DESIGN, SIMULATION ANALYSIS AND FABRICATION OF THE CONCEPTUAL INNOVATIVE HAND TOOL FOR TUBER HARVESTER

ABDUL SSOMAD BIN M ABD HALIM

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Thesis submitted in Fulfillment of the Requirement for the Degree of Master of Science in the Faculty of Agriculture, Biotechnology and Food Sciences Universiti Sultan Zainal Abidin June 2013

DECLARATION

I hereby declare that the thesis is based on my original work except for quotations and citations, which have been duly acknowledged. I also declare that is has not been previously or concurrently submifted for any other degree at Universiti Sultan Zainal Abidin or other institutions.

Abdul Ssomad Bin M Abd Halim

Date:

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ACKNOWLEDGEMENT Alhamdulillah - All praises be to Allah (S.W.T), the Most Beneficent and the Most Merciful.

I would like to express my heartiest gratitude and in debtedness to my supervisor, Dr Mohd Hudzari B. Hj Razali, for his valuable time, advice and suggestions, consistent guidance and constant encouragement throughout the course of study. A word of thanks and appreciation to my co-supervisor Tn. Hj. Noordin Asimi Bin Mohd Noor, who have continually helped me in my research work and checked my thesis draft and for their time, effort and critical comments that are very valuable in making this thesis a reality. The author is thankful to Unit Perancangan Ekonomi Negeri (UpEN),

Terengganu, Malaysia for sponsoring the agriculture mechanization research for Dioscorea Hispida. The author wishes to thank Universiti Sultan Zainal Abidin, Kuala Terengganu, Malaysia and Universiti putra Malaysia for their supports. I would like to express my appreciation and thanks to En. Mohamed Bin Yunus, En Amir Fadzli Bin Abd Ghani, En. Soran Jalal Bin Abdullah and other staff of Faculty of Design Arts and Engineering Technology, Universiti Sultan Zainal Abidin (UniSZA), Terengganu in assisting me during the fieldwork and laboratory work, similarly, I would like to appreciate their assistance.

lam grateful to my family member including my parents, wife, sisters, brothers-in- law, and parents-in-law, there are no words that could describe my feeling to all of you. Thank you for your moral support, encouragement, patience, sacrifices, love and prayers. I would like to express my humble apology to those individual, who helped me but may not find their names in my narration here.

APPROVAL

I certify that an Examination Committee has met on 5 June 2013 to conduct the final examination of Abdul Ssomad Bin M Abd Halim, on his Master of Science thesis entitled "Design, Simulation Analysis and Fabrication of the Conceptual lnnovative Hand Tool for Tuber Harvester,, in accordance with the regulations approved by the senate of Universiti Sultan Zainal Abidin. The Committee recommends that candidate be awarded the relevant degree. The members of the Examination Committee are as follows:

Mohd Zakaria Bin lsmail, PhD. Professor Faculty of Agriculture, Biotechnology and Food Sciences Universiti Sultan Zainal Abidin (Chairperson)

Mohd Hudzari Bin Hj Razali, PhD. Senior Lecturer Faculty of Agriculture, Biotechnology and Food Sciences Universiti Sultan Zainal Abidin (Member) Noordin Asimi Bin Mohd Noor, MSc. Lecturer Faculty of Design Arts and Engineering Technology Universiti Sultan Zainal Abidin (Member)

Saiful Bahri Bin Mohamed, PhD. Lecturer Faculty of Design Arts and Engineering Technology Universiti Sultan Zainal Abidin (lnternal Examiner) Wan lshak Bin Wan lsmail, PhD Professor Faculty of Engineering Universiti Putra Malaysia (External Examiner)

+k ^r; flI*. PROF. DR. NOORHAYATI MANSOR, CMA Dean of Graduate School Universiti Sultan Zainal Abidin Date:

2o APPTL

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This thesis has been accepted by the Senate of Universiti Sultan Zainal Abidin as fulfillment of requirements for the degree of Master of Science.

