MohdRidhwanRamliMFKA2010.pdf

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DESIGN OF NEW INTERLOCKING BRICKS MAKING MACHINE

MOHD RIDHWAN BIN RAMLI

A project report submitted in partial fullfilment of the

requirements for the award of the degree of

Master of Engineering (Mechanical

Advanced Manufacturing Technology)

Faculty of Mechanical Engineering,

Universiti Teknologi Malaysia

MAY 2010


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To my beloved my wife Zariwani Zakaria, dedicated supervisor Associate Professor

Zainal Abidin Ahmad, Tn. Haji Fadhil Ahmad, Tn. Haji Azhar Zubir, and Mr. Helmi

Ahya Ilmuddin . Thank for all your support .


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ACKNOWLEDGEMENT

Alhamdullilah, thank to Allah, because of Him we are still here, breathing

His air, pleasuring His entire gift in this world. And most of all, for giving me

opportunities to learn His knowledge.

This work was supervised by Associates Professor Zainal Abidin Ahmad at

the Universiti Teknologi Malaysia. I greatly appreciate all his help and guidance.

I am indebted to lovely wife, Zariwani Zakaria whose help, encouragement

and patience I would never have gotten this thesis completed and who made it all

worthwhile.

I would also like to thank my friends, Imran Ibrahim, Huzaimi A. Hamid, and

Hamzah Mahmood for their support and encouragement and other help throughout. I

am also grateful to Tuan Haji Fadhil Ahmad and Tuan Haji Azhar Zubir who also

gave me a great deal of support and encouragement.

Finally, thank you to all the other people who have supported me during the

course of this work. Thank You! Thank You!


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ABSTRACT

This report presents a systematic approach to enhance the current design of

interlocking brick machine. The design starts with data gathering from the literature

review and information given by the interlocking bricks maker. Product specification

is then being developed and refine to the specific points. The weaknesses of the

current design are being analyzed by looking at the movement waste done by the

machine operator and the machine limitation is being identified. The interlocking

bricks are different from other normal bricks as it requires no mortar or cement for

masonry work. This bricks interlocked with each other by means of positives and

negative frogs on the top and bottom of the bricks which disallow the horizontal

movement of bricks. Selection of best design is chosen from the several design

concepts proposed. Finally, the drawing and detail design is produced according to

standard and ready to be built by the machine developer.


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ABSTRAK

Kertas ini mempersembahkan penyampaian sistematik tentang bagaimana

untuk menambahbaikan rekabentuk sedia ada bagi mesin membuat bata.

Pengubahsuaian dan penambahbaikan mesin yang sedia ada adalah bertujuan untuk

meningkatkan produktiviti pengeluaran bata. Langkah pertama untuk membuat

rekabentuk baru bagi projek ini adalah mengumpul maklumat dengan membuat

kajian ilmiah tentang rekabentuk sedia ada dan mengumpul maklumat daripada

pengeluar bata tempatan. Kelemahan yang terdapat pada mesin sedia ada diuji

dengan melihat pergerakkan operator mesin dimana segala pergerakkan yang

membazir akan dikenalpasti untuk penambahbaikan. Had penggunaan mesin juga

akan dikenakpasti untuk dilakukan proses yang sama. Bata yang dihasilkan oleh

mesin ini adalah berbeza dengan bata yang lain kerana penggunaannya tidak

memerlukan semen untuk dilekatkan antara satu sama lain. Bata jenis ini mempunyai

kunci positif dan negative yang membolehkan ianya melekat sendiri tanpa

menggunakan semen. Setelah beberapa konsep rekabentuk dihasilkan, Cuma yang

terbaik akan dipilih untuk diteruskan dengan menghasilkan lukisan kejuruteraan

mengikut piawaiannya dan sedia digunakan oleh pengilang untuk menghasilkan

mesin ini.


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TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENTS iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF ABBREVIATIONS xiii

LIST OF SYMBOLS xiii

LIST OF APPENDICES xiv

1 INTRODUCTION

1.0 Introduction 11.1 Objective 41.2 Scope of Work 5

2 LITERATURE REVIEW

2.0 Introduction 7


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2.1 Overview of the Previous Data on

Bricks Making Machine 7

2.2 Overview on the Previous Data Regarding

Research on the Interlocking Bricks 16

3 METHODOLOGY

3.0 Introduction 17

3.1 Concept development phase 18

3.1.1 Identifying customer needs 18

3.1.2 Establishing target specifications 18

3.1.3 Concept generation 19

3.1.4 Concept selection 19

3.1.5 Setting final specification 20

3.2 Concept development

3.2.1 Identifying customer needs 21

3.2.2 Establishing target specifications 22

3.2.3 Concept generation 29

3.2.4 Concept selection 39

3.3 Discussion 43

4 RESULT AND DISCUSSION

4.1 Product architecture 46

4.1.1 Detail Design 47

4.1.2 Material and Process Selection 55

4.1.3 Detail Drawing 65

4.2 Components analysis 77

4.2.1 Top Structure 78

4.2.2 Table Structure 80


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4.2.3 Compactor Structure 82

4.2.4 Planar base Structure 84

4.3 Cost analysis 86

4.3.1 Guideline for Calculating

Bricks selling Price 86

4.3.2 Machine component and

Raw Material Cost 90

4.4 Product design specification 101

5 CONCLUSION

5.1 Introduction 103

5.2 Conclusion 104

5.3 Future Development 105

REFERENCES 108

APPENDICES 111


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LIST OF TABLES

TABLE NO. TITLE PAGE

3.1 Customer statement and interpretation 213.2 Customer needs 223.3 Matrix table 283.4 Needs-matrix table 283.5 Concept 1 description 353.6 Concept 2 description 373.7 Concept 3 description 393.8 Concept screening matrix 403.9 Concept scoring matrix 424.1 Material and process selection 55

4.2 Hydraulic function diagram 71

4.3 Material cost 97

4.4 Screw and nuts cost 98

4.5 Mechanical system and equipment cost 99

4.6 Manufacturing cost 100

4.7 Final product design specification 101

5.1 Project 1 schedule 106

5.2 Project 2 schedule 107


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LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Type of Interlocking Brick 4

1.2 Flow chart represents the scope of work 6

2.1` Brick making machine by Hans C. Sumpf 8

2.2 Brick making machine by Judson A. Hereford 9

2.3 Brick inverter machine by Nicholas Lyons and C.K. George 10

2.4 Brick making machine by C.D. Vernon 11

2.5 Brick making machine by Lewis Polak 12

2.6 Brick making machine by Donald P. Chennells 13

2.7 Small size bricks making machine 14

2.8 Medium size bricks making machine 15

2.9 Large size bricks making machine 16

3.1 Method of designing the interlocking brick making machine 20

3.2 Cement charging/loading 30

3.3 Operator leveled the cement 30

3.4 Device to turn the brick 30

3.5 Process of turn the brick 313.6 Before compaction process 31

3.7 Pressure loading on bricks 32

3.8 Operator manually pick-up the brick one by one 32

3.9 Operator manually insert lower mold plate one by one. 33

3.10 Concept 1-Cantilever concept (3D view) 34

3.11 Concept 1-Cantilever concept (Drawing view) 34

3.12 Concept 2-Center cylinder concept (3D view) 36

3.13 Concept 2-Center cylinder concept (Drawing view) 36


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3.14 Concept 3-Horizontal compaction concept (3D view) 38

3.15 Concept 3-Horizontal compaction concept (Drawing view) 38

4.1 Total assembly design 48

4.2 Mold assembly design 49

4.3 Table structure assembly design 50

4.4 Top structure assembly design 51

4.5 Charging system assembly design 52

4.6 Inside control panel 53

4.7 Electrical Wiring Diagram 66

4.8 PLC Wiring Diagram 67

4.9 Indicator Lamp Wiring diagram 68

4.10 Hydraulic circuit diagram 69

4.11 Top structure stress analysis 78

4.12 Top structure displacement result 79

4.13 Table structure stress analysis 80

4.14 Table structure displacement result 81

4.15 Compactor structure stress analysis 82

4.16 Compactor structure displacement result 83

4.17 Planar Base structure stress analysis 84

4.18 Planar base structure displacement result 85

4.19 Total assembly drawing 92

4.20 Mold assembly 93

4.21 Table assembly drawing 94

4.22 Top structure assembly drawing 95

4.23 Charging system assembly drawing 96


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LIST OF ABBREVIATIONS

CAE - Computer Aided Engineering

CATIA - Computer Aided Three-Dimentional Interactive Application

D - Bore Diameter

DfX - Design for Assembly, Manufacturing, and Environment

EDM - Electrical Discharge Machine

Kg - Kilogram

KN - KiloNewton

PDS - Product Design Specification

PLC - Programmable Logic Controller

LIST OF SYMBOLS

- pi (3.1415)

