsible for their medical

fees. Therefore, this would not bring any win-win situation for both sides, either

worker or the plantation owner.

c. High cost for current loose fruit collector

The current loose fruit collector is too expensive and the operation cost of the

machine or maintainer cost is far behind the total revenue of loose fruits. This is

one of the reasons why the owner gives up in picking up the loose fruits.

2.5 Objectives

To design a loose fruits collection device for palm oil plantation to make sure there are no more loose fruits wasted.

To fabricate out a prototype loose fruits collection device and tested by engineering tests to ensure it can be used widely in future.

After the brainstorming among the group members, we plan to design the following product features so that the worker able to collect or pick up the fruits with more easily. However, all the design features must fulfill the following objectives.

Design a device that can easy to collect or pick up the loose fruits from the ground.

To reduce the time that is needed to collect the loose fruit. To separate the loose fruits from debris. To increase the quantity and quality of palm oil at the mill. To reduce works back pain of the loose fruits collector

2.6 Project Risk

Time ConstraintsCompletion of whole loose fruit collector project takes only two semesters. The total time available might not enough to complete the project development process. Besides that, prototyping and detailing design of every small part are time consuming.

CostThis research of loose fruit collector might require higher cost because we buy accessories with small amount quantity. We might overrun the budget for project or lack of funding for the prototyping.

Prototype Testing

Testing which has been done might not as accurate as the true value due to lack of available facilities and technical skills. The final prototype might fails as inaccurate result get from testing.

Management RiskManagement of the project and cooperation among the team members would be the most important part to ensure that the successful of project. In addition, resources management such as human resource, time management and work life commitment would be important to relish this project.

2.7 Project Benefit

Benefit to the groupa. After the group discussion, we able to figure out project planning, market studies,

design requirement, concept generation, concept selection and embodiment product design.

b. Group members become more willing to state out their points and ideas.c. The interaction between the group members becomes stronger.d. Group members pay more attention to visibility of product, including the concept

design and operation select.e. Able to establish the natural match relations between customer needs and

engineering design.

Benefit to the departmenta. Once the product is designed successfully, the reputation of CAD/CAM and

Manufacturing Department will be improved.b. Create a cooperate culture between students and staffs of department.c. Once the product is designed successfully and efficiency, there are more research

opportunity will be given from FELDA and MPOB.

Benefit to the nation and societya. Once the product is designed successfully and efficiency is proven, we may

improve the Gross National Income of palm oil industry.b. From the economics views, once the quantity supply of a particular product was

increased caused by the improvements of technology, a lower equilibrium price will be reached. Directly, the price of raw palm oil decrease will also decrease the cost of production for palm oil industry. Finally the society will get the maximum total surplus from palm oil products.

c. Support the small plantation holders in term of increase the percentages of harvesting fruits.

d. Increase the entire value chain from plantations to downstream activities once the amount of collecting fruits increase.

3. PROJECT PLANNING 3.1 Task and Time Planning

Semester 1:

Dates

10/1

0

17/1

0

24/1

0

31/1

0

Introduction        

Literature review

12/1

0      

Problem statement

12/1

0      

Objectives

12/1

0      

Project risk  

19/1

0    

Project benefit  

19/1

0    

Project Planning        

Task planning    

26/1

0  

Activity identification and planning    

26/1

0  

Market Studies        

having a tour to MPOB serdang       1/11

survey and interview       2/11

Market analysis       2/11

Product Benchmarking       2/11

Technology Benchmarking       2/11

Dates 7/11

14/1

1 21/11

28/1

1 5/12 12/12

Design Requirement and Objectives            

Customer Need Analysis 9/11          

Requirement Analysis 9/11          

Metric development

11/1

1          

Standard Search

11/1

1          

Calculation models

11/1

1          

Quality Functional of Deployment

(Phase 1)  

16/1

1        

Concept Generation            

Defining design problems     23/11      

Solution exploration     23/11      

physical decomposition     23/11      

functional decomposition     23/11      

Morphological Box     25/11      

Concept sketch      

30/1

1 7/11  

Concept Selection            

Concept testing         9/11  

Concept analysis (FEA/CFD/ etc)         9/11  

Evaluation Matrix         9/11  

Report Hands Up           14/12

3.2 Activity Identification and Planning

Contents Descriptions Person In Charge1. Introduction    

1.3 Literature Review Overview of the project TEAM

1.4 Problem Statement  

1.5 Objectives  

1.6 Project Risk  

1.7 Project Benefit    

2. Project Planning    

2.1 Task and Time Planning Overview of the project Pang Sze Kuan

2.2 Activity Identification and

Planning

   

