Report Horse Feeding Lalala

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CHAPTER 1

INTRODUCTION & BACKGROUND RESEARCH

1.0 Introduction

In order to design the horse feeding mechanism at UTM equine some back

ground research was carried out in areas that are related to this problem. The problems

can be divided into few areas as follows.

1.1 Feeding time of the horse [Bala]

Horse feeding time plays an important part as well. Horse can become stressed

if they are feed long period of intervals between their meals. They will perform well if

they are feed well and according to the time. Generally horse should be fed three to

five times per day. It should be fed little and often. Currently UTM equine is practicing

three meals per day. Morning 6.45 is, afternoon 12.00 pm and evening 6.45 pm. There

should be a delay for any activities or exercise for at least two hours after the horse

feeding. This is because horse with a full stomach will have a great pressure on its

lungs and can cause improper breathing. At the same time horse also should not be fed

immediately after exercise. It’s best to follow the same time for the horse feeding as it

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will get used to its routine time fast. Horse will tend to get stressed if their daily meal

routine changed frequently.

1.2 Codes of Recommendations for Horse Welfare – Feeding [Chin YS]

In the United Kingdom (UK), there is an act, called the “Animal Welfare Act

2006” that is used to protect class of animals that is described in the act. However,

there is no act that is targeting specifically on horses. In order to perform more research

on for horse welfare, codes of recommendations and minimum standards of New

Zealand and Australia are being used. Noteworthy the terms “codes of

recommendation” and “minimum standards”, instead of “rules and regulations”, or

“act”, are being used as these are recommendations for best horse welfare.

Other than horse’s welfare, human safety, especially workers’ safety is a

concern in the code of recommendations. This is to ensure no accidents and incidents

happen.

Not all of the contents will be discussed, but major items relating to feeding of

horses is presented.

1.2.1 Feeders [Bala & Chin YS]

There is also recommendation for placement of feeders and water container.

Feeders and water containers are recommended to be raised to a height of about 1.07m

and placed in a corner. They should be smooth and free of protrusions, resist tipping

over and should be easy to clean.

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1.2.2 General Feed Requirements [Bala & Chin YS]

In its natural state, the horse eats a variety of forages (mainly grasses) to meet

its nutritional needs. Due to the small size of its stomach, the horse will normally

consume its daily intake over 16-20 hours. When the energy requirements are low,

such as for horses in light work, dry broodmares and non-working horses, fresh forage

can provide most of the horse’s needs. When pasture is limited, however, the diet

should be supplemented with dried forage, which is hay or chaff.

Provided the stocking rate is correct, most broodmares can meet their energy,

protein and mineral demands from an adequate supply of good quality spring pasture,

since they have adequate time to consume the quantities required.

When a horse is working, its feed demands increase and a pasture-only diet

may not be sufficient to meet the increased needs. Forage takes a long time to digest

and the horse may not physically be able to eat enough to sustain its needs. Horses in

moderate-to-heavy work generally need supplementary feeding in the form of grains

or concentrates.

1.2.3 Supplementary Feeds [Bala & Chin YS]

Horses are very selective of their food. They use their whiskers, lips and

incisors to feel and choose what they want to eat. Horses are herbivores and they have

a unique digestive system. They have a very long digestive system and require a high

fibre meal. Normally horse spends most of the time eating.

When considering the supplementary feeding of horses, an important point to

note is that horses tolerate poor feed poorly. Horses will not thrive unless they are fed

good feeds in the right quantities. The contents below describe the nutritional value to

the usual food and supplements that is fed to UTM horses.

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Hay is the most important nutrition for the horse. So in feeding the horse, it is

very important to focus on the type and the quality of the hay. Hay is the mixture of

grass and legumes which is dried until about 18% of the moisture remains. Hay is a

form of roughage commonly fed to horses to supplement pasture. It must be of good

quality to supply nutritional requirements and avoid health problems. Hay should be

dry at the time of feeding, smell fresh and be free from dust and mound. To reduce

potential respiratory problems, it is important that chaff is dust-free. Normally hay is

fed in the forms of square cubes for stabled horse. Dampening of feeds with high chaff

content, just before feeding, is recommended to aid digestion and prevent dust

inhalation.

Figure 1.1: Hay in square cube forms

Oat is another mixture in the meal that is very important. It requires a lower

digesting energy by horse and at the same time contains high fibre compared to other

grains. Oats is very safe to feed, as it forms a loose mass in the stomach which aids

digestion. Oats should be bright in appearance. Bruising is considered by many to aid

digestion, but the storage of bruised oats reduces its nutritional value and should be

avoided. Oat well suited to the horse digestive system and easily digested compared to

other grains.

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Figure 1.2: Oat

UTM is giving blended feed called the “cool performance”, or CP in short, to

the horses. Providing the manufacturers’ feeding recommendations are followed (this

information should be printed on the label along with an analysis of ingredients), these

provide a simple method of supplementation. Where small numbers of horses have

similar supplementary feeding needs, premixed balanced feeds can save the horse

owner work and ensure continuity of diet.

Chaff is simply dried forage that has been cut into small pieces. The principle

advantage of chaff is that it can be mixed with the concentrate portion of the feed so

that the horse consumes forage with the concentrate. This can slow the intake of

concentrate and prevent starch overload in the large intestine.

Oil is also added in horses’ feed. With the high calorie demands of elite

performance horses, Oils plays an important role in reducing grain intake. Oils contain

2.5 times more energy than oats and also are digested more efficiently in the horses’

small intestine. Thus reduces the ‘sugar high’ sometimes associated with high grain

intakes [3]. Unless fat (e.g. some type of vegetable oil) is added to the diet, horse

rations are very low in fat, typically less than 2%-3%. However, horses are able to

digest and absorb dietary fat quite well (up to 20% of their energy intake). In fact, it is

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important that horse diets contain at least some fat or oil–it is needed to facilitate

absorption of the fat-soluble vitamins A, D, E, and K.

Supplement such as salt to be included in concentrated mixture in the meal.

Salt normally very helpful when horse are craving and vitamins will be beneficial to

horse when feeding low quality of hay, illness, active in sports or travelling. Beside

these minerals such as calcium, phosphorus, sodium or potassium also include into the

concentrated mixture.

1.2.4 Specific Feed Requirements

UTM horse’s activities were described in the first part of this chapter. This sub-

chapter will describe in more detail on the feed requirements, based on maintenance

and activities.

Feeding levels can be worked out in terms of either dry weight expressed as

kilograms of dry matter (kg DM), which can then be converted into actual weight fed.

Besides this, feeding level can also be expressed as energy content in mega calories

(MCal). This method is more accurate as it takes into account the different energy

values of the same weight of feeds. It should be used by those involved in training

horses for strenuous activities that require high levels of fitness and for stud properties.

For simplicity, the amount of feed required by the horse is made up of two

factors:

(i) Maintenance needs;

(ii) Activity needs (which include rate of work, growth, lactation and

pregnancy).

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Both requirements must be satisfied to maintain body condition and weight.

1.2.4.1 Maintenance Needs [Chin YS]

Maintenance feeds is the amount required to maintain the horse at rest. "At

rest" means that the work required of the horse is no greater in physical activity than

that expected of a healthy horse grazing freely in a paddock. This includes horses being

spelled from their usual work, learners’ horses which rarely get into a canter, and

pleasure horses ridden carefully at a relaxing pace for no more than 1 hour/day.