P - Pressure

C - Degree Celsius

F - Degree Fahrenheit


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LIST OF APPENDICES

APPENDIX NO. TITLE PAGE

A-1 Machine assembly drawing 112

A-2 Mold assembly drawing 113

A-3 Table assembly drawing 114

A-4 Top structure assembly drawing 115

A-5 Charging system assembly drawing 116

A-6 Brick pusher drawing 117

A-7 Charger drawing 118

A-8 Compactor drawing 119

A-9 Container drawing 120

A-10 Cover drawing 121

A-11 Hinge drawing 122

A-12 Middle bar drawing 123

A-13 Mold drawing 124

A-14 Movable base drawing 125

A-15 Planar base drawing 126

A-16 Horizontal plate structure drawing 127

A-17 Pusher base drawing 128

A-18 Pusher shaft drawing 129

A-19 Rod drawing 130

A-20 Slider base drawing 131

A-21 Slider compactor drawing 132


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A-22 Slider pusher drawing 133

A-23 Structure table 1 drawing 134

A-24 Structure table 2 drawing 135

A-25 Structure base drawing 136

A-26 Table structure drawing 137

A-27 Top mold drawing 138

A-28 Top structure 1 drawing 139

A-29 Top structure 2 drawing 140

B-1 Hydraulic cylinder 141

B-2 Hydraulic power pack 1 142

B-3 Hydraulic power pack 2 143

B-4 Vibration motor 144

C-1 Socket hex cap screw 145

C-2 Bolt, washer and nut 146

C-3 Bearing bush 147

D Steel; cost estimation 148


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CHAPTER 1

INTRODUCTION

1.0 Introduction

No construction is possible without bricks. Since many centuries brick making

has been practiced by human beings. Presently, bricks are easily made by using

machines using new technologies. Generally two types of bricks are manufactured by

using machines that are concrete block machines and clay brick machines. Different

types of automatic machines use different techniques to make bricks. The raw materials

used by the machines for making interlocking bricks are fly ash, sand lime, iron oxide,

lime sludge, quarry wastes etc.

The focus of this project is on the production of concrete bricks, specifically interlocking

bricks which offer a speedier, cost effective, environmentally sound alternative to

conventional walling materials. It is based on the principle of densification of a lean

concrete mix to make a regular shape, uniform, high performance masonry unit.

Concrete Block Technology can be easily adapted to suit special needs of users by

modifying some design parameters such as mix proportion, water to cement ratio and


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type of production system. It is an effective means of utilizing wastes generated by stone

crushers, quarrying and stone processing units. The technology has high potential in

areas where raw materials are easily available. The new technique in producing this

interlock brick can generate a highly profitable business for micro and small scale

building material producers and construction companies. The market for this type of

brick in Malaysia is not yet growing at a rapid rate, even though there are demands in

construction industries due to low production rate which reflect the cost of brick itself.

1.0.1 Interlocking Brick Specification

The interlocking bricks are different from other normal bricks as it requires no

mortar or cement for masonry work. This bricks interlocked with each other by means of

positives and negative frogs on the top and bottom of the bricks which disallow the

horizontal movement of bricks. There are various application of this bricks namely; load

bearing wall, lintels, sills, wall corners etc. The specifications and the characteristics of

this brick depend on the machine used to manufacture it. The most common size of brick

is 300x150x120mm. The basic raw material is cement, fine aggregate and coarse

aggregate. Very little water is used. This is possible only with mechanized compaction

and vibration and gives the block high quality in spite of the lean mix, which uses very

little cement. Weight of this brick is about 2 - 3 Kg.


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1.0.2 Production of Interlocking Brick Process

Current process of producing the interlocking brick is produced using a semi-

mechanized stationary type machine. The other production systems are - manual moulds

that require hand tamping, a mobile semi-mechanized egg-laying machine and fully

mechanized system that combines compression and manual concrete filling in mould.

The machine also compacts and consolidates the mix so that the blocks are uniform in

size and attain desired physical properties. The blocks are cured for a minimum period

of 14 days, before they are ready to use. On an average 600-800 blocks can be in 8 hours

by 1 skilled and 6-8 semi-skilled workers.

In this project, a high quality machines in which optimize from the current

machine design is going to propose according to the feedback and the need from the

interlocking brick maker.

1.0.3 Types of Interlocking Bricks

There are various types of interlocking bricks. The most commonly used cement

interlocking bricks are;

i. Regular Shaped Brickii. Half Size Brickiii. U-Shaped Brick

See figure 1.1 for types of interlocking brick


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Half Size Brick Regular Shaped Brick

U- Shaped Brick

1.1 Objective

The main objective of this project is to design a new bricks making machine with

new features and simplifying the machine for one man operation in order to reduced

operational cost and maximizes the production rate. Furthermore, the purpose of this is

to design the interlocking bricks making machine that suitable for SME entrepreneurs.

Figure 1.1: Type of Interlocking Brick


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1.2 Scope of project

The scope of project is clearly define the specific field of the research and ensure that

the entire content of this thesis is confined the scope. This project is start with the

literature review on product specification in order to satisfy the project objectives. After

obtaining the product specification, this project is done base on the scope below;

Project will focus on interlocking brick making machine only. Designing the inter-locking brick making machine that fulfill the project

objective.

Machine design to suit the regular interlocking bricks (Figure 1.1). The project goes until detail design of interlocking brick making machine. The major output of this project is to produce the detail drawing for the machine

design.

Fabrication of machine is excluded in this project.

The scope of work can be described in terms of flowchart as per the following Figure 2.


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`

Figure 1.2: Flow chart represents the scope of work

Literature Review on

Interlocking Bricks Making Machine

Machine Specification

Conceptual Design

Selection of Best Concept

Project II

Detail Design for Selected

Concept

Materials Selection

Machine Simulation (Software)

Detail Drawing

Project I


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Hans C. Sumpf [1] patent a machine comprising the combination of a

substantially horizontal main frame, wheels supporting the main frame above the ground,

power means to propel the main frame over and along the ground, a substantially

horizontal secondary frame, a vertically open brick mould supported in the secondary

frame for the vertical movement relative to the latter, means to lower and raise the

secondary frame to carry the mould to a point immediately adjacent the ground or to a

point elevated above the ground, a carriage carried on the secondary frame, means to the

carriage back and forth from end to end of the secondary frame, a mix feeding hopper

mounted on the carriage and movable therewith and effective to discharge the mix into

the mould during movement of the carriage. (See figure 2.1)

Figure 2.1Brick making machine by Hans C. Sumpf

Judson A. Hereford [2] designing portable brick manufacturing apparatus

mounted on a skid pad includes two brick making systems. Each system includes a ring

with three open ended mould boxes mounted to the ring in equiangular spacing

thereabout. Two systems share a compacting station share a compacting station and a

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brick ejection station. In one system, hoppers, conveyors a blender and a spray nozzle

deliver soil and additive to a mould boxes. (See figure 2.2)

Figure 2.2Brick making machine by Judson A. Hereford

Nicholas Lyons and C.K. George [3] invented the inverter multi-cell moulds

used in a brick making machine includes a first carrier for transporting a mould through

a first arcuate path, a second carrier for transporting a mould through a second arcuate

path to cause inversion of a mould and means for transferring a mould from the first to

the second carrier.(See figure 2.3)

S5

8

IG


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Figure 2.3Brick inverter machine by Nicholas Lyons and C.K. George

C.D. Vernon [4] designing concrete brick making machine, comprising standards,

a boring and packing head, mean rotatable supporting the head between the standards,

means for rotating the head, a carriage arranged between the standards, including an

elongated vertically extending head at each end. Shafts are fixed on head at several

points and extending beside the standard, roller on said shafts engaging said standard,

mean for lifting and lowering carriage, and spring bumpers positioned in the line of

movement of said heads as and the for the purposes set forth. (See figure 2.4)

n l


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Figure 2.4Brick making machine by C.D. Vernon

J.G. Charles [5] designing the brick making machine comprising a concrete feed

distributor subassembly, a mould and vibrating subassembly, a motor and frame

subassembly, a stamp and stripper subassembly, and a pallet feed and conveyor

subassembly operatively connected.