3. Market Studies    

3.1 Market target Determine the target customer Ching Han Leong

3.2 Market Survey Form and

Interview

Collecting data Ummu

3.3 Market analysis & Data

Interpretation

interpreting data into customers

needs

Shamsinah

3.4 Technology Benchmarking Making comparisons between

existing technology or platform to

pick the loose oil palm fruit

Aribah

3.5 Product Benchmarking Making comparisons between

existing products in the market

and benchmarking on relevant

technology

Aribah

4. Design Requirement and

Objectives

   

4.1 Customers' Need Analysis identify the existing problem that

customers faced and solving the

design problem

Shamsinah

4.2 Quality Functional of

Deployment (Phase 1)

translating customer requirements

into engineering requirements

Ummu

5. Concept Generation    

5.1 Defining Design Problem and

Solution Exploration

defined problem and the sub

functions for solution

Ching Han Leong

5.2 Physical Decomposition defined the part of the design and

its function

Aribah

5.3 Functional Decomposition Shamsinah

5.4 Morphological Box chart with all the possible design

for each part

Pang Sze Kuan

5.5 Concept Sketch design sketch with pros and cons TEAM

6. Concept Selection    

6.1 Concept Testing and Analysis analysis, rough FEA Pang Sze Kuan

6.2 Evaluation Matrix use scoring method to use the best

design

TEAM

7. Embodiments    

7.1 System Architecture review the flow of force, material Ching Han Leong

and signal on the machine

7.2 Quality Functional of

Deployment (Phase 2)

translating engineering

requirements into each part

needed

Ummu

7.3 Geometry Layout (Standard

Part Indentification)

to defined de roughly size of each

part and the machine

Pang Sze Kuan

7.4 Technical Design Drawing detail drawing of design and

component

TEAM

7.5 System and Component CAD  

7.6 Material Selection and

Justification

selection and identify material

needed in design

Ching Han Leong

7.7 Product Calculation provide needed calculation for

designing parameter, calculate

considered factor with engineer

knowledge, detail appropiate

calculation

TEAM

7.8 Fishbone defined the problem exist for the

design

Ummu

7.9 Failure Mode Effects and

Analysis

defined the problem and how

offen it occurs

Shamsinah

7.10 Detail component testing carry out needed experiment for

getting actual engineering value

which needed for design

Aribah

7.11 Prototyping    

8. Manufacturing Planning    

8.1 Manufacturing Process

Selection

identify suitable manufacturing

process, description for particular

fabrication process needed

Ching Han Leong

8.2 Assembly Process sequence of relevant assembly

process

Aribah

9. Prototype    

9.1 Prototype Costing prototying cost TEAM

9.2 Prototype material supplier teasting  

9.3 Fabrication fabrication  

4. MARKET STUDIES4.1 Market Target

According to Economics Transformation Report, as 2009, Malaysia has the total land

area of palm plantation is 4.7millions hectares. New plantation expansion of Malaysian

companies abroad due to land limitations in Malaysia. There is currently a total of 6.6

million hectares of land for agricultural use in Malaysia, of which 4.7 million hectares

(71 percent of total) is used for oil palm plantations.

a. Our focus customers group can be divided into two for palm plantation in Malaysia,

they are Private Estate and Government Estate.

b. Understand the customers group will help us to understand the purchasing power for

our product.

c. According to pie chart, Private Estate as our major customers group. However, there

are some reason for us to Government Estate as our primary customer for the

product.

42 16

7

60

11

plantation ownership in Malaysia

FECRARISDAFelda BerhadState SchemesPrivate EstateSmallholders

Plantation companies in our Malaysia(customers) :

4.3 Market Analysis & Data Interpretation

We had conducted an interview with Mr.Muzzammil, who are officer of environmental

department at Malaysian palm oil board (MPOB). Mr. Muzzammil received his degree in

computer aid design program from the university Malaya in few years ago. Currently, he

is taking Master in palm oil research from MPOB.