If fed to appetite, the average horse will consume 2% of its bodyweight, as dry

matter, to meet daily maintenance requirements. Regular condition scoring or

weighing will help establish any individual variation required from the 2% bodyweight

guideline. Table 1.2 shows the approximate maintenance dry matter feed requirements

of different weights of horses.

Individual horses have varying digestive capabilities which affect maintenance

requirements. Periods of extremely cold weather may also increase maintenance needs

by up to 30%. Temperament is a further factor to be taken into account, as nervous or

highly strung horses consume far more energy than do quiet horses of the same

bodyweight.

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Table 1.1: Average daily maintenance requirements of horses.

Bodyweight Dry matter (kg) Digestible energy

(MCal)

150 3 5.9

200 4 7.4

250 5 8.9

300 6 10.4

350 7 11.9

400 8 13.4

450 9 14.9

500 10 16.4

550 11 17.9

600 12 19.8

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1.2.4.2 Activity Needs of Working Horses [Bala & Chin YS]

Horses are normally they are very athletic type. This shows that they need

sufficient energy to maintain their weight and to do their jobs. An average horse

weighs about 450 kilograms will need approximately 15000 calories a day. However

it’s calories to be increased to 25000 calories if does riding activities but not to be too

strenuous. If the same horse involves in strenuous activities such as daily ridding,

involves in competition and also gallop jumping then it’s calories to be increased to

33000 calories. As we know the horses in UTM are very active and involve in

competition as well. This means horses in UTM falls in the 3rd criteria and they need

proper feeding according to time.

The general rule of thumb for working horses is:

(i) Light work requires an extra 25% energy (above maintenance);

(ii) Moderate work an extra 50%;

(iii) Heavy work requires more than an extra 100%.

1.3 Horse feeding ratio [Bala]

There are totally seventeen horses in UTM equine. Each horse requires a

different type of ratio for each meal (breakfast, lunch and dinner). This is because the

ratio of the mixtures is purely depends on the type of the activities the horse involved

and how active is the horse. However this becomes very tedious to the workers because

they have to stay late in the evening in order to prepare the mixing for each horse next

day. The table below shows the meal distribution for each horse according to its ratio

and timing.

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Table 1.2: Maintenance water requirements of horses

Horse Name

Early Morning Afternoon Evening

Chaff CP Chaff CP Hay Chaff CP Hay

Billy 0.5 0.5 0.5 1 1.5 0.6 1.25 2

Saphire 0.5 0.5 0.5 1 1.5 0.5 1 2

Bold Sabre(Arab) 0.5 0.5 0.5 1 1 1 0.5 1.5

Blue Bronco 0.5 0.5 0.5 1 1 1 0.5 1.5

Moon Shadow 0.5 0.5 0.5 1 1 1 0.5 1.5

Loretta 0.5 0.5 0.3 0.5 1 0.4 0.5 1

Bonita 0.5 0.5 0.3 0.5 1 0.4 0.5 1

Dada 0.5 0.5 0.5 1 2 0.6 1 2

Neil Dancer 0.5 0.5 0.5 1 1.5 0.5 0.75 2

Zack Phenomena 0.5 0.5 0.5 0.75 1.5 0.5 0.75 2

Hard Foundation 0.5 0.5 0.5 1 1 0.5 1 2

Roy Austin 0.5 0.5 0.6 1 2 0.6 1.25 2

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Jack 0.5 0.5 0.5 1 1 0.5 1 1.5

Sunny 0.5 0.5 0.5 0.75 1.5 0.5 0.75 1.5

Qosmo 0.5 0.5 0.6 1 2 0.6 1.5 2.5

Silver Barloo 0.5 0.5 0.5 1 2 0.6 1.5 2.5

Pinocchio 0.5 0.5 0.6 1 2 0.6 1.5 2.5

1.4 Ergonomics [Bala]

The feeding container that being used in UTM equine is not ergonomically

sufficient for the horse to eat. This discomfort causes the horse to damage the feeding

container. Finally the horse food spills down and cause contamination when it mixes

with their own waste. Taking into consideration of this some studies was done on the

horse shape, body measurement, eating posture and vision.

1.4.1 Horse Shape & Measurement [Bala]

The height of the horse is measured from the withers, where the neck meets the

back. Withers actually are the rigid part between the shoulder blades of a horse. It is

the tallest point of the horse. Normally this point is used because it is the stable point

of the horse. The horse shape and height is measured using hand and inches. One hand

is approximately equals to 4 inches. If the measurement of the horse states 14.2 H, it

refers to 14 hands and 2 inches which 58 inches. The weight of the horse is normally

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between 380 kilograms to 550 kilograms. The larger horse normally weighs between

500 kilograms to 600 kilograms and measures about 15.2 H. The figure 1.3 below

shows the typical parts of the horse body.

Figure 1.3: Body parts of the horse

1.4.2 Horse eating posture [Bala]

The horse body posture also plays important criteria that we have to take into

consideration. The body of the horse works most efficiently when eating at ground.

When the horse puts the head down to eat the lower jaw drops forward and when the

horse lifts its head to chew the jaw slides back. This forward and backward movement

helps to grind the teeth and keep it at the optimum length. However this does not

happen when the horse is fed with head from the ground. That’s why it is important to

feed at the ground level. Horses in UTM are fed in both methods. The hay is laid in

the ground; where else the other meals are fed through container. Figure 1.4 illustrates

best horse eating posture.

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Figure 1.4: Best horse eating posture

1.4.3 Horse binocular vision [Bala]

The food served to the horse should be within the horse binocular vision. The

horse binocular vision is about 65°. This is to make sure that the horse could capture

the whole image of the food that being served and there would not be any wastage.

The figure 1.5 below shows the horse binocular vision.

Figure 1.5: Visual field of the horse

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1.5 Gather Raw Data from Customer [Afiq]

Consistent with our planning of creating new feeding system directly

from customer, gathering data involves contact with customers and experience

with the use of environment of the product. One method of customer approach

which is interview session.

Based on the information that we had obtained from Mr. Idris Jala who

is one of the management staff in Equine Park, the horse feeding system has

been practiced with manual way since the equine park was built in UTM. We

have founded several issues, which we had founded during interview, was that

they consumed lots of time and energy to feed the horses. We might see table

1.1 which had shown the problems that the staff is always facing during feeding

the horses.

Table 1.3: Interpretation of Raw Data

Customer: Equine’s Staff in UTM Interview(s): Chin, Bala & Afiq

Address: Equine Park Centre, UTM, Skudai Date: 20/09/2014

Telephone: 019-7722333 Currently uses: Manual Feeding System

Type of User: Trainer & Coach

Question/Prompt Customer Statement Interpreted Need

How many times actual

feeding meal?

Actual feeding meal is 3

times. However, 5 meals

are recommended.

Feeding system that can

supply food every time

horse is needed.

How is the mixture done? The mixture needs to be

done manually by mixing

each of the element of the

food depend on meal time

in the bag.

The feeding system can

stir the mixture and can be

setting in meal time.