Florentin J. Pearne, Frank S. Pearne, and Frederick G. Robso [6] designing three

main components of brick making machine which are cement charging, bricks

compression, and bricks arrangement station.

Lewis Polak [7] patent the brick making machine by using vertical shaft powered

by crank shaft journal at the top thereof, a vertically moveable mould guided in the side

of the frame. The gear mechanism is used to operate the crank shaft. (See figure 2.5)


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John M. ODonnell [8] invented the process of manufacture of brick in which

having plurality of refractory brick characterized by uniformity of strength. It consists of

feeding system, compacting system, and charging system.

Figure 2.5Brick making machine by Lewis Polak

Yu-Fu Chen and Twu Ku Lin [9] designed the machine that used the pressure

mechanism to move the raw brick materials downwards and load into the filler trough,

than conveyed into the vacuum trough and compressed out through the forming holes.

Marc M. Breedlove [10] designed the machine that improving the appearance of

clay bricks. The patented items are the funnel shape of hopper in communication with a

vibrating mechanism.

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- j


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Donald P. Chennells [11] designing a concrete block-molding machine having a

concrete mix feed station, and a concrete molding and block ejection station adjacent to

the feed station wherein the concrete molding and block ejection station has a vibratile

plate having a plurality of holes in a pre-selected hole pattern and a support plate

dimensioned and patterned to form a bottom face of a molded concrete block. (See

figure 2.6)

Figure 2.6Brick making machine by Donald P. Chennells

In figure 2.7 show a small size machine currently available in market with single mold

operating system. This is a manual bricks making machine with 50 tons hydraulic

system and the production rate by using this machine is 800 bricks per day. The origin of

this machine is from India.

r ~


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Figure 2.7Small size bricks making machine

In figure 2.8 show a medium size machine currently available in market with four mold

cavities operating system. This is a semi-automatic bricks making machine with 60 tons

hydraulic system and the production rate by using this machine is 1800 bricks per day.

The origin of this machine is from Thailand.


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Figure 2.8Medium size bricks making machine

In figure 2.9 show a large size machine currently available in market with twelve mold

cavities operating system. This is a fully automatic bricks making machine with 100 tonshydraulic system and the production rate by using this machine is 17000 bricks per day.

The origin of this machine is from China.


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Figure 2.9Large size bricks making machine

2.2 Overview of the previous data regarding researched on the interlocking bricks.

In this sub-chapter, the overview of the previous researches about interlocking

bricks is briefly discussed in order to clearly justify the necessitate sources of previous

researches to be referred for this project.

Humberto C. Lima Jr, Fbio L. Willrich and Normando P. Barbosa [11]

Experimental study of three load bearing walls is presented and discussed in this paper.

The walls were of soil-cement bricks made with three different material proportions, in

which two of them had part of the cement amount replaced by crushed ceramic waste.


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CHAPTER 3

METHODOLOGY

3.0 Introduction

This chapter consists of methods for completing product development activities.

The applied methods, which are well-structured, provide a step-by-step approach to

complete the task of this project. Based on these methodologies, there are three

advantages expected. Firstly, the decision processes is completely made, reducing the

possibility of moving forward with unsupported decisions. Secondly, by acting as

checklist of the key steps in a development activity and ensure that the important

issues are not forgotten. Third, these structured methods are largely self-documenting; in

the process of executing the method, the record of the decision-making process can be

used for future reference. Figure 3.1 show the flow chart for completing this project.


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3.1 Concept Development Phase

Development process demands the coordination among functions of the

integrative development methods, which is called as the front-end process. The front-

end process generally contains many interrelated activities such as;

3.1.1 Identifying customer needs

The goal of this activity is to understand customers needs(users need)and to

effectively communicate them for the optimization job of current machine used. The

output of this step is a set of carefully constructed customer need statement, organized in

a hierarchical list, with importance weightings for many or all of the needs.

The data are obtained mainly by interviewing the user of interlocking brick making

machine and also from the observation of the current machine design. The identification

of the current machine design weaknesses is really helpful in providing the target

specification.

3.1.2 Establishing target specifications

Specifications provide a precise description of what a product has to do. It is the

translation of the customer needs into technical terms. Targets for the specifications are

set early in the process and represent the guide for generating the idea of machine


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modification. Later these specifications are refined to be consistent with the product

concept. The output of this stage is a list of target specifications.

3.1.3 Concept generation

The goal of concept generation is to thoroughly explore the space of the product

concepts that may address the customer needs. Concept generation includes a mix of

external search, creative problem solving, and systematic exploration of the various

solution fragments. The result of this activity is three generative concepts, each

typically represented by a sketch and brief descriptive text.

3.1.4 Concept selection

Concept selection is the activity in which the generated concepts are analyzed

and sequentially eliminated to identify the most promising concept(s). The process is

using the weightage value and a given marks. The highest score can be considered as a

chosen concept. Several iterations may initiate additional concept generation and

refinement. After evaluating three generated concepts in previous


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3.1.5 Setting final specification

The target specifications set earlier in the process are revisited after a concept has

been selected and tested. At this point, the specific values of the metrics reflecting the

constraints inherent in the product concept, limitations identified through technical

modeling, and trade-offs between cost and performance.

Identifying customer needs

Start

Establishing target

specifications

Concept generation

Concept selection

Setting final specification

Product Architecture

Finish

Project 1

Project 2

Detail

Drawing

Detail

Design

Material

selection

Process

Mechanical Drafting

Hydraulic & Electrical

Circuit Schematic

Diagram

Figure 3.1Method of designing the interlocking brick making machine


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3.2 Concept development

This subtopic shows the preliminary result obtained for completing product

development activities.

3.2.1 Identifying customer needs

Table 3.1, shows the finding data from the interviewing of interlocking brick

making machines user. ( Teras Maju Dinamik Sdn.Bhd. Tikam Batu, Sungai Petani,

Kedah.)

Table 3.1Customer statement and interpretation

Question/Prompt

Customer Statement Interpretation

Director

Increase production rate from 700 brickper day to 20,000 brick per day (???)

Reduce manpower Short ROI time period

Increase productivity One man operation Low machine cost

Engineer

It all automatic, only by single touch! No waiting time. Minimum 4 mould cavities per

compaction

Uniform pressure distribution Cooling system No messy maintenance.

Simple operation. Non-stop machining

cycle

Minimum 4 moldcavity

High compactionrigidity

Machine withcomplete system

Easy maintenance


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Labor

I dont like topress the compactor severaltimes just to make sure the brick meet it

dimension.

The brick is push to the conveyor andhave to turn to obtain the below mould

plate manually

Fool proof operation Automated operation

Suggested

Improvement

Nice rigid machine and marketable. An alert system and a safety feature. Marketable machine Effective alert system.

3.2.2 Establishing target specifications

Product specifications represent an unambiguous agreement in order to satisfy

the customer needs. The term product specifications are meant to describe the precise

description of what the product has to do. Where the most importance is no 5 and less

importance is no 1. After identifying the customer needs, target specifications are being

set. Customer needs are generally expressed in the language of customer. The primary

customer needs for machine improvement are listed in Table 3.2.

Table 3.2Customer needs

No Need Importance

1 High production rate 5

2 Minimum 4 bricks per cycle 53 One man operation 5

4 Simple operation. 5

5 Comes with auto arrange brick system 5

6 Comes with cement charging system 5

7 Comes with cooling system 2


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8 Fool proof operation 4

9 Automated function 3

10 Uniform pressure distribution 2

11 Can be easily access for maintenance 2

12 Safe to handle 2

13 Low cost machine 1

14 Marketable machine 1

15 Comes with alert system 1

3.2.2.1 High production rate

The machine must be able to increase the productivity of the brick output. The

main reason is it can supply the highly demand of interlocking brick in the construction

industries. This need is very important so that it is highly rated (5) as it is the factor of

the need of optimization the current machine design.