INTERVIEW #1 (Mr. Muzzammil)

Preparing for the product design (market stage)

Mr Muzzammil stated that majoring in Computer Aided Design is the first step in

preparing for his profession. He pointed out that palm fruit are important for our country

this is because Malaysia are the bigger palm fruit exportation country in the world,

followed by Indonesia. As it has over 100 years of experience and a strong market

leadership in terms of productivity and R&D, the Malaysian palm oil industry play an

important role to the Malaysian gross national income, which present about RM52.7

million for the palm oil industry.

Knowing what the customer needs can also be very helpful in our product design,

according to Mr.Muzzamil. With that information, we can utilizes our product

characteristics and match with the customers’ needs. He also pointed out that not only

design is a design work, but understand who is our customers, size of the market,

potential of the market, and customer needs are very important.

Realities of the product design.

He state that, design a product with low cost but efficiency, is a difficult task for us. For

him, the definition of efficiency for our product (loose fruits collector) is influenced by

three factors, they are low debris, high capacity and lower damage percentage for the

loose fruits. However, he also pointed out that, most of their customers emphasize the

cost of the product, customers always try to get maximum benefit from the particular

product, which is low cost and high effieciency. He also pointed out that, some of the

plantation owners, especially the small scale plantation, they rather to ask their worker to

pick up the loose fruits by their own than buy a collector to collect the loose fruits. The

main reason is they want to save the cost instead of spend money and buy a collector

device. Therefore, even we able to design a high efficiency product, but the plantation

owners still choose not to purchase our product because of the cost.

Anyway, he encourage us take the current loose fruits collector as a reference and try to

modify it so that the product features can be improved in term of the efficiency.

Nowadays, big size of vacuum machine only available in the big company such as

SimeDarby and IOI plantation. They make a lot of convenience to take workers, but they

cannot separate the debris with the loose fruits very well when they use the pipe to suck

all the things from the ground to the machine.

4.4 Technology Benchmarking

Source Technique Power,

kW

Collecting rate,

kg/min

Debris,

%

Injury,

%

Muhammad Salih

(1988)

Rubber Strain

atoolto collectthe oil palm fruit using therubberstrain. Fruitcollectedone by one. The rate of collectionis75pieces/ min(0.75 kg/min) and nodebris iscollected. However, fruitinjuryis high.

Press method

0.75 0 20

Mohd. Zohadie

(1992)

Rotating Brush Collector

It uses a brush broom to pick the fruit off the ground. Mohd. Zohadie (1992) has adapted the design above and found that a machine

4 1.4 < 30 0

driven by 4 kW petrol engine is able to reap all the fruits on the ground. Preliminary observations indicate that the machine is able to collect 1.4 kg / min and there was a 30% percentage of debris.

Parameseven

(1992)

Plate Collector

the main components of the device includes a main frame, rubber collector plates, barrier pieces, collector box, regulator of fruit and castor wheels.

This tool is rolled over the fruits. Fruit will be caught in between the plates which indirectly acts as a front wheel. Seeds that are caught will be in accordance with rotation of the plates and will be barred by a barrier that serves to push the fruit into the containers.The average capacity of the collection was 1.67 kg / min. However, the fruit collected are injured even though there is no debris.

Push method

1.67 0 <10

Harris

(1995)

Modified Plate Collector

They pay more attention to reducing injuries in the oil palm fruit. The design of this tool is divided into two main systems of the driver and store system.

The driver system will ensure that the fruit is in a position parallel to the movement of the wheel to ease the wheel to clamp the fruits before

Push method

0.66 0 18

it is lifted into the container. The carrier is a disc-shaped and coated with soft plastic to avoid any injury to the oil palm fruit. The efficiency of this device on the average is 80% and has the ability to collect 0.66 kg / min. Percentage of debris is zero, but the fruit is injured by 18%.

Wan

(1993)

Indirect Vacuum Collector

It uses the concept of producing a blow that will produce suction. The machine is designed with several key components, namely:i. Blow unit,ii. Suction unit, andiii. Venturi unit.

This machine is creating a suction power at a venturi unit as a result from the changes in velocity after getting power supply from the blow unit.

Preliminary observations indicate that this machine is 100% debris free and have the ability to collect 0.3 kg / min with a 2.25 kW of power.No fruit is injured during the collection.

2.25 0.3 0 0

Ahmad Zamri

(1994)

Direct Vacuum Collector

Waste suction machine has been modified and developed to suck the oil palm fruit. Air is sucked by the fan through the suction nozzle of the machine. A lift effect was

3.75 1.13 < 8 0

created and the palm fruit along with the debris are sucked in together and separated by a filter.