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Do you have any meal

mixture standard?

Don’t have any mixture

standard. However, we

prepare the mixture based

on horse requirement.

Moreover, every horse has

their own ratio of the food.

The feeding system able

to measure and sense the

amount of the food.

What is the problem of

current practice?

Due to use manual system,

we have to supply by

ourselves. Sometimes, we

need overtime because we

don’t have enough

manpower. Moreover, we

need to feed the horse on

time. Otherwise, the horse

will eat the food late and

the training time will

postpone which is not

good for the horses.


to feed the horse by time

like morning, afternoon,

evening and night. On the

other hand, the system

able to feed on time. So

that, the horse able to rest

2 hours after meal time for

training exercise.

Food separation Hay needs to be isolated

from other mixtures.

The feeding system have

their own space for each

of the element of the

mixture like Cp, Chaff,

oil, oat, calcium and hay.

However, hay has its own

space.

Water Supply The horses need 80 L per

day for its drinking water.

The worker needs to

check manually.

Sometimes, the worker

forgot to check water level

which made the horse

become thirsty.


provide water

continuously and can fill

the water automatically

without manual

inspection.

Food storage The food especially hay

have to keep in cold

environment. So that, the

nutrition and quality can

be maintained.


provide not only feeding

the horses but also storing

the food with cooling

system.

Hygienic The mixture, water and

hay are always

contaminated by soil dust


to cover the food by any

seal type. Moreover, the

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because the container is

not covered with any seal.

container can be clean

easily.

Aesthetic The container shape make

the horse uncomfortable

during eating its meal. The

container shape also make

body posture of the horse

become wrong and may

affect the horse

performance.

The shape have to follow

biological posture of the

horse during meal session.

1.6 Organize The Needs into Hierarchy. [Afiq]

We have to organize the needs that we have chosen from previous section into

hierarchical structure in figure 1.6. The structure typically consist of a set of primary

needs, each one of which will be further characterized by a set of secondary needs.

The primary needs are the most general needs, while the secondary and tertiary needs

express needs in more detail. Figure 1.6 shows that the resulting hierarchal structure

of needs for horse feeding system.

We had founded that they consumed lots of time and energy to feed the horses.

They only used a bag to mix the food and lot of manpower were needed to provide and

preserve the food for the horses.

The horses also consume water which is 80 L per day. Thus, the feeding system

need to supply water continuously. One more important thing that the horses need to

be fed on time to avoid late training time. The horses can be trained 2 hours after their

feeding time based on explanation from Mr. Idris because of good food digestion. On

the other hand, they have to provide three meals per day instead of five meals as other

equine parks do for their horses. So that, the system able to supply food continuously.

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Feeding Horses System

Time

Able feed on time Able feed 5 times per day

Able supply water continuously

Mixture

Able to control element of food according each horse

need

Able to control the ratio of the food.

Able to isolate hay from main mixture

Able to supply hay continuously.

Food Storage

Able to store in cold environment

Able to sense the quality of the food after open the

pack

EnvironmentAble to seal the food from soil dust and contaminate

particle.

Materials

Need Ergonomic

Easy clean & handle

Figure 1.6: The hierarchal Structure for Feeding Horses System

The horses also consume water which is 80 L per day. Thus, the feeding system

need to supply water continuously. One more important thing that the horses need to

be fed on time to avoid late training time. The horses can be trained 2 hours after their

feeding time based on explanation from Mr. Idris because of good food digestion. On

the other hand, they have to provide three meals per day instead of five meals as other

equine parks do for their horses. So that, the system able to supply food continuously.

Each of the horse has their specific mixture depend on time which they are be

fed. As example, in the morning, they are fed with Chaff and Cooling performance.

However, in afternoon, they add more mixture which is oat. So that, the system is able

to control each of the element of the food. Each of the horses has been provided

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standard ratio for capacity of the food. That mean that each of the horses have their

own standard requirement for feeding ratio depend on their physical attribution

example like weight, height, gender and others. Thus, the system is able to measure

and sense the ratio.

For food storage, the quality of the food is inversely proportional with time.

The quality of the foods can be reduced if we stored the food with long time duration.

It will affect the performance of the horse. So that, the feeding system can be able to

store the food in cold environment. Moreover, the quality of the food can also be

sensed the feeding system.

In term of environment, the foods are always contaminated by soil dust and

contaminate particle from surrounding. Thus, the feeding system need to seal the

container. Moreover, in term of material, the container needs to be ergonomic. The

feeding system also requires the container which can clean and handle easily.

1.7 The Relative Importance of the Needs [Afiq]

____________________________________________________________________

The Feeding System_________________________________________ Before we continued with scoring activity, we have to indicate on a scale of 1 to 5.

Please use the following scale:

1. Feature is undesirable.

2. Feature is not important.

3. Feature would be nice to have.

4. Feature is highly desirable.

5. Feature is critical.

Importance of feature on scale of 1 to 5

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__5__Feeding machine able to feed the horses on time

__3__Feeding machine able to feed the horses 5 times per day

__5__Feeding machine able to supply water continuously

__5__Feeding machine able to control element of food according each horse need

__4__Feeding machine able to control the ratio of the food.

__5__Feeding machine able to isolate hay from main mixture

__3__Feeding machine able to supply hay continuously.

__5__Feeding machine able to store in cold environment

__5__Feeding machine able to sense the quality of the food after open the pack

__5__Feeding machine able to seal the food from soil dust and contaminate particle.

__5__Feeding machine able to be clean & handle easily

__5__Feeding machine able to be ergonomic depend on the biological of the horses

1.8 The Summary [Afiq]

Based on section 1.3, we had done our scoring where nine of critical needs

have to be focused for designing the feeding machine. The critical needs are:

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1. Feeding machine able to feed the horses on time

2. Feeding machine able to supply water continuously

3. Feeding machine able to control element of food according each horse need

4. Feeding machine able to isolate hay from main mixture

5. Feeding machine able to store in cold environment

6. Feeding machine able to sense the quality of the food after open the pack

7. Feeding machine able to seal the food from soil dust and contaminate

particle.

8. Feeding machine able to be clean & handle easily

9. Feeding machine able to be ergonomic depend on the biological of the

horses

However, the other needs only desirable if we included in the system which

are:

1. Feeding machine able to feed the horses 5 times per day

2. Feeding machine able to control the ratio of the food.

3. Feeding machine able to supply hay continuously.

Based on the scoring result, we can focus on the critical needs which is

important and crucial part in the feeding system. With this information, it will be easy

for us to create product design specification (PDS).

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CHAPTER 2

PRODUCT DESIGN SPECIFICATION

2.1 Customer [Afiq]

The customer will be the Equine Centre Park in UTM, Skudai. An interview

session was prepared and held at Equine Centre UTM, Skudai. From the interview

session, the following conclusion can be made:

1. The manual feeding system causes insufficient number of times to feed the

horses.

2. Current feeding system is not totally hygienic.

3. The food become waste after the horses finished eating its food.

4. The food storage is not in proper manner and standard for the food.

5. Man power is not enough because of cost reduction.

6. The Equine Centre Park in UTM, Skudai is willing to upgrade the feeding

system.