3.2.2.2 Minimum 4 bricks per cycle

The machine must have minimum four (4) mold cavities as it can produce four

interlocking bricks in one time. This is one of the factors that can increase productivity.

More mold cavities can rapidly increased the production rate.


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3.2.2.3 One man operation

The machine operation must be handled by a single worker only (one man

operation).

3.2.2.4 Simple operation process

Machine is operated by a simple on/off button only and no complicated process

in producing the interlocking bricks.

3.2.2.5 Complete with automatic arrangement brick system

Compare with the current machine system, for producing the interlocking brick

there is no proper process for arrangement of brick after it being produced. The main

objective of this system is to arrange the bricks on the pallet automatically.


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3.2.2.6 Complete with concrete charging system

The raw material/concrete is automatically loaded to the mold cavities before the

compression process begins. The process of charging is repeated automatically after

compaction process cycle take place.

3.2.2.7 Equipped with cooling system

The cooling system or cooling unit functions to cool down the hydraulic system

as heat is highly generated by the non-stop compaction process.

3.2.2.8 Infallible operation

The compression process compact the true value of pressure once. No need for

compress repetition.


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3.2.2.9 Automated function

Machine can run automatically for the process of cement charging/ loading to the

mold, compression, and arrangement of brick after compression.

3.2.2.10 Uniform pressure distribution

Compression pressure is uniformly distributed and applied on the brick during

compacting process.

3.2.2.11 Easy accessed for maintenance

Machine can be easily maintained and easily accessed for maintenance area.

3.2.2.12 Complete with alarm system

Alarm system sense the need of cement loading/charging and also detecting the

movement of operators body part inside the compactionarea for safety precaution.


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3.2.2.13 Safe to handle

Standard operation procedure is one of the factors that make the machine

handling is safe.

3.2.2.14 Low cost machine

The cost to build this machine must be reasonable and within the capability of

SME entrepreneurs so that the return of investment time can be shortened.

3.2.2.15 Marketable machine

Machine appearance and performance must be competitive and at affordable

price so that it benefit the SME entrepreneur.

The most useful metrics are those that reflect as directly as possible the degree

to which the product satisfies the customer needs. The relationship between needs and

metrics is central to the entire concept of specifications. The working assumptions is that

a translation from customer needs to a set of precise, measurable specifications is

possible and that meeting specifications will therefore lead to satisfaction of the

associated customer needs as shown in table 3.3.


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Table 3.3Matrix table

Metric No. Need Nos. Metric Imp. Units

1 1,2,4,5,6,9,11,15 Production rate 5 Cycle/Hour

2 3 Labour 5 Manpower

3 7 Cooling rate 2 kW

4 8,10 Compression pressure 5 Pa

5 11 Maintenance 1 Subj.

6 12,15 Safe Standard 3 SIRIM

7 13,14 Unit price (machine) 2 RM

8 14 Aesthetic 1 Subj.The relative importance of each metric and the units for the metric are also shown Subj is an

abbreviation indicating that a metric is subjective.

Table 3.4Needs-matrix table

NO Metric

Productionrate

Labour

Coolingra

te

Compression

pressure

Maintenan

ce

SafeStand

ard

Unitprice

(machine)

Aesthetic

1 High production rate 2 Minimum 4 bricks per cycle 3 One man operation 4 Simple operation. 5

Comes with auto arrange brick

system 6

Comes with cement charging

system

7 Comes with cooling system 8 Fool proof operation 9 Automated function 10 Uniform pressure distribution 11

Can be easily access for

maintenance


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12 Safe to handle 13 Low cost machine 14 Marketable machine 15 Comes with alert system

3.2.3 Concept generation

After identifying a set of customer needs and establishing the target product

specifications, the concept of modified interlocking brick making machine can be

generated by identifying the main problem that preventing customer to get their needs

and requirement.

3.2.3.1 Problem Identification

Current machine design unable to increase productivity, this is mainly due to;

i. Time wasting by doing the cement charging/loading and leveling the cement.(Time required: 50 seconds). See figure 3.2 & 3.3.

ii. Manually obtaining the lower mold plate as operator needs the device to turn thebrick (Time required: 45 seconds). See figure 3.4& 3.5.

iii. The load applied several time on the interlocking brick (Time required: 15seconds). See figure 3.6 &3.7.


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iv. Operator need to manually pick-up the brick one by one after compactionprocess before start the new process cycle (Time required: 20 seconds). See

figure 3.8.

v. The mold lower plates are manually inserted one by one (Time required: 45seconds). See figure 3.9.

(Picture taken at Teras Maju Dinamik Sdn.Bhd. Tikam Batu, Sungai Petani, Kedah)

Figure 3.2Cement charging/loading Figure 3.3Operator leveled the cement

Figure 3.4Device to turn the brick


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Figure 3.6Before compaction process

Figure 3.5Process of turn the brick

Lower mold

late


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Figure 3.7Pressure loading on bricks

Figure 3.8Operator manually pick-up the brick one by one.


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After identifying the weaknesses of the current design, literature review (chapter

2) is uses to get the basic idea of the existing solution concepts. The propose concepts

are then generated according to the problem solution and establishment of customer

needs and specification. So the challenge is to design a interlocking brick making

machine that fulfilling the target product specification. The knowledge in mechanical

and hydraulic systems is crucially needed for generating the design concept.

3.2.3.2 Concept 1

Cantilever concept refer to figure 3.10 and 3.11

Figure 3.9Operator manually insert lower mold plate one

by one.


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Figure 3.10Concept 1-Cantilever concept (3D view)

Figure 3.11Concept 1-Cantilever concept (Drawing view)


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Table 3.5Concept 1 description

No Requirement Description

1 Production rate

Automatic charging/loading and brick ejecting system

Reducing the waste identified previously.Productivity increase as production time being reduced.

2 Labour One man operation with the simple control panel

3 Cooling rate The cooling system is inside the panel box

4Compressionpressure

Vertical compression hydraulic systemThe location of cylinder is beside of machine itself.

5 MaintenanceMaintenance is easy due to all critical item are in the

machine control box

6 Safe Standard Machine operation is able to follow the safety standard;however in this design the moving parts are expose to theworking environment.

7Unit price(machine)

n.i.l.

8 AestheticThe machine dimension is a bit long due to charging/loading

system, others are nice and tidy

3.2.3.3 Concept 2

Center cylinder concept refer to figure 3.12 and 3.13


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Figure 3.12Concept 2-Center cylinder concept (3D view)

Figure 3.13Concept 2-Center cylinder concept (Drawing view)


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1 Production rate

Automatic charging/loading and brick ejecting system

Reducing the waste identified previously.

Productivity increase as production time being reduced.2 Labour One man operation with the simple control panel


4Compressionpressure

Vertical compression hydraulic systemThe location of cylinder at the center of machine itself.

5 MaintenanceMaintenance is easy due to all critical item are in themachine control box

6 Safe Standard

Machine operation is able to follow the safety standard; as

this machine concept is compact and all moving part are

inside the machine working area.

7 Unit price(machine)

n.i.l.

8 AestheticThe machine is compact and suitable for small working area.Machine is nice and compact.

3.2.3.4 Concept 3

Horizontal compaction concept refer to figure 3.14 and 3.15


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Figure 3.14Concept 3-Horizontal compaction concept (3D view)

Figure 3.15Concept 3-Horizontal compaction concept (Drawing view)


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1 Production rate

Automatic charging/loading and brick ejecting system (the

bricks are drop as the compaction cylinder retract and

conveyor will transfer the bricks)Reducing the waste identified previously.

Productivity increase as production time being reduced.

2 Labour One man operation with the simple control panel


4Compression

pressure

Horizontal compression hydraulic system

The location of cylinder is below the charging container.

5 MaintenanceMaintenance is easy due to all critical item are in the

machine control box

6 Safe Standard

Machine operation is able to follow the safety standard; as

this machine concept is compact and all moving part areinside the machine working area.

7Unit price

(machine)n.i.l.

8 AestheticThe machine is compact and suitable for small working area.

Machine is nice and compact.

