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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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ii
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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iii
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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v
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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vii
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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viii
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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x
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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1
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
62~ ~ ~ 7 ~ 4 /i :5 6 1 / '7 . -- . . ---- _ -- _ . ~ .
f \ /I~ 115 Z4 fz ~ -. * vI 14 1 q ~ 1i --='\; 1 r ~ ~ /--:=:J . . .- _ . ~15 \.
12
7
F L< ;J( ) 11
1It 44 '7
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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.
toI : 61 I 2I I I I II I ~Ir
1 rc _
- 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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Table 3.6Concept 2 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 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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Table 3.7Concept 3 description
No Requirement Description
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
3 Cooling rate The cooling system is inside the panel box
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.
Assemble by welding process
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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
i) Steel Plate(Mild Steel)
Milling, drilling,
and
counterboring.
11
Plate Structure
i) Angle Barii)Steel Bar
Cut by sawing,
and drilling
Assemble by welding process
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15
Slider Base
i) Steel Plate(Mild Steel)
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.
Assemble by welding process
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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:: ....
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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.
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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