Transported oil palm fruits were collected in containers driven by 3.75 kW engine, while debris through the propeller blades and sprayed out by the propeller.Preliminary observations indicate that the machine could suck 1.13 kg / min. Present the percentage of waste is less than 8%.Muhammad Salih, and MohdTaufiq (1995) has adapted the machine on with a little change in results in debris separation.

Ahmad Hitam

(1995)

Direct Vacuum Collector

Suction force is obtained from the petrol engine and they are connected to two large container that serves as a storage for palm oil and debris. Field tests demonstrated the ability of this machine is between 1.0 to 1.2 kg / min of accumulated waste content of less than 10% compared with 0.7 - 1.4 kg / min and trash content exceeding 20% of the common way of collecting.

3.75 1-1.2 < 10 0

Khalina

(1996)

Indirect Vacuum Collector

By using the principles of blow-suction, the air velocity is used as the main medium to produce a suction forceThe main part of this machine consists of 25.2 kW of

2.25 1.2 0 0

power blowing machine, a filter unit which is located at the end of the suction duct, a container, vessels and blow ducts. From preliminary observations, the machine is capable of collecting oil palm fruits at 1.2 kg / min without any injuries. No debris collected during this test done.

MohdSolahDeraman

(2010)

The roller is rolled with a little pressure against the ground causing the wires or rods of the case to split open and to trap the loose fruit inside the case. Once the loose fruits are entrapped inside, the wires or rods of the case will return to their normal position. All debris smaller than the spaces between the wires or rods will drop from the case, and therefore will result in only debris-free loose fruits being collected.

Roll Method

0.75 0 <10

4.5 Product Benchmarking

Manufacturer/Model

Diagram Power,

kW

Dimension Collecting Rate,

kg/min

Debris,

%

Fruit Injury,

%

Kingoya

Kingoya Method

Pull Technique

0.5 0 0

MPOB

Roller Type Loose Fruit

Picker

Push-Pull Technique

Width 280mm

Diameter 120mm

Length 1000mm

0.75 10 0

Bag-A-Nut

16”-Mac Pick-Up

Removable Basket

Push Technique

Basket Width 16”

1 30 0

EikSeng Machinery

Vacuum Collector

for Palm Oil VCPO-77

3.6 (40 x 54 x 80)cm

4.5 50 0

Weiss McNair

836 P.T.O. Hazelnut Harvester

45 Length: 209"Wheelbase: 80

1/2"Height: 76"

5 0 0

5. DESIGN REQUIREMENT AND OBJECTIVES

5.2 Design Target Specification

No Customer needs Rank

1 Lightweight 3

2 Easy to install 2

3 Multifunction 1

4 High efficiency 5

5 Easy to maneuver 5

6 High capacity 3

7 Use mechanical mechanism 3

8 Mobile (move freely) 5

9 low price 5

10 High durability 5

11 Acceptable size 3

12 Environmental friendly 1

13 Easy to maintain 3

14 easy to operate 4

15 easy storage 4

16 Lasts a long time 3

17 Is safe in a crash 2

18 Detachable 1

19 Good appearance 1

20 Simple 5

5.3 List of Needs-metrics

No metric Need No’s Units

1 Egornomic Design 5,8,14 Subj

2 Number Of Components 1,2,8,11,13,14 Subj

3 Lifespan Of Device 10,13,16 years

4 Total Mass 1,5,8,14 kg

5 Stability Of The Device (Mass Distribution ) 5,8,14

6 Hardness Of Material 9,10,16

7 Time To Assemble/Disassemble 18 s

8 Volume Of Storage 1,6 m3

9 The Position Centre Of Gravity 5,8 m

10 Bending Strength 1,9,10,17 Pa

11 Melting Point Of Material 10,16 C⁰

12 Size Of Device 1,2,5,8,11,14,15,17 m2

13 Warranty 17 years

14 Density Of Material 1,5,8,9 kg/m3

15 Corrosion Resistance Of Material 9,10,12,16

16 Type Of Material Use 1,5,8,9,10,12,16,17,1

9

Subj

17 Total Cost 9 RM

5.5 Calculation model

1. Power to move the machinea. P = F x V

Where F = force to move the machine, V = velocity of the machine

b. P = T x ωWhere T = torque of the wheels, ω = angular velocity of wheel

2. Rotational energy of the machinea. K = (1/2) x I x ω2

Where I = inertia of wheel, ω = angular velocity of wheel

3. Kinetic energy of the machinea. K = (1/2) x M x V2

Where M = mass of the machine, V = linear velocity of the machine

4. Modulus of resilience Explanation: the energy that can be absorbed per unit volume without creating a permanent distortion.