3.2.4 Concept selection

The first step in using Concept Screening is to identify the criteria that will be

use and can generate significant debate itself. Each concept is then being examines and

compares it against each criterion to give it a relative score. The scoring scheme for this

are +1, 0 and -1 to show better, same, worse or may have values to indicate how much

better or worse it is. Each option then has its score totaled to show its overall score

relative to the base option. If one option scores much higher, then this is clearly likely to

be the best choice.


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3.2.4.1 Concept screening

The purpose of concept screening is to narrow down the concept selection. In

addition, the concepts are analyzed for improvement possibilities. The reference concept

for the analysis has been identified, which is the existing interlocking brick making

machine which is currently used. The machine is used as reference because it is

currently represents the high production rate brick making machine available in

Malaysia. Furthermore, it is a straightforward and familiar concept which can easily

access. There are 3 concepts which are going to be compared against the reference

concept. The comparison will be done with related to all customer needs.

From the evaluation of the concept screening, concept 1 and concept 2 having

the same rank (table 3.8). This mean Concept 1 in which having a cantilever type of

hydraulic cylinder attachment and Concept 2 in which having cylinder at the center is

fulfilling the customer requirement is rank as the most preferable concept; the second

most preferable concept is concept 3 which used the horizontal compaction system.

Concept 3 is eliminated from the concept selection which means that the concept is

below the standard customer expectation.

Table 3.8Concept screening matrix

Selection Criteria Current Concept 1 Concept 2Concept 3

(Horizontal)

High production rate - + + -

Minimum 4 bricks per cycle - + + +

One man operation - + + +

Simple operation. - + + +

Comes with auto arrange brick system - + + +

Comes with cement charging system - + + +

Comes with cooling system 0 0 0 0

Fool proof operation - + + -


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Automated function - + + +

Uniform pressure distribution - + + -

Can be easily access for maintenance 0 0 0 0

Safe to handle - + + -

Low cost machine 0 - - -

Marketable machine 0 + + +

Comes with alert system - + + +

SUM + 0 12 12 8

SUM 0 4 2 2 2

SUM - 11 1 1 5

Net Score -11 11 11 3

Rank 4 3 2 6

Continue? No Yes Yes No

Rate the conceptRelative Performance Rating

Much worse than reference 1

Worse than reference 2

Same as reference 3

Better than reference 4

Much better than reference 5

3.2.4.2 Concept scoring

A concept-scoring matrix (Table 3.9) relates the concepts chosen from the

screening matrix to customer needs using weights to show the importance of needs. The

reference in the scoring matrix is not only one concept as it is in the screening matrix.

The reference is spread out among concepts for each need, giving better results since one

concept would not be completely average in all categories. The score rating from one to

five is given to each concept according to their need depending on the importance to the

overall design with five being the most important and one being the least important. This


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way of scoring makes the concept-scoring matrix more accurate than the concept

screening importance to the overall design with five being the most important and one

being the least important. After all categories and concepts are scored, the score is

multiplied by the weight and added down a column. The weight percentage is based on

the customer requirements priority. From the listed customer needs, several important

needs are valued with high percentage of weightage.

Concept 2 scored higher than concepts 1. This concept has a vertical

compression system that has a bridge to support the hydraulic cylinder. Even though

both of concept using the hydraulic system to compact the brick, the structure of how the

cylinder being attached to the structure affecting the process of machine operation.

Furthermore, concept 2 has a compact shape in which having more aesthetic value

compare to concept 1. Comparing the safety features between both concepts, concept 2

due to having a compact shape, moving machine part is minimize and became more

safety to the machine operator, while concept 1 has a moving part expose to area

working area. From the concept selection activities, the interlocking brick making

machine that bas bridge support cylinder has proved to satisfy most of the customer

requirements. From this selection, Concept 2 has been chosen as the selected concept.

However, it is not a mandatory to follow exactly this concept. This process is just a

guideline in designing the modification that need to improve in order to fulfill the

customer requirements and needs.

Table 3.9Concept scoring matrix

Concept

1

Concept

2

Selection Criteria Weight RatingWeighted

ScoreRating

Weighted

Score

High production rate 10.4% 5 0.52 5 0.52

Minimum 4 bricks per cycle 10.4% 5 0.52 5 0.52

One man operation 10.4% 5 0.52 5 0.52

Simple operation. 10.4% 5 0.52 5 0.52


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Comes with auto arrange brick

system10.4%

5 0.52 5 0.52

Comes with cement charging

system10.4%

5 0.52 5 0.52

Comes with cooling system 4.2% 5 0.21 5 0.21

Fool proof operation 8.3%4 0.332 5 0.415

Automated function 6.3% 5 0.315 5 0.315

Uniform pressure distribution 4.2% 5 0.21 5 0.21Can be easily access for

maintenance4.2%

5 0.21 5 0.21

Safe to handle 4.2% 4 0.168 5 0.21

Low cost machine 2.1% 4 0.084 4 0.084

Marketable machine 2.1% 3 0.063 4 0.084

Comes with alert system 2.1% 5 0.105 5 0.105

Total Score Rank4.817 4.963

Rank 2 1

Continue? NO YES!!!

Rate the concept

Relative Performance Rating

Much worse than reference 1

Worse than reference 2

Same as reference 3

Better than reference 4

Much better than reference 5

3.3 Discussions

This type of projects involves a major modification effort to enhance the current

design become automated and high production rate. The new optimized machine must

have an excellent working principle compared to current machine used.


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This phase begins with the needs of customer thru interviews (site visit), and

observing the product in use. From customer, the statements are interpreted in terms of

customer needs. These interpret data are organize into a hierarchical list where consist of

a set of primary needs and a set of secondary needs. The relative importances of the

needs are established in term of numerical importance weighting for a subset of the

needs. Scale of 1 to 5 (1 not important and 5 highly importance) are used to summarize

the importance data.

The target specifications for interlocking brick making machine are established

after the customer needs have been identified. A good way to generate the list of metric

is to contemplate each need in turn and to consider what precise, measurable

characteristic of the product will reflect the degree to which the product satisfied the

need. The units of measurement are most commonly conventional engineering units.

After identifying a set of customer needs and establishing target product

specifications, the machine modification concept is being generated. Three concepts

generated for proposed modification, which are interlocking brick making machine that

have cantilever structure holding compaction cylinder (Concept 1), brick making

machine that have cantilever structure holding compaction cylinder (Concept 2), and

brick making machine that have horizontal compression system (Concept 3).

In concept selection, the concepts being evaluated with respect to customer needs

and other criteria, comparing the relative strengths and weakness of the concepts, for

further investigation. To narrow the number of concepts quickly and to improve the

concepts, the screening matrix is used. The current machine design used has been chosen

to become reference concept, against which all other concepts are rated. In concept

scoring, the concepts are weighted relative to the importance of the selection criteria and

focuses on more refined comparisons with respect to each criterion. The concept scores


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are determined by the weighted sum of the rating. Concept 2 is selected as it obtain

higher score compare to the concept 1. Final product specification then being refine

according to the chosen concept before developing the detail design of the interlocking

brick making machine with bridge supporting compaction cylinder system.


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CHAPTER 4

RESULT AND DISCUSSION

4.1 Product Architecture

The architecture of a product can influence many aspects of its life-cycle

performancefrom the design phase through to the recycling of a product and the reuseof fragments of its design. Product architecture choice therefore deserves careful

consideration, which would be facilitated by the ability to represent and assess

alternatives at an early stage.

In this context, product architecture refers to the conceptual structure of a design.

It has been defined by Ulrich [1] as the arrangement of functional elements, the mapping

from functional elements to physical components, and the specification of the interfaces

among interacting physical components. Others extend this definition to include the

division of a product into functional modules and component-sharing relationships

within a family of products.


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Product architecture may be represented using a product modeling language.

There are many such languages, which vary in the types of information they represent

and the way in which they do so. Models of a products architecture cons tructed in such

languages may be used for various purposes, including communication between the

client and a design team or within a design team, or (the focus of this paper) for

assessing the product against life-cycle objectives. These objectives may be classified

into performance-related objectives and those related to other aspects of the products

existence. Many objectives in the second class, also termed non-functional requirements,

are addressed by Design for X (DfX) methods (where X may be Assembly,

Manufacture, Environment etc.) [1].