From the interview session, we can conclude that the improvement of feeding

system needs to be considered due to maintain the health quality and performance of

the horses. This equipment should be aimed at all the horses at the Equine Centre Park

in UTM, Skudai.

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2.2 Time Scale [ChinYS)

1) 18-19 October 2014 - Product design specification and concept generation.

2) 8-9 November 2014 - Evaluation of concepts and finalisation of concept.

3) 6-7 December 2014 - Completion of final design

4) 28 December 2014 - Presentation of completed model.

2.3 Environment [Afiq]

i. Resistance to adverse weather: If the equipment is exposed or partially exposed

on the outdoor, then it must withstand all extreme weather.

ii. Temperature: The equipment should perform well and can’t be damaged by

ambient temperature in range from 7.0 Cº to 40 Cº based on the environment

temperature.

iii. Pressure: The equipment should be perform and can’t be damaged by

atmospheric pressure from 101325 Pa and above.

iv. Corrosion resistance: The unit should be resistant corrosion from water vapour

and dry air which are contained in atmospheric air.

v. Dust: The equipment can be sealed and filtered from dust and small particle.

vi. Keeping an inventory of the waste deposited into each waste container.

2.4 Performance [Afiq]

i. Time: The equipment can be setting variably in time depend on the range in

second, hour, day, week, month and year which is needed.

ii. Quantity of Food Measurement: The equipment is able to measure and sense

the weight of the food depends on the quantity requirement that needed by the

horses.

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iii. Storage: The food need to be stored under room temperature which is 25 deg

C depend on the requirement of the food. Feed should be stored in containers

with close-fitting, hinged lids to prevent the entry of vermin. Materials used

also should be water-resistant or waterproof to prevent spoiling of feed. Metal

should be the preferred material of choice.

iv. Capability: The equipment can stir the mixture in the container which can be

controlled in term of time and speed of the rotation.

v. The equipment can sustain a stress impact from the horses due to avoid

machine breakdown.

vi. The equipment is easily carried and handled by operator who is in charge for

feeding horses.

2.5 Processes [ChinYS]

i. There are no limitations to the manufacturing processes as there are no

constraints on the manufacturing facility.

ii. The mechanical parts can be done in UTM Mechanical Department where

possible.

iii. Electrical, electronics, wiring, and control system can be integrated by UTM’s

Electrical Department.

iv. Other heavy parts, if not possible to be manufactured in UTM, can be

outsourced to qualified suppliers near UTM.

2.6 Installation [Bala]

i. All wear and tear parts should be bolted type connection, for easy replacement.

ii. All the permanent connections should be welded.

iii. Hinge to be installed for folding parts.

iv. Engineering tolerance and fit required for assembly parts.

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v. Bolts and nuts to be used in metric standards.

vi. Parts length to be kept at minimum size for easy installation, replacement and

shipping.

vii. All bolted connections should sustained collision force due to horse behaviour

during meal period.

viii. Perform tightness check on bolt connections.

ix. Appropriate tolerance should be given to assembly parts to avoid misalignment

during installation.

x. Moving parts such as bearing, pulleys and beltings must be supplied with

enough lubricants.

xi. If there are any high precisions parts in use then it is necessary to be installed

with dowel pin.

xii. All electrical installation such as wiring of electrical cables must be done in

proper manner and tidy.

2.7 Material [ChinYs]

i. Material of feeder must be non-poisonous, and does not pose any harm to

horses.

ii. Material of feeder must be durable enough so that feeder will not be damaged

by horses due to chewing.

iii. For the construction of body of machine, the material must be non-corrosive

so that the machine will be able to last within its operating life.

iv. Chosen material for body of machine must be resist to wear and tear.

v. Chosen material for body of machine must not be too reflective as reflection of

sunlight may cause certain psychological effect to horses.

vi. Chosen material must be strong enough to withstand strong impact due to

kicking of horses.

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2.8 Ergonomics [Bala]

i. All hand switches must be suitable for the height of operating personnel.

ii. All the switches must be able to be operated by one finger; point finger.

iii. The food container should be easily accessed by the operator so that it can be

refilled when it’s empty.

iv. The food container should give allowance for the horse to drop the lower jaws

forward when the horse puts the head down to eat.

v. The food container should accommodate the average horse face length

53 cm – 60 cm, 21 cm – 22 cm width and height which is 14 H – 15 H.

vi. The food to be served within visual field of the horse; which is 65° from the

face centre and take note of the blind spot area which is 3°

vii. There should not be any sharp edges for safety purpose of the horse and the

operator.

2.9 Safety [Bala]

i. Avoid any sharp edges on the parts of the feeding system

ii. The feeding system should not create any tripping hazard, head knock injury

or obstruction to both operator and horse.

iii. All the parts of the materials that are direct contact with the horse food should

not create any chemical hazard that might cause food poisoning.

iv. All the electrical wiring should be done with proper earthling.

v. Electrical wiring, switches and other devices should be insulated to avoid any

contact with water or rain.

vi. Any machine lubricants should not drip into the food container that could

contaminate the food.

vii. Minimize wiring exposure to horse to prevent any hazard and damage.

viii. Feeding system should minimize the exposure of the food to environment so

that there is no any contamination from surrounding.

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ix. Feeding system to be included with red coloured emergency stop button for

case of emergency.

x. Signage of “don’t touch on the moving parts” to be included with the machine.

xi. Feeding system to be included with auto alarm system if there is any case of

emergency to alert the operator.

2.10 Shipping [Bala]

i. Assembly parts will be stored in boxes and top side facing upwards.

ii. Lengthy parts will be folded and will be stored in boxes.

iii. Bolts, nuts and screws will be kept in plastic bags and stored together with the

assembly parts which it belongs to.

iv. All the parts will be transported by lorry.

2.11 Maintenance [Bala]

i. Preventive maintenance chart to be established during initial stages for best

performance.

ii. Frequency based maintenance to be done on the moving parts such as bearings

and beltings.

iii. Counter to be installed to monitor numbers of cycles done for moving parts.

iv. Checklist to be filled up each time the maintenance is done.

v. Bolts and nuts tightness to be checked frequently.

vi. All maintenance parts to be removed and installed with minimal duration.

vii. Operating manuals should be in three copies.

27

2.12 Documentation [ChinYS]

There are several documents need to be presented upon completion of the

design mechanism. This is to ensure machine is operated correctly and safely.

i. Standard Operating Procedure (SOP) - ensures operators (UTM Equine Park

workers) are able to operate the machine correctly. The SOP must be very

comprehensive, that must include, but not limited to:

ii. Construction of machine design

iii. Detailed description of operation manual

iv. Safety precautions

28

CHAPTER 3

CONCEPT GENERATION

3.1 Introduction [Afiq, Bala & Chin]

A concept is an idea that is sufficiently developed to evaluate the physical

principles that govern its behaviour. Concept generation is a five step method. The five

step methods are:

i. Clarify the problem

ii. Search externally

iii. Search internally

iv. Explore systematically ( Morphology chart )

v. Reflect on the solution process.

To clarify the problem a general statement was defined based on the back

ground research done. The general statement summarises the input and the output to

the overall system.

29

Figure 3.1: General statement

Input: Food in powder and pellet form.

Output: Food for each meal timing (breakfast, lunch and dinner) according to each

horse nutrition eating ratio.