a. Ur = σy2 / 2E

Where σy = yield strength of the material, E = modulus elasticity

5. Modulus toughnessExplanation: energy of mechanical deformation per unit volume

Energy/volume = ∫0

ϵ

σdϵ

6. Size of the fruit storage tankVolume of the tank storage = w x t x hWhere w = width of the tank, t = length of the tank, h = height of the tank

Numbers of loose fruits that can be store = (Total volume of the tank) / (average volume for one loose fruit)

7. Stability of the machine at the incline slopeHere, we ensure the centre of mass of the machine do not fall out the base area of the machine on the slope. (Static condition)

Tan Ѳ = L / hWhere Ѳ = incline angle, L = length of the machine, h = height of the machine

8. Maximum load /critical load for the hollow rodFor the round shape hollow rod,

Area, A = ( π4 )(d0

2 – d12)

Inertia moment, I = π

64 (d04 – d1

4)

Pcr = ¿2 x E x I) / L2

For the square hollow beamArea A = b0

2 – b12

Inertia moment, I = (1/12)(b04 – b1

4)

Pcr = ¿2 x E x I) / L2

9. Beam deflection ∆y = (PL3)/ (3EI)Where P = force, L = length of the beam, E = elasticity modulus, I = moment of inertiaѲ = (PL2)/ (2EI)Where P = force, L = length of the beam, E = elasticity modulus, I = moment of inertia

a. Handle design in term of deflection- Determine deflection of end C cause by force P

Portion AB:Bending energy = (P2LAB

3) / (6EI)Torsion energy = (P2LBC

2LAB) / 2GJ

Portion BC:Bending energy = (P2LBC

3) / 6EI

Total energy, U = (bending energy + torsion energy)portion AB + ( bending energy)portion BC

Deflection, δ = (2U) / P(Deflection at the end C caused by force P)

b. Pathway design for the roller collectorLet say the collector roller move from point A to point C, determine the deflection at the end C

Δc = (2/3) (PL3) / (EI)Deflection at end c

Ѳ = (1/6) (PL2) / (EI)Deflection angle at C

c. Base of the machineDetermine the reaction force at each support, A = collector roller, B = front wheel, C = rear wheel, assume that there are no deflection at the point A.

Reaction force at C, Rc = (1/2)(RA) + (1/2)(RB)

Portion ABDeflection energy,(δUAB) / ( δRA) = (1 /24) (RAL3) / ( EI)

Portion BCDeflection energy,(δUBC) / ( δRA) = (RAL3) / (12EI) + (WL4) / (48EI)

By the assumption deflection point A is 0,

(δUAB) / ( δRA) + (δUBC) / ( δRA) = 0

Therefore the reaction force at each point,RA = -(1/6) (WL)RB = (3/4) (WL)Rc = (5/12) (WL)

W = total weight of the machine after the storage tank is full. L = total length of the base beam

10. Shear stress at the pin or screw pointa. For double shear,

τ = (F) / (2A)Where F = force act on the pin / screw, A = area of shear

b. Bearing stress,σ = (1/2) (F) / (A)Where F = force on the pin / screw, A = bearing area

11. Maximum shear stress in the beamτ = (VQ) / (It)Where V = transverse shear force, Q = first moment of area, I = moment of inertia, t = width of the section

12. Factor of safety

F.S = (allowable force or stress) / (ultimate force or stress)

13. Size of the collector roller

Assumptions and comparison: a. The roller is perfectly cylinder shapeb. We taking the average weight of a loose fruit, which 10g (reference :

http://www.simedarbyplantation.com/upload/Newsletter_March_2008.pdf)c. To increase the capacity of collector roller, we compare the roller with the size of

MPOB roller. In our design, we target the capacity storage is more than the MPOB roller.(Reference: http://palmoilis.mpob.gov.my/publications/TOT/TT-419.pdf)