4.1.1 Detailed Design

The designed interlocking brick making machine consist of four major sub-

assemblies in which having several components or parts that can be classify to standard

parts and custom part. Figure 4.1 show the overall machine assembly design. The main

feature of this designed machine is that it is purposely design in a compact size with a

fully automatic function in order to produce bricks in four mold cavities.

The parallel acting actuators or cylinders at the top structure assembly applying

80 tone of force for pressing the bricks in mold cavities. The next process, the bottom

cylinder will push the compacted bricks up in which ready to be push out on to conveyor

(unavailable in this design) by the charger then the bottom cylinder will retract and

concrete charging into mold take place simultaneously as the bottom cylinder retract.

Then, comes the work of vibration motors under the table structure ensuring the concrete

is fully loaded into mold.


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The process continue with charger retraction under the container for concrete

refill, vibration motor attached on the container is helping the refilling process and this

work simultaneously with the movement of top cylinder to press the concrete in mold.

The processes are continuously done automatically.

4.1.1.1 Mold

Mold assembly (figure 4.2) consists of six different parts and each of it can be

produce by conventional machine process except for mold itself which require the

modern machining process namely Wire EDM. One of the six parts is M10 Hex cap

Figure 4.1Total assembly design


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screw. Details can refer to figure 4.15. The mold is attached on the table structure by

bolt M20.

4.1.1.2 Table Structure

Table Structure assembly (figure 4.3) consists of fifteen different parts and each

of it can be produced by conventional machine process and join by using welding

Figure 4.2Mold assembly design


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process for the structure. Beside M16 and M12 bolt and nut, this sub-assembly consists

of two vibration motor and a hydraulic cylinder. Details can refer to figure 4.16. The

mold is attached on the table structure by bolt M20.

4.1.1.3 Top Structure

Top Structure assembly (figure 4.4) consists of thirteen different parts and each

of it can be produce by conventional machine process except for top mold itself which

require the modern machining process namely Wire EDM and join by using welding

Figure 4.3Table structure assembly design

[ ] C TI V for Student [ SSEMBLY T BLE SSY C TProductj ~ ~


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process for the structure (hinge and compactor, and top structure 2) component. Beside

M24, M20 and M10 bolt, nut, and hex cap screw, this sub-assembly consists of two

hydraulic cylinders. Details can refer to figure 4.17. This structure is attached on the

mold structure by M20 bolt.

Figure 4.4Top structure assembly design

JC TI V for Student [ SSEMBLY TOP COMPOHEHT C TProduct]

' I st rt [ ] CATIA 5for tl denl: r ~ k o t 48PM


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4.1.1.4 Charging System

Charging system assembly (figure 4.5) consists of sixteen different parts and

each of it can be produce by conventional machine process (except for charger,

container and cover suitable process is laser cutting).and join by using welding process

for the structure (brick pusher, slider base, structure base, and charging structure)

component. Beside M20, M12, and M4 bolt, nut, and hex cap screw, this sub-assembly

consists of one hydraulic cylinder and also a vibration motor. Details can refer to figure

4.18. This structure is attached on the mold structure by M16 bolt and table structure by

M12.

Figure 4.5Charging system assembly design

] C TI V forStudent [ SSEMBLY CH RGING SSY C TProductj ~ ~


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In this sub-assembly lays the heart of the machine whereby the control system

devices are place inside the control panel. The control panel consists of on/off knob, two

hand control as a point of operation safeguarding device. The palm button must be

depressed concurrently and maintained during the hazardous down stroke of the ram.

Release of palm button reverses or stops the action of ram. The controls offered also

include a light curtain interface. All the electronics parts are placed inside the control

panel box (figure 4.6).

Figure 4.6Inside control panel


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4.1.2 Material and Process Selection

Table 4.1Material and process selection

No. Part Material Manufacturing

Process

1

Brick pusher assembly

i) Steel rod(Mild Steel) Cutting process

by hacksaw

ii) Sheet metal(Mild Steel)

Cut by shearing

machine; Laser

cutting, etc.

Assemble by welding process

2

Charger

i) Steel bar Cutting processby hacksaw

ii) Sheet metal(Mild Steel)

Cut by shearing

machine; Laser

cutting, etc.



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3

Compactor

i) Metal plate(Mild Steel)

Milling, drilling,

counterboring.

4

Container

i) Sheet metal(Mild Steel)

Laser cutting,

Turret punching,

and welding

process for

joining.

5

Cover

ii)Sheet metal(Mild Steel)

Laser cutting,

Turret punching,

and welding

process for

joining.


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6

Hinge

i) Steel bar Milling anddrilling process

Join on the top of compactor by

welding process

7

Middle Bar

i) Steel Bar(Mild Steel)

Cut by sawing

process, drilling,

and tapping.

8

Mold

i) Steel Block(Mild Steel)

Drilling and

wire cutting


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9

Movable Base

i) Steel Plate(Mild Steel)

Milling, drilling,

counterboring

and wire cutting

10

Planar Base


Milling, drilling,

and

counterboring.

11

Plate Structure

i) Angle Barii)Steel Bar

Cut by sawing,

and drilling



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15

Slider Base


Steel plate cut

into several

parts, then

further withmilling and

drilling process.

The parts then

join by welding

process.

16

Slider Compactor

i) Steel rod(Carbon steel)

Cut by sawing

process drilling

and tapping.

17

Table Structure 1

i) Angle Bar(Mild Steel)

Cut by sawing

process drilling.


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18

Table Structure 2

i) ParallelFlange

Cut by sawing

process drilling.

19

Structure Base

i) Steel Bar(Mild steel)

Cut by sawing

process, drilling,

and welding.

20

Table

i) Angle Barii)

ParallelFlange

Cut by sawing

process, drilling,

milling, and

welding.


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21

Top Mold

i) Steel Block(Mild Steel)

Drilling, tappingand wire cutting

22

Top Structure 1

i) ParallelFlange

Cut by sawing

process drilling,

and milling

23

Top Structure 2

i) ParallelFlange

Cut by sawing

process drilling,

and milling

ii) Steel Bar(Mild Steel)

Cut by sawing

process, and

drilling.



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27

Bottom Cylinder (PMC42008)

- Stroke150mm

- BoreDiameter

30mm

- Force 1KN

Standard

hydraulic

cylinder with

bottom

mounting

28

Top Cylinder (PMC21020)

- Stroke450mm

- BoreDiameter

80mm

-

Force800KN

Custom

hydraulic

cylinder with

special

mounting


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4.1.3 Detail Drawing

4.1.3.1 Mechanical drawing

See Appendix A

4.1.3.2 Electrical/electronic design

4.1.3.2.1 Electrical wiring

All wiring pertaining to this project is carried out during this stage. Upon which

all the connections are based on well-documented forms of terminal block. The

installation such as wires, switches, and sensors are done before the programming is

carried out. Terminal blocks are used to joint programmable logic controller input/output

with all the sensors, push button, solenoid valve, indicator lamp, and switches. Input and

output addressing are labeled for easy references when troubleshooting is carried out.

MCB are used after the isolation switch for safety purpose, as well as used to limit the

current rating where the circuit breaker will break if the current exceeded the rating. This

will prevent damage of the electrical instrument used.


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Figure 4.7Electrical Wiring Diagram

4.1.3.2.2 PLC wiring

Programming using programmable logic controller provides an idea on how to

automate a semi-automated process that is done in the industry. Programmable logic

controller is used to give an output when trigger the input signals. This provides the user

with a signal input for the mechanism to move step by step that set by the programmable

logic controller.

Motor Motor

E - - - - - - - - - - - : f - - - - - - - - - - - - - - - - - - - - - - - - - - - -- = = = _ _ _ ~ l

: pr;=J ;=J ;: ELC EMERGENCY

0 1 l WT H\ : M IN SWTCH,,,

Me ,,,,,, POWER SUPPLY ,, 4VDC, i I7 200,,


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Figure 4.8PLC Wiring Diagram

4.1.3.2.3 Indicator Lamp Wiring

Figure 4.9 shows that the Indicator lamp wiring diagram for the electrical design.

Q1.0, Q1.1 and Q1.2 are connecting direct to PLC S7200 as an output. The Indicator

Reed Switch

Normally Open Switch

Normally Close Switch

Solenoid Valve

Sensor

Tower Lamp

MTR

ST NR E V

PLC S7 2 U 226


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lamp supply is 240Vac which are connected through Relay 1 for yellow lamp, Relay 2

for red lamp and Relay 3 is for green lamp.