General statement: To disperse all the food in the form of powder and pellet in proper

ratio for the particular meal timing (breakfast, lunch and dinner) for the designated

horse.

Energy: Electrical power.

From the above general statement the sub system needed was identified. All

the sub systems are gathered to make up the system. Take note that some sub system

will be further break down to create another sub system. Refer to figure 1 and 2 below.

Figure 3.2: Series of sub system

General statement Input Output

Input

Food mixing

Food delivery

Feeder

Food container

Timer

Output

30

Figure 3.3: Break down food mixing sub system

Figure 3.4: Morphology chart 1[Afiq, Bala & Chin]

Input

Storage

Measurement of food

Selection of type of meal

Container transportation of mixing

Food dispenser

Output

31

From the above sub systems the morphology chart is used to refine the sub

system. Refer to figure 3.4 and figure 3.5.

Figure 3.5: Morphology chart 2[Afiq, Bala & Chin]

Based on the morphology chart the conceptual design sketches were done. The

conceptual sketches will explain the functions, forms and components. There were

totally seven sketches was done to explain the concepts. All the concepts are shown in

the figures below.

32

Figure 3.6: Concept 1 [Bala]


33

Figure 3.8: Concept 3 [Chin YS]

Figure 3.9: Concept 4 [Chin YS]

34

Figure 3.10: Concept 5 [Afiq]


35


A scoring sheet was developed to select the final conceptual design. The table

3.1below shows the scoring sheet. As per scoring sheet the design concept 6 had been

selected as the final concept.

36

Table 3.1 Scoring Sheet

Criteria Weight

(W)

Concepts

1 2 3 4 5 6 7

Rating,

R

W x

R

Rating,

R

W

x R

Rating,

R

W

x R

Rating,

R

W

x R

Rating,

R

W

x R

Rating,

R

W

x R

Rating,

R

W

x R

Ergonomics for

workers 7 5 35 5 35 5 35 2 14 5 35 5 35 5 35

Ergonomics for

horse 7 5 35 5 35 4 28 3 21 2 14 4 28 4 28

Hygienic 12 2 24 5 60 5 60 3 36 5 60 3.5 42 5 60

Safety for

workers 7 5 35 3 21 5 35 2 14 5 35 5 35 4 28

Safety for horse 7 2.5 17.5 3 21 3 21 4 28 2 14 5 35 3 21

User friendly 6 5 30 4 24 4 24 5 30 5 30 5 30 5 30

Easy to

maintain &

clean 12 3 36 2.5 30 4 48 3 36 2 24 3 36 3 36

Easy to install 7 4 28 3 21 4 28 3 21 4 28 4 28 5 35

Machine cost is

low 7 3 21 2 14 4 28 3 21 4 28 4 28 2 14

Less manpower 15 5 75 5 75 4 60 4 60 2 30 5 75 5 75

Accurate food

measurement 13 2 26 4 52 3 39 3 39 3 39 3 39 2 26

Total 100 362.5 388 406 320 337 411 388

37

CHAPTER 4

CONCEPT DEVELOPMENT

4.1 Introduction [Afiq, Bala & Chin]

As the design concept 6 had been selected as the final concept, further

development was done to make improvement to any failure risk on the final concept

selected. FMEA tool was used to study the potential cause of failure and the precaution

method to be taken. In FMEA all the function affected, failure modes, failure effects

and cause of failure will be studied to come out with proper recommended action. The

FMEA was done on the flake form food container, food delivery unit and pallet food

container. The details of the FMEA are shown in the table 4.1 and 4.2 below. However,

we need to determine functional analysis first before we proceed to the FMEA. The

purpose of functional analysis is to reduce repeated function during design process.

The detail functional analysis are shown in figure 4.1.

38

Figure 4.1: Functional Analysis for the horse feeding system.

39

Table 4.1: FMEA – Flake-form food container [Chin YS]

No. Function

Affected

Potential

Failure Modes

Potential Failure

Effects

Potential Causes

of Failure Recommended Actions

Responsible

Person Taken Actions

1

Pneumatic

cylinder

movement

No compressed

air supply

Unable to move rod,

thus unable to drop

food to mixer

Main power supply

cut off

Use compressor that has

emergency/alternative

power supply run using

gasoline or petrol.

Chin YS

Source for compressor that has

alternative power supply, and

test for its reliability.

2

Unable to move rod,

thus unable to drop

food to mixer

Compressor tank

leakage

Testing results from supplier

must show high reliability

for the tank's service life.

Regular checks and

maintenance.

Supplier Test tank reliability.

3

Unable to move rod,

thus unable to drop

food to mixer

Compressor motor

failure



for the compressor's service

life.

Supplier Test compressor reliability.

40

Regular checks and

maintenance.

4 Cylinder part

failure

Unable to move rod,

thus unable to drop

food to mixer

Wear and tear of

moving parts



for the compressor's service

life.

Regular checks and

maintenance.

Supplier

Go through technical sheets

and suggest checking and

maintenance schedule

5 Cylinder shaft

and choke

holding fixture

Shaft buckle

Choke (that is

connected to shaft)

unable to be lifted up,

thus unable to drop

food to mixer

Weight of food too

heavy

Design shaft with given

diameter and length so that

it will not buckle.

Chin YS Calculate optimum shaft

diameter.

6 Choke

disconnected

from shaft

Choke (that is

connected to shaft)

unable to be lifted up,

Weight of food too

heavy

Obtain technical sheet and

test results from supplier. Chin YS

Test shaft fastener over mould

using high load.

41

thus unable to drop

food to mixer

42

Table 4.2: FMEA – Food delivery unit [Bala]

No. Function

Affected

Potential Failure

Modes

Potential Failure

Effects

Potential Causes of

Failure

Recommended

Actions Responsible Person Taken Actions

1 Sliding

Mechanism

No power to pull

the slider plate

Food will not be

transferred to main

mixer

Air cylinder failure

Change the drive

mechanism from

pneumatic to electrical

motor with high torque

Bala Electric motor with

high torque is chosen

Food will not be

transferred to main

mixer

Over weight of food

dispersed from the food

cylinder to food

transfer container

Change the drive

mechanism from

pneumatic to electrical

motor with high torque

Bala Electric motor with

high torque is chosen

Food will not be

transferred to main

mixer

inability of the load

sensor to detect the

weight

check for the sensitivity

of the sensor Supplier

Supplier need to give

the sensitivity of the

sensor and adjusting

method

43

Food will not be

transferred to main

mixer

insufficient clearance

of the slider plate and

the food transfer

container

Increase the tolerance

during assembly of the

slider plate to food

transfer container

Bala Done

2 Mixer Inadequate angle for

mixing

Improper food

mixing

Plate angle not

sufficient for mixing

Install rotating

assembly Bala Done

3 Feeder

Feeder space

inadequate Horse avoid eating

Insufficient feeding

space for horse face

Enlarge the feeding

space Bala Done

Injury to horse face Horse avoid eating sharp edges at the food

container

Chamfer the sharp

edges Bala Done

44

Table 4.3: FMEA – Pallet Food Container [Afiq]