Therefore, the design criteria for the roller musti. Width > 280mmii. Diameter > 120mm

d. We assume there are no debris inside the rollere. The oil palm fruits are ovoid in shape varying in length from about 2 cm to more

than 5 cm and in weight from 3 grams to 30 grams. Botanically, the fruit consists of a nut surrounded by fleshy fibrous mesocarp. The nut consists of the kernel within its shell (endocarp)(Source: The Oil Palm – C.W.S Hartley 2nd Edn.)(Reference: http://www.uneca.org/fssdd/events/WorkshopTradeJan2011/Documents/asia/study%20paper/Case%20study%20Palm%20oil%20Malaysia.pdf)

13a. Volume of the collector rollerV = (𝝅r2) x L

Where r = radius of the roller, L = length of the roller

13b. Maximum numbers of loose fruits inside the rollerN = (volume of the collector roller) / (average size of one loose fruit)

13c. maximum weight inside the loose (fully loose fruits)W = N x (average weight of one loose fruits, 10g)

13d. Size between the gaps of wires.

Average size of one loose fruit, length from about 2cm to 5cm, diameter from about 1cm to 2.5cm.

Therefore, to design the gap distance, we must fulfill the above criteria.

6. CONCEPT GENERATION6.1 Defining Design Problem and Solution Exploration

Design requirements Design Solution

1. Low cost and high efficiency

design

a. Materials selection

b. Design features

2. Counter back pain a. Do some mathematic calculation to

the product design

b. Ergonomic design

3. Decrease the rate of debris a. Design an external part to separate

the fruit and debris

b. Design features on the collector part

c. Weight increasing

4. High mobility a. Material selection

b. Design features

c. Ergonomic design

5. Increase the storage capacity a. Design an external part to store the

loose fruits

b. Weight increasing

6. Avoid in using electricity and

petrol for the collector device

a. Design a simple and efficient product

b. A mechanical design that can

minimize the human power

consumption

7. Long lasting and reliable a. Material selection

b. Know stress distribution analysis for

the whole part of product.

6.2 Physical Decomposition

6.3 Functional DecompositionFUNCTIONAL DECOMPOSITIONCollect loose fruitcollectorloose fruit goes into hollow part of the rollerroller with strip roll on loose fruitseparate debris from loose fruitloose fruit leave from the separator and big size stone stay on the separatorcollected loose fruit pour on the separatormove from point A to point BFruits storage

6.4 Morphological Box

Parts Types

Collector

- Vacuum

Movable

- Wheel

Storage

- Box - Plastic/Cloth

Power generator - Human Power - Electrical - Battery - Motor(fuel)

Separator

- Separate with a net - Separate with a cage and fan

6.5 Concept Sketch

Concept 1

60cm

Top View 3D view

35cm

90cm

Front View Side View

Ways to operated:

Push the loose fruit collector onto the loose fruits. The loose fruits are collected by going thru the gap into the roller in front of the

machine. When the loose fruits in the roller are almost full, pull the handle to lift up the roller

along the pathway and turn at the top to pour out all the loose fruits in the separator. Rocks which bigger size than the loose fruits are separated and loose fruits go thru

the funnel and keep in the bag.

Concept 2

ADVANTAGES DISADVANTAGES

Low cost Included separator Bigger capacity Movable Lightweight Use only human power Environmental friendly

Easy to maneuver Hard to refill Need to design a specific rod/way

170cm

Top View 3D View

500cm 350cm

Front View Side View

ADVANTAGES DISADVANTAGES

Wide collecting area Use mechanical Environmental friendly Save time Capacity

Big size No separator to separate fruits

from debris Low durability Mobility Cost high

Ways to operated:

Loose fruit collector is attached together with the bulldozer. This machine work together with the bulldozer to save time because workers can

collect the loose fruits at the same time when collect the big bunch of the oil palm fruits.

When this machine passes by between the oil palm trees, The two side of the collector will closed.

This action can make sure that all the loose fruits can be collected by only one time passing by.

Concept 3

Top View 3D View

55cm

100cm

70cm

Front View Side View

Ways to operated:

Using manpower to push the loose fruit collector onto the loose fruits. The loose fruits are collected by going thru the gap into the roller. When the roller is full, workers have to press the gripper on the handle. The both side of the roller will push inside and the gap will become bigger. Pour out the loose fruits thru the bigger gap into the basket.

ADVANTAGES DISADVANTAGES Lightweight Easy to maneuver Human power Mobility Small size Separated Environmental friendly Lower cost

Time consuming time Low capacity Low durability

The basket can be removed from the handle.