L

N

Q1.2

Q1.1

Q1.0

0V

YELLOW

RED

GREEN

RELAY 1

RELAY 2

RELAY 3

Figure 4.9Indicator Lamp Wiring diagram


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4.1.3.3 Hydraulic Circuit Diagram

Figure 4.10Hydraulic circuit diagrams

For the hydraulic fluid to do work, it must flow to the actuator and or motors,

then return to a reservoir. The fluid is then filtered and re-pumped. The path taken by

hydraulic fluid is called ahydraulic circuit of which there are several types. Open center

circuits use pumps which supply a continuous flow and close loop circuit which can

work with higher pressure. In this circuit design close loop hydraulic circuit system is

used due to its advantages over open loop circuit. Besides well work with high pressure

requirement this system also not using directional valve and having better response. The

pump swivel angle covers both positive and negative flow direction. However, the cost

Top Cj1lnder PressPusner Bottom Cl1inder Press , , ,

B B

, , , , , , ow: g , , , , , ,ST .....T ... , f ; .u ,, . . g ,STOP g , , , , , , . T;. ~ ~ J T;. ; 1 [ ; 1 I c 1 0:: ....
http://en.wikipedia.org/wiki/Filter_(oil)http://en.wikipedia.org/wiki/Hydraulic_circuithttp://en.wikipedia.org/wiki/Hydraulic_circuithttp://en.wikipedia.org/wiki/Filter_(oil)


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of using this close loop circuit is quite high due to equipment use to avoid overheat and

leakage. This is due to pump cannot be utilized for any other hydraulic function in an

easy way and cooling can be a problem due to limited exchange of oil flow. High power

closed loop systems generally must have a 'flush-valve' assembled in the circuit in order

to exchange much more flow than the basic leakage flow from the pump and the motor,

for increased cooling and filtering.

The flow is returned to tank through the control valve's open center; that is, when

the control valve is centered, it provides an open return path to tank and the fluid is not

pumped to a high pressure. Otherwise, if the control valve is actuated it routes fluid to

and from an actuator and tank. The fluid's pressure will rise to meet any resistance, since

the pump has a constant output. If the pressure rises too high, fluid returns to tank

through apressure relief valve.In the hydraulic systems designed it consists of;

i. Hydraulic pumpii. Control valves

iii. Actuatorsiv. Reservoirv. Accumulators

vi. Hydraulic fluidvii. Filters

viii. Tubes, pipes and hosesix. Seals, fittings and connections

According to table 4.2 this new machine performs at 85 seconds per cycle

compare to current machine used. The performance of this machine is three time higher

as compare to current machine which perform at 3 minutes per cycle.
http://en.wikipedia.org/wiki/Pressure_relief_valvehttp://en.wikipedia.org/wiki/Pressure_relief_valve


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Table 4.2 Function diagram

ComponentTime

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85

Designation Identification SignalStep

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Cylinder A A11

0

Cylinder B B11

0

Cylinder C C11

0

Vibrator 1 M1On

Off

Vibrator 2 M2On

Off

71


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4.1.3.3.1 Basic calculation of hydraulic power needed

Hydraulic power is defined as Flow x Pressure. The hydraulic power supplied by

a pump: P in [bar] and Q in [lit/min] => (P x Q) 600 [kW].

The machine needs to apply the forces of 800kN (Maju Dinamik Sdn. Bhd.) on the

concrete particle inside the mold in order to form the interlocking brick.

Therefore;

From top structure designed, bore diameter = 112mm, after compensate for

10mm wall cylinder.

Area for hydraulic bore = (D/2)2= (0.112m)

2

= 0.04m2

Required force = 800kN

Pressure = Force / Area

= 800kN / 0.04m2

= 20 Mpa (200 bar)

According to standard hydraulic part in catalog in Appendix, the most suitable

cylinder with required stroke is PMC21020 with 5 bore diameter, shaft diameter 2.5,

and 20 stroke (required stroke 18 or 460mm).

Due to high pressure system required the power unit also should carefully

selected in order to make sure that the system is under power which mean the bricks are

not well compress and may rise a quality issue to the end user. However if the high


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power of power unit is chosen the system can be say as under utilize as the power

required is less than supplied by power pack unit and furthermore, the cost is higher than

the middle power of power pack unit.

According to standard power unit in catalog in Appendix, the most power unit

with required 200bar of pressure is 255617 part number with 3000psi and 5 gallon of

reservoir tank capacity in which sufficient enough to supply the hydraulic oil for both

cylinders during operation and hold the oil during machine shut down.

4.1.3.3.2 Weaknesses of hydraulic system and it counter measure

4.1.3.3.2.1 Abnormal Noise

Abnormal noise in hydraulic systems is often caused by aeration or cavitations.

Aeration occurs when air contaminates the hydraulic fluid. Air in the hydraulic fluid

makes an alarming banging or knocking noise when it compresses and decompresses, as

it circulates through the system. Other symptoms include foaming of the fluid and erratic

actuator movement. Aeration accelerates degradation of the fluid and causes damage to

system components through loss of lubrication, overheating and burning of seals.

Air usually enters the hydraulic system through the pumps inlet. For this reason,

it is important to make sure pump intake lines are in good condition and all clamps and

fittings are tight. Flexible intake lines can become porous with age; therefore, replace

old or suspect intake lines. If the fluid level in the reservoir is low, a vortex can develop,


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allowing air to enter the pump intake. Check the fluid level in the reservoir, and if low,

fill to the correct level. In some systems, air can enter the pump through its shaft seal.

Check the condition of the pump shaft seal and if it is leaking, replace it.

Cavitation occurs when the volume of fluid demanded by any part of a hydraulic

circuit exceeds the volume of fluid being supplied. This causes the absolute pressure in

that part of the circuit to fall below the vapor pressure of the hydraulic fluid. This result

in the formation of vapor cavities within the fluid, which implode when compressed,

causes a characteristic knocking noise.

The consequences of cavitations in a hydraulic system can be serious. Cavitation

causes metal erosion, which damages hydraulic components and contaminates the fluid.

In extreme cases, cavitations can cause mechanical failure of system components. While

cavitations can occur just about anywhere within a hydraulic circuit, it commonly occurs

at the pump. A clogged inlet strainer or restricted intake line will cause the fluid in the

intake line to vaporize. If the pump has an inlet strainer or filter, it is important for it not

to become clogged. If a gate-type isolation valve is fitted to the intake line, it must be

fully open. This type of isolation device is prone to vibrating closed. The intake line

between the reservoir and pump should not be restricted. Flexible intake lines are prone

to collapsing with age; therefore, replace old or suspect intake lines.

4.1.3.3.2.2 High Fluid Temperature

Fluid temperatures above 180F (82C) can damage seals and accelerate

degradation of the fluid. This means that the operation of any hydraulic system at


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temperatures above 180F is detrimental and should be avoided. Fluid temperature is too

high when viscosity falls below the optimum value for the systems components. The

temperature at which this occurs is dependent on the viscosity grade of the fluid in the

system and can be well below 180F.

High fluid temperature can be caused by anything that either reduces the

systems capacity to dissipate heat or increases its heat load. Hydraulic systems dissipate

heat through the reservoir. Therefore, the reservoir fluid level should be monitored and

maintained at the correct level. Check that there are no obstructions to airflow around

the reservoir, such as a buildup of dirt or debris.

It is important to inspect the heat exchanger and ensure that the core is not

blocked. The ability of the heat exchanger to dissipate heat is dependent on the flow rate

of both the hydraulic fluid and the cooling air or water circulating through the exchanger.

Therefore, check the performance of all cooling circuit components and replace as

necessary.

When fluid moves from an area of high pressure to an area of low pressure

without performing useful work (pressure drop), heat is generated. This means that any

component that has abnormal internal leakage will increase the heat load on the system.

This could be anything from a cylinder that is leaking high-pressure fluid past its piston

seal, to an incorrectly adjusted relief valve. Identify and change-out any heat-generating

components.