No. Function Affected

Potential Failure Modes

Potential Failure Effects

Potential Causes of Failure

Recommended Actions Responsible Person

Taken Actions

1 Plate Opener Stuck to open Hinge will be broken

Hinge Failure Protect hinge from any dust or particle covered by metal

plate

Afiq Vendor required to modified the hinge

2 Stuck to open Hinge will be broken

Bolt and nut bending lead to

failure

Need to ensure using high tensile stress bolt and nut

Afiq Supplier need to supply suitable bolt and nut

3 Valve/Dampener No torque to open

Solenoid Valve not function

Plunger unable to create magnetism

Calibrate or inspect solenoid valve based on maintenance

schedule

Afiq Need to plan Total Preventive Maintenance schedule

4 No torque to open

No air supply Air compressor not function well

Need to Maintain air compressor based TPM

schedule

Afiq Need to plan Total Preventive Maintenance schedule

4 Valve stuck during closing

Bearing Failure Large particle slip into bearing

Using suitable valve for pallete

Afiq Supplier need to supply suitable valve for special

application

45

CHAPTER 5

ENGINEERING ANALYSIS

5.1 Material Selection for Horse Feeding Equipment [Afiq, Bala & Chin]

High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a

polyethylene thermoplastic made from petroleum. With a high strength-to-density

ratio, HDPE was selected as our material selection for the feeding horse machine.

HDPE is known for its large strength-to-density ratio. The density of HDPE can range

from 0.93 to 0.97 g/cm3. Although the density of HDPE is only marginally higher than

that of low-density polyethylene, HDPE has little branching, giving it stronger

intermolecular forces and tensile strength than LDPE.

The difference in strength exceeds the difference in density, giving HDPE a

higher specific strength. It is also harder and more opaque and can withstand somewhat

higher temperatures (120 °C/ 248 °F for short periods, 110 °C /230 °F continuously).

Furthermore, HDPE has several features that give us particular advantage to use this

material.

46

The advantages are:

i. UV resistant

ii. Moisture resistant

iii. Fungus and Moulds resistant

iv. Abrasion resistant

v. Graffiti can be easily cleaned

vi. Stain resistant

vii. Chemical resistant

viii. High durability

ix. Low coefficient of friction

x. Food Grade for food industries application

xi. High impact strength

xii. Fire retardant

xiii. Low maintenance cost

xiv. No delamination

xv. Easily work with most wood and metal working tools

xvi. Vacuum formable

xvii. Thermal formable

Moreover, with the aid of innovation and advanced manufacturing facilities

backed by a dedicated team of experts, this material can undergo several processes

which are nearly same as steel like thermoforming, HDPE sheets extrusion process,

CNC Routing and Engraving and Plastics Welding.

If we compared with other plastic materials in figure 5.1, we may determine

that HDPE has the lowest properties in term of tensile strength, flexural strength,

compressive strength, shear strength and impact strength. It is reasonable for our

requirement to meet reasonable factor of safety which we will discuss on next section.

47

Figure 5.1: Comparison Table for plastic material.

48

49

5.2 Engineering Analysis

5.2.1 Slider holder [Bala]

Based on figure 5.2, we had analysed slider holder part which is subjected to

bending stress by the load. After we did some engineering calculation, we optimized

the data and did the comparison by changing the size and length to determine suitable

size where we can meet our requirement for safety factor which is less than 4.

(b)

(a)

(c)

Figure 5.2: The slider holder which is subjected to bending stress by load. (a)

and (b) Isometric view (c) Side view

50

Table 5.1 shows that the comparison for each parameter that we have changed

to optimize the design.

Table 5.1: Comparison Table for Optimization for the slider holder

Based on the table 5.1, we may conclude that the third optimization is chosen

due to,

1 << F.S << 4

(Detail calculation can be referred in Appendix section.)

5.2.2 Food Discharge Unit [Bala]

Based on figure 5.3, we had analysed food discharge part which is subjected to

bending stress by the load. After we did some engineering calculation, we optimized

the data and did the comparison by changing the size and length to determine suitable

size where we can meet our requirement for safety factor which is less than 4.

No b

(mm)

h

(mm)

I

(mm4)

𝝈𝒎𝒂𝒙

(MPa)

𝝈𝒂𝒍𝒍𝒐𝒘

(MPA) F.S Result

1. 5 30 1.125 x 10-8 1.64 31.6 19.62 Bad

2. 5 20 3.33 x 10-8 3.69 31.6 8.6 Bad

3. 5 10 4.17 x 10-8 14.78 31.6 2.13 Good

51

(a)

(b)

Figure 5.3: The food discharge unit part which is subjected to bending stress by load.

(a) Isometric view (b) Side view



52

Table 5.2: Comparison Table for Optimization for the food discharge unit

Based on the table 5.2, we may conclude that the second optimization is

chosen due to,

1 << F.S << 4

Therefore, HDPE sheet plastic will be used to with the dimension b = 80 mm,

h = 4 mm and length = 160 mm.


5.2.3 Rod Actuator [Afiq]

Based on figure 5.4, we had analysed rod actuator part which is subjected to

shear stress by the load. After we did some engineering calculation, we optimized the

data and did the comparison by changing the diameter size and mass to determine

suitable design where we can meet our requirement for safety factor which is less than

4.

No b

(mm)

h

(mm)

I

(mm4)

𝝈𝒎𝒂𝒙

(MPa)


(MPA) F.S Result

1. 80 5 8.33 x 10-10 6.48 31.6 4.8 Bad

2. 80 4 4.27 x 10-10 10.1 31.6 3.12 Good

53

(b)

(a)

Figure 5.4: The rod actuator part which is subjected to bending stress by load F (a)

Full scale drawing (b) Internal force analysis



54

Table 5.3: Comparison Table for Optimization for the rod actuator

Based on the table 5.3, we may conclude that the fifth optimization is chosen

due to,

1 << F.S << 4

Therefore, HDPE sheet plastic will be used to with the mass = 52.5kg/day and

D = 10 mm.


5.2.4 HDPE Mounting Plate [Afiq]

Based on figure 5.5, we had analysed HDPE mounting plate part which is

subjected to tensile stress by the load. After we did some engineering calculation, we

optimized the data and did the comparison by changing the diameter size and mass to

determine suitable design where we can meet our requirement for safety factor which

is less than 4.

No D

(mm)

A

(mm2)

F

(N)

m

(kg/day)

𝝉𝑭𝒂𝒊𝒍

(MPa)

𝝉𝒂𝒍𝒍𝒐𝒘

(MPa)

F.S Result

1. 15 176 147.15 15 23.3 0.83 28 Bad

2. 10 78.5 147.15 15 23.3 1.87 12.4 Bad

3. 10 78.5 220.75 22.5 23.3 2.81 8 Bad

4. 10 78.5 367.88 37.5 23.3 4.68 5 Bad

5. 10 78.5 515.03 52.5 23.3 6.56 3 Good

55

Figure 5.5: The HDPE plate part which is subjected to tensile stress by load



b

h

56

Table 5.4: Comparison Table for Optimization for the HDPE plate

Based on the table 5.4, we may conclude that the third optimization is chosen

due to,

1 << F.S << 4

Therefore, HDPE sheet plastic will be used to with the mass = 52.5kg/day and

h = 10 mm.