Concept 4

50cm

50cm

Top View 3D View

100cm

Front View Side View

Ways to operated:

Run by motor. Switch on the vacuum and suck all the loose fruits on the ground. The loose fruits will follow the pathway into a cage. There is a fan which runs together with the motor. The fan blows away all the debris where the loose fruits will be trapped in the cage. The cage can be taken out to collect the loose fruits.

ADVANTAGES DISADVANTAGES Well separated Fast collecting rate Use less human power Consumption high High durability

Higher cost Complex design Heavy Waste power Hard to maintain

7. CONCEPT SELECTION

7.2 Evaluation Matrix

Concept screening

Analysis of Concept:

No. Selection criterionConcept 1 Concept 2 Concept 3 Concept 4

rating rating rating rating1 Easy to maneuver - + + +

2 Low cost + + + -

3 Durability 0 - 0 +

4 Light weight + - + -

5 Multifunction + 0 0 +

6 High capacity 0 0 0 +

7 Move freely + - + -

8 Easy to maintain + + + -

9 Separator + - - +

10 High efficiency + + - +

11 easy to operate + - + -12 Simple + - + -

Sum +’s 9 4 7 6

Sum 0’s 2 2 3 -

Sum -’s 1 6 2 6

Net score 8 -2 5 0

Rank 1 4 2 3

Continue? yes no yes no

“-” = worse than “0” = same as “+” = better than

Concept Scoring

NO.SELECTION

CRITERION

  CONCEPT 1 CONCEPT 3

weight RATING weighted

score

RATING weighted

score

1 Easy to maneuver 5 4 20 4 20

2 Low cost 5 2 10 4 20

3 Durability 5 0 0 0 0

4 Light weight 3 2 6 4 12

5 Multifunction 1 5 5 1 1

6 High capacity 3 4 12 1 3

7 Move freely 5 3 15 5 25

8 Easy to maintain 3 3 9 4 12

9 Separator 4 5 20 0 0

10 High efficiency 5 5 25 2 10

11 easy to operate 4 3 12 4 16

12 Simple 5 3 15 4 20

Total score   39 149 29 142

      CHOSEN    

Rate the concepts:

7.2 Final Conceptual Design

This is the final conceptual design that is chosen for the industrial project.

Relative performance RatingMuch worse than reference 1Worse than reference 2Same as reference 3Better than reference 4Much better than reference 5

7.2 Final Conceptual Design

This is the final conceptual design that is chosen for the industrial project. This design is taken from the concept 1 as it got the highest point for the concept screening and concept scoring. This is a simple concept with low cost, low maintenance, and no need much skill handle it.

This loose fruit collector is design as shown in picture. Human power used to move this machine onto the loose fruits.

Loose fruits are collected by going thru the gap into the roller. When the roller is almost full, the roller can be lifted up along the pathway as shown in picture below.

Then the roller is turn vertically by the handle and the loose fruits will drop on the separator. The separator can be taken out from behind to throw away the stones which collected together.

Loose fruits without debris and stones go thru the funnel and keep in a bag.

8. REFERNCESAbdul-Shukor Abdullah (2006). Collaborative Learning Analysis In Mechanical Engineering Design Project. Unisel, Malaysia.

Christie F.R; Sathianathan M. (2011). Improving the Environmental Sustainability and the Export Competitiveness in the Food Sector: Case of the Malaysian palm oilIndustry. http://www.uneca.org/fssdd/events/WorkshopTradeJan2011/Documents/asia/study%20paper/Case%20study%20Palm%20oil%20Malaysia.pdf

General Information. http://www.ipni.net/ppiweb/filelib.nsf/0/9BF9AC573FE5E3DB48256B49002F64E7/$file/OP%20HB%20Mat%20p1-8.pdf

Nurulhuda Kasim (April 2009). Separation Technique of Crude Palm Oil at Clarification Area via Optimum Parameters. http://umpir.ump.edu.my/862/1/Nurulhuda_Kasim.pdf

Sime Darby Plantation Sdn Bhd (March 2008). Bimonthly Publication, Loose Fruit VS Lost Income, pp8. http://www.simedarbyplantation.com/upload/Newsletter_March_2008.pdf

Solah Deraman; Rahim Shuib; Salleh Jaafar (June 2009). Roller-type Oil Palm Loose Fruit Picker. http://palmoilis.mpob.gov.my/publications/TOT/TT-419.pdf

Wikipedia. http://en.wikipedia.org/wiki/Oil_palm