Air generates heat when compressed. This means that aeration increases the heat

load on the hydraulic system. As already explained, cavitations is the formation of vapor

cavities within the fluid. These cavities generate heat when compressed. Like aeration,


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cavitations increases heat load. Therefore, inspect the system for possible causes of

aeration and cavitations.

In addition to damaging seals and reducing the service life of the hydraulic fluid,

high fluid temperature can cause damage to system components through inadequate

lubrication as a result of excessive thinning of the oil film (low viscosity). To prevent

damage caused by high fluid temperature, a fluid temperature alarm should be installed

in the system and all high temperature indications investigated and rectified immediately.

4.1.3.3.2.3 Slow Operation

A reduction in machine performance is often the first indication that there is

something wrong with a hydraulic system. This usually manifests itself in longer cycle

times or slow operation. It is important to remember that in a hydraulic system, flow

determines actuator speed and response. Therefore, a loss of speed indicates a loss of

flow.

Flow can escape from a hydraulic circuit through external or internal leakage.

External leakage such as a burst hose is usually obvious and therefore easy to find.

Internal leakage can occur in the pump, valves or actuators, and unless you are gifted

with X-ray vision, is more difficult to isolate.

As previously noted, where there is internal leakage there is a pressure drop, and

where there is a pressure drop heat is generated. This makes an infrared thermometer a


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useful tool for identifying components with abnormal internal leakage. However,

temperature measurement is not always conclusive in isolating internal leakage and in

these cases the use of a hydraulic flow-tester will be required.

The influence of internal leakage on heat load means that slow operation and

high fluid temperature often appear together. This can be a vicious circle. When fluid

temperature increases, viscosity decreases. When viscosity decreases, internal leakage

increases. When internal leakage increases, heat load increases, resulting in a further

increase in fluid temperature and so the cycle continues.

Proactively monitoring noise, fluid temperature and cycle times is an effective

way to detect conditions that can lead to costly component failures and unscheduled

downtime of hydraulic equipment. In most cases, informed observation is all that is

required.

4.2 Components Analysis

In this section, the critical parts which are top structure and the table structure are

being tested by putting the maximum force along its structure. The analysis are

conducted by using the CAE software namely CATIA V5 in order to obtain the result.


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4.2.1 Top Structure

The maximum forces 800kN exerted at the cylinders mount and also distributed

along top plate. Figure below shows the result of simulation analysis, it seems that the

maximum Von Mises Stress does not exceed that Yield Strength of the structure, so that

the top structure can be considered as tough enough to work with 800kN forces from

hydraulic cylinder.

Figure 4.11Top structure stress analysis

I JCATIA V for Student [ naIYSls topstructure CATAnaIYSls] g ~ r R J

DisplayOn deformed meshOn boundaryOver all the modelExtrema ValuesMin: 12045.8 N_m2Max: 1.67058e 008 N_mFilters3D elements:Components: AllDefined MaterialsMaterial: SteelYoung Modulus: 2e 011N_m2Poisson Ratio: 0.266Density: 7860kg_m3Thermal Expansion: 1 17e-005_Kdeg

Yield Strength: 2.5e 008N_m2

_ x

II> I:;


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4.2.4 Planar Base Structure

The maximum forces 800kN exerted on the planar base and distributed along it

face. Figure below shows the result of simulation analysis; it seems that the maximum

Von Mises Stress does not exceed that Yield Strength of the structure, so that the table

structure can be considered as tough enough to work with 800kN forces from hydraulic

cylinder.

Figure 4.17Planar Base structure stress analysis

>Object name: Von Mises stress nodal values . 1DisplayOn deformed meshOn boundaryOver all the modelExtrema ValuesMin: 239568 N_m2Max: 2.16376e+008 N_m2Filters3D elements:Components: All

Defined MaterialsMaterial: SteelYoung Modulus: e OllN_mPoisson Ratio: 0.266Density: 7860kg_m3Thermal Expansion: 17e-005_KdegYield Strength: 2.5e+008N_m2

l>-. .::>

c O;.{f j


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The analysis also shows the result of displacement of the compactor structure

after applying the 800kN forces on it. The maximum displacement 0.273 mm occurs at

the center of the top plate, and it seems this maximum displacement is still not

exceeding the elastic region of the top plate material properties.

Figure 4.18Planar base structure displacement result

]C TI V for Student [AnaIYSls ] x

~ ~ j)Il;.iJ ~

l ro. ~

~ i l

~

~~

~


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4.3 Cost Analysis

In todays competitive business environment, pricing strategy can be a critical

factor that can make the difference between success and failure. Organisations that are

cost efficient would have a clear competitive advantage, therefore accurate and timely

cost information can go a long way in helping these organisations become successful.

Organisations also need to control their cost through effective budgeting and variance

analysis. This will enable them to quickly take corrective action and steer the

organisation back on track.

4.3.1 Guidelines for Calculating the Brick Selling Price

The data presented in this sub topic is meant to help entrepreneurs to estimate the

production cost of compressed brick with a view to identifying the lowest costing

technology and size of production. A methodological framework for the estimation of

production costs is described in the following sections.

It should be noted that the cost of producing compressed brick will vary a great

deal from country to country and even from one area to another within the same country.

Unit production costs will differ in relation to local conditions.

Causes for cost variations include:

Availability of soil, whether it is available on site or has to be transported to thesite.


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Suitability of the soil for stabilisation, and thus the type, quality and quantity ofstabiliser needed. It may also be necessary to buy sand if the soil has an

excessively high linear shrinkage,

Current prices of materials. Whether the blocks are to be made in rural or urban areas, size and type of

equipment used and quality required.

Current wage rates and productivity of the labour force.

It is important to note that block making can be carried out on a self-help basis,

where labour costs are eliminated. Furthermore, soil is often available at no cost. The

methodological costing technique consists of 12 steps that may be sub-divided into two

main parts:

(a) Determining quantities of the various inputs (Steps 1 to 6),

(b) Estimation of the cost of each input and computation of unit production costs

(Steps 7 to 12). These steps are briefly described in the remaining part of this

section.

Step 1 - Determine the quantity of blocks to be produced in a given period of

time. The number will be a function of market demand, availability of finance, acquired

production techniques, etc.

Step 2 - Calculate amount of material inputs required for the chosen scale of

production. The basic materials are suitable soil, sand (if needed for linear shrinkage

modification), stabiliser and water. Some oil, for example used engine oil, will be

needed as a mould release agent.


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Step 3 - List of equipment required. This will include items for digging and

moving soil, preparing soil with a crusher or sieving screen, mixing, a device for

moulding the blocks, a covered yard for curing the blocks and an office. Provision

should also be made for soil investigation and testing equipment. Chapters 2 to 4 provide

information on the type of materials, equipment and infrastructure needed. The cost of

industrial pieces of equipment may be acquired from equipment suppliers and

manufacturers, (see Appendix III), or from local workshops in cases where the

equipment is produced locally.

Step 4 - List of labour requirements. The productivity of the labour force may not

only vary from one country to another, but also from one site to another within the same

country. It is important to specify the length of the working day, the number of days

worked per week and the number of working weeks per year, taking into account an

allocation of time for leave of absence during the year. The level of skill requirements

must also be determined.

Step 5 - Other local services and facilities may be required, such needs may include:

land for quarrying soil for block making, land for production area, land for curing area and storage of raw materials, provision of access to working area for delivery of materials and dispatch of

products.

Step 6 - Computation of working capital requirements. In addition to funds required

for purchase of equipment and land as itemised in the preceding steps, it will be

necessary to have sufficient financial resources for the purchase of raw materials and

payment of wages for a period of one month, since there can be no income from the sale

of blocks until they have been made and cured. If difficulties are anticipated in obtaining


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any particular commodity, it might be necessary to maintain enough stocks for a period

longer than one month. It may also be desirable to use some of the first products in the

construction of the covered area, offices, etc., in order to reduce the cost of items under

Step 3. It will then be necessary to slightly increase the working capital to allow for the

number of blocks that will be used for this purpose, rather than sold.

Step 7 - Annual cost of materials identified in Step 2 must be calculated. Clay, sand

and water are often extremely cheap items. The mould-releasing agent will not be

needed in large amounts so should cost very little. Reject engine oil may be acquired at a

very low price or obtained free in some cases.

Step 8 - Computation of depreciation costs of equipmen

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