5.2.5 Tank Support Beam [Chin YS]

Tank support beam is used to support the weight of food tank and the support

structure itself. Thus it is crucial for this item not to yield or buckle so that the tank

will not fall off the support and cause failure of whole food delivery system.

The analysis is as follows, using stress, σ (force / area) applied on beam and

compared with the material’s yield strength.

No N1,2

(N)

b

(mm)

h

(mm)

W

(N)

m

(kg/day)

𝝈𝑭𝒂𝒊𝒍

(MPa)


(MPa)

F.S Result

1. 36.79 2 25 73.58 7.5 31.7 0.73 43 Bad

2. 36.79 2 10 73.58 7.5 31.7 1.84 17 Bad

3. 257.4 2 10 515.02 52.5 31.7 12.87 2 Good

57

Beam

Height 14.74 mm

Width 2.08 mm

Length 75.68 mm

Load/Mass

Holder 0.162 kg

Tank 0.266 kg

Food 1 kg

Total 1.428 kg

Total weight 14.009 N

Material - HDPE

Yield strength 29.5 Mpa

Moment calculation

Weight/Force, F 14.009 N

Moment 1.060 Nm

Stress calculation

Distance to NA, c 7.37 mm

Second moment of area, I 555.1 mm^4

Stress, σ 1.408E+07 Pa

Analysis

Material yield strength 29.5 Mpa

Stress calculated 14.1 MPa

58

Figure 5.6: Holding beam of tank holding structure.

Material chosen was initially metal, which has very high strength relative the

overall load given. Thus material is suggested to be changed to plastic, which has also

enough rigidity and strength to hold the whole system. Suggested plastic material is

high density polyethylene (HDPE). The stress calculated is approximated half of

HDPE’s yield strength. This gives the beam a safety factor of 2, which is very much

desirable in design.

5.2.6 Cylinder Shaft [Chin YS]

Cylinder shaft is one of the few moving parts and due to its slender structure,

it is calculated for its buckling strength. Buckling force is calculated using following

equation.

𝐹 =𝜋2𝐸𝐼

𝐿2

Tensional stress is neglected because effect of buckling force is higher than tensional

stress in slender object.

59

Figure 5.7: Cylinder shaft.

Shaft dimensions

Diameter 5 mm

Length 475 mm

Material - Aluminium 1100

Elastic modulus, E 6.89E+10 Pa

Mass

Food 1.000 kg

Choke 0.224 kg

Choke Ovrm 0.001 kg

Total 1.225 kg

Total weight 12.012 N

Design safety factor, k 3

Design weight 36.0 N

Analysis

Second moment of area, I 3.1E-11 m4

Buckling force, F 92.5 N

Re-define shaft geometry

Outer diameter 4 mm

Inner diameter 2 mm

Second moment of area, I 1.2E-11 m4

Buckling force, F 35.5 N

Cylinder shaft

60

Based on calculation, using 5mm diameter solid shaft will give additional

safety factor of about 3. Thus the geometry of shaft is change to a hollow one to change

the second moment of area. The suggested dimensions are, outer diameter of 4mm,

and inner diameter of 3.6mm. The material of choice is Aluminium 1110, because

aluminium will not corrode over time, thus will not pollute food.

61

CHAPTER 6

COSTING

6.1 Costing Design [Afiq, Bala & Chin]

Table 6.1: Fabrication, Installation and Transportation cost.

62

Costing is another important part in design. A good design will be able to

meet design criteria, and at the same time uses minimal cost. Cost includes material

cost, labour cost, production cost, administrative cost, and transportation cost. The

horse feeding system is cost estimated as table 6.1.

Therefore, the total cost that we have estimated is RM 3049.58. This cost is

desirable and reasonable to purchase. Moreover, the feeding horse system is semi-

automatic machine where it can be used without consume any additional cost

afterward.

63

CHAPTER 7

HORSE FEEDING SYSTEM OPERATION

7.1 Auto Horse Feeding System Operation [Afiq, Bala & Chin]

System operation for our feeding horse machine is user friendly where the

operator can operate the machine without any difficulties. This can be ensured by

referring to figure 7.1 where the process flow chart had been constructed. Therefore,

it is easy for a user to understand in a correct way.

Figure 7.1: The process flow chart for the horse feeding system.

64

The instruction how to operate this system can be referred as below,

1. Food in pellet form and powder will be loaded manually to its individual tanks.

2. This food is loaded for one week of the horse meal consumption.

3. As the meal time approaches, the timer will trigger signal to the tanks to

disperse the food to the plastic containers.

4. The weight sensor which is located below the slider plate will measure the

weight of the food dispersed by the tanks.

5. The weight sensor will send signal to tank to stop dispersing the food when the

weight is as per the ratio is detected.

6. Next signal will be send to the controller to release the food to the mixer..

7. This is sliding mechanism where the motion is driven by electrical motors.

8. While the food drops down, the rotating mechanism inside the mixer will rotate

to get a proper mixing.

9. This rotating will take place until all the food is fallen to the food discharge

unit.

10. When the sensor at the bottom of the food discharge unit detects the total

amount of weight of the food for the horse per meal, it will discharge the food

through the food slide to the meal container.

11. This cycle will take place for each meal timing based on the timer.

12. The meal timing and the ratio will be registered to the system main controller

according to each individual horse in UTM Equine Park.

65

CHAPTER 8

MACHINE LAYOUT

8.1 Isometric Drawing

66

8.2 Orthogonal Drawing (Front View)

67

8.3 Detailed Drawing

8.3.1 Detail view of sliding mechanism

8.3.2 Detail view inside of Mixer

68

8.3.3 Detail view of Food Discharge Unit

8.4 Assembly Drawing

8.4.1 Assembly Drawing For Hay

Hay Slider 1

Hay Slider 2

Hay Slider 3

Hay Slider 4

Hay Slider 5

Hay Tank

69

8.4.2 Assembly Drawing For Horse Feeding System

70

REFERENCE

Abdul Rahim Abdul Manaf (2006). Mekanik Bahan Dan Elasticity. Universiti Malaya

Malaysia: Penerbit Universiti Malaya.

Budynas, R.G. and Nisbett, J.K. (2011). Shigley’s Mechanical Engineering Design (9th

ed.). New York: Mcgraw-Hill.

Stephens, R.I., Fatimi, A., Stephens, R.R., and Fusch, H.O. (2001). Metal Fatigue in

Engineering. (2nd ed.). Canada: A Wiley-Interscience Publication.

71

APPENDIX

Slider Holder Calculation (Bala):

(a)

(b)

Figure 1: The slider holder which is subjected to bending stress by load. (a)

Isometric view (b) Side view

1. 𝐼 = 𝑏ℎ3

12, b = 5 mm and h = 30 mm ,

M = 9.81 x 0.125 = 1.23 N.m

𝐼 = 0.005(0.03)3

12= 1.125 × 10−8𝑚4,

𝜎𝑏𝑒𝑛𝑑 𝑀𝑎𝑥 = 𝑀𝑐

𝐼, 𝜎𝑏𝑒𝑛𝑑 𝑀𝑎𝑥 =

1.23(0.015)

1.125×10−8 = 1.64 𝑀𝑃𝑎

72

𝜎𝐴𝑙𝑙𝑜𝑤 = 31.6 𝑀𝑃𝑎 (From material properties table)

F.S = 31.6

1.64= 19.62 (Too large)

2. 𝐼 = 𝑏ℎ3

12, b = 5 mm and h = 20 mm ,

M = 9.81 x 0.125 = 1.23 N.m

𝐼 = 0.005(0.02)3

12= 3.33 × 10−9𝑚4,



1.23(0.015)

3.33 × 10−9 = 3.69 𝑀𝑃𝑎


F.S = 31.6

3.69= 8.6 (Too large)

3. 𝐼 = 𝑏ℎ3

12, b = 5 mm and h = 10 mm ,

∑ 𝑀 = 0 M = 9.81 x 0.125 = 1.23 N.m

𝐼 = 0.005(0.01)3

12= 4.17 × 10−10𝑚4,



1.23(0.015)

4.16 × 10−10 = 14.78 𝑀𝑃𝑎


F.S = 31.6

14.78= 𝟐. 𝟏𝟑 (OK)

73

Food Discharge Calculation (Bala):

(a)

(b)

Figure 2: The food container unit which is subjected to bending stress by

load. (a) Isometric view (b) Side view

1. 𝐼 = 𝑏ℎ3

12, b = 80 mm and h = 5 mm ,

∑ 𝑀 = 0 M = 27 x 0.08 = 2.16 N.m

𝐼 = 0.08(0.005)3

12= 8.33 × 10−10 𝑚4,



2.16(0.0025)

8.33 × 10−10 = 6.48 𝑀𝑃𝑎

74


F.S =𝜎𝐴𝑙𝑙𝑜𝑤

𝜎𝑀𝑎𝑥 =

31.6

6.48= 𝟒. 𝟖 (Too Large)

2. 𝐼 = 𝑏ℎ3

12, b = 80 mm and h = 4 mm ,

∑ 𝑀 = 0 M = 27 x 0.08 = 2.16 N.m

𝐼 = 0.08(0.004)3

12= 4.27 × 10−10 𝑚4,



2.16(0.002)

4.27 × 10−10 = 10.1 𝑀𝑃𝑎


F.S = 𝜎𝐴𝑙𝑙𝑜𝑤

𝜎𝑀𝑎𝑥 =

31.6

10.1= 𝟑. 𝟏𝟐 (OK!)

75

(b)

Rod Actuator (Afiq):

Figure 3: The rod actuator part which is subjected to bending stress by load F (a) Full

scale drawing (b) Internal force analysis

1. F = mg, where m = mass = 15 kg & g = gravitational acceleration = 9.81 m/s2

F = (15kg)(9.81m/s2) = 147.15 N

(+ ) ∑ 𝐹𝑦 = 0 -F – V = 0

V = -F = -147.15 N = 147.15 N ( )

(a)

76

𝜏𝑎𝑙𝑙𝑜𝑤 = 147.15 𝑁

𝜋(15 × 10−3)2

4

= 0.83 𝑀𝑃𝑎

𝜏𝐹𝑎𝑖𝑙 = 23.3 𝑀𝑃𝑎

F.S = 𝜏𝐹𝑎𝑖𝑙

𝜏𝐴𝑙𝑙𝑜𝑤 =

23.3

0.83= 𝟐𝟖 (Too Large)

2. F = mg, where m = mass = 15 kg & g = gravitational acceleration = 9.81 m/s2

F = (15kg) (9.81m/s2) = 147.15 N

(+ ) ∑ 𝐹𝑦 = 0 -F – V = 0

V = -F = -147.15 N = 147.15 N ( )

Change diameter to 10 mm


𝜋(10 × 10−3)2

4

= 1.874 𝑀𝑃𝑎




23.3

1.874= 𝟏𝟐 (Too Large)

3. F = mg, where m = mass = 22.5 kg/day & g = gravitational acceleration = 9.81

m/s2

F = (22.5 kg) (9.81m/s2) = 220.75 N

(+ ) ∑ 𝐹𝑦 = 0 -F – V = 0

V = -F = -220.75 N = 220.75 N ( )

77


𝜋(10 × 10−3)2

4

= 2.81 𝑀𝑃𝑎




23.3

2.81= 𝟖 (Too Large)


m/s2

F = (37.5 kg) (9.81m/s2) = 367.87 N

(+ ) ∑ 𝐹𝑦 = 0 -F – V = 0

V = -F = -367.87 N = 367.87 N ( )

𝜏𝑎𝑙𝑙𝑜𝑤 = 367.87𝑁

𝜋(10 × 10−3)2

4

= 4.68 𝑀𝑃𝑎




23.3

4.68= 𝟓 (Too Large)


m/s2

F = (52.5 kg) (9.81m/s2) = 515.03 N

(+ ) ∑ 𝐹𝑦 = 0 -F – V = 0

V = -F = -515.03 N = 515.03 N ( )


𝜋(10 × 10−3)2

4

= 6.56 𝑀𝑃𝑎

78




23.3

6.56= 𝟑 (OK!)

Plastic Plate (Afiq):

Figure 4: The HDPE plate part which is subjected to tensile stress by load

b

h

79

1. W = 7.5 kg x 9.81 m/s2 = 73.58 N,

∑ 𝐹𝑦 = 0 = −73.575 + 𝑁1 + 𝑁2

∑ 𝑀 = 0 - 73.575(112.50 x 10-3) + N2 (225 x 10-3) = 0

N2 = 73.575 – N1

- 73.575(112.50 x 10-3) + (N2 = 73.575 – N1) (225 x 10-3) = 0

N1, 2 = 36.79 N

𝜎𝑎𝑙𝑙𝑜𝑤 = 36.79 𝑁

25 × 10−3 × 2 × 10−3= 0.735 𝑀𝑃𝑎

F.S = 𝜎𝐹𝑎𝑖𝑙

𝜎𝐴𝑙𝑙𝑜𝑤 =

31.7

0.735= 𝟒𝟑 (Too large!)

2. W = 7.5 kg x 9.81 m/s2 = 73.58 N,

∑ 𝐹𝑦 = 0 = −73.575 + 𝑁1 + 𝑁2

∑ 𝑀 = 0 - 73.575(112.50 x 10-3) + N2 (225 x 10-3) = 0

N2 = 73.575 – N1

- 73.575(112.50 x 10-3) + (N2 = 73.575 – N1) (225 x 10-3) = 0

N1, 2 = 36.79 N

80

Change length plate,


10 × 10−3 × 2 × 10−3= 1.839 𝑀𝑃𝑎



31.7

1.839= 𝟏𝟕 (Too large!)

3. W = 52.5 kg/day x 9.81 m/s2 = 515.025 N, (Increase mass)

∑ 𝐹𝑦 = 0 = −515.025 + 𝑁1 + 𝑁2

∑ 𝑀 = 0 - 515.025 (112.50 x 10-3) + N2 (225 x 10-3) = 0

N2 = 515.025 – N1

- 515.025(112.50 x 10-3) + (515.025 – N1) (225 x 10-3) = 0

N1, 2 = 257.40 N


25 × 10−3 × 2 × 10−3= 12.87 𝑀𝑃𝑎



31.7

12.87= 𝟐 (OK!)

81

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