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PROF, DR. NOORHAYATI MANSOR, CMA Dean of Graduate School Universiti Sultan Zainal Abidin

Date: 2o AlatL ,6tl

DESIGN, SIMULATION ANALYSIS AND FABRICATION OF THE CONCEPTUAL INNOVATIVE HAND TOOL FOR TUBER HARVESTER

ABSTRACT Dioscorea hispida (D. hispida) is a poisonous plant normally found in wildlife forest where scientific studies have shown that its tuber contains toxic poison and can be consumed after its poison is removed. On the other hand, harvesting the tuber of D. hispida is time consuming and difficult due to the existing hand tool is heavy and required a large force to harvest the tubers. Therefore, the essential development of an innovative hand tool harvester is required to improve and facilitate the harvesting process. Using digital gauge, tuber exlraction force was measured in order to be fed into the Computer Aided Design (CAD) simulation. Three designs of hand tools (straight, bent and fulcrum) were proposed and the design selection was based on the lowest displacement and stress value. This was done using SolidWorks CAD software. Further analysis was conducted to select the best material for the selected design based on stress analysis and factor of safety. The results from field experiments showed that the bent type hand tool required less force to extract the D. hlsprda in comparison to the traditlonal hoe. A force reduction at approximately of 10 % was achieved by the newly proposed design as well as fabrication from material which is lighter and stronger.

Keywords: Dioscorea hispida, Hand Tool Harvester, Simulation and Modelling,Stress Analysis, SolidWorks

REKA BENTUK, A'VAI'S'S SIMULASI DAN FABRIKASI ALAT TANGAN KONSEP YANG BERINOVATIF BAGI PENUAIAN UBI

ABSTRAK Dioscorea hispida (D. hispida ) adalah tumbuhan beracun yang biasanya ditemui dalam hutan hidupan liar di mana kajian saintifik telah menunjukkan bahawa ubi mengandungi racun toksik dan boleh dimakan setelah racunnya dikeluarkan. Sebaliknya , menuai ubi D. hispida ini memakan masa dan sukar kerana alat tangan yang sedia ada adalah berat dan memerlukan daya yang tinggi untuk menuai ubi. Oleh itu, pembangunan penting dalam alat tangan inovatif penuai diperlukan bagi menambahbaik dan memudahkan proses menuai. Dengan menggunakan tolok digital, daya pengeluaran ubi telah diukur untuk di masukkan data ke dalam Perisian Rekabentuk Berbantukan Komputer (CAD) simulasi. Tiga reka bentuk peralatan tangan ( lurus, bengkok dan "fulcrum" ) telah dicadangkan dan pemilihan reka bentuk adalah berdasarkan nilai anjakan yang paling rendah dan nilai tekanan yang paling rendah. lni dilakukan dengan menggunakan perisian CAD. Analisis lanjut dijalankan untuk memilih bahan terbaik untuk reka bentuk yang dipilih berdasarkan analisis tekanan dan faktor keselamatan. Keputusan daipada eksperimen menunjukkan bahawa jenis alat tangan bengkok memerlukan tenaga yang rendah berbanding dengan cangkul tradisional untuk mengekstrak D. hispida. Pengurangan daya sebanyak 10% telah dicapai oleh reka bentuk yang baru serla fabrikasi daripada bahan yang lebih ringan dan kuat.

Katakunci: Dioscorea hispida, Alat Tangan Penuai, Simulasi dan permodelan, An a I i si s Teka n a n. Sol idWo rks

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TABLES OF CONTENTS PAGE

DECLARATION ACKNOWLEDGEMENT

t

iv

APPROVAL ABSTRACT

vii

ABSTRAK

viii

TABLE OF CONTENTS

ix

LIST OF FIGURES

xiii

LIST OF TABLES

xvi

LIST OF ABBREVIATIONS

xvii

CHAPTER

1

1.0 INTRODUCTION 1.1 Background 'l

.2 Morphological on D. hispida

6

1.2.1 Type of Harvest

7

'l.2.2The Root System

7

1.2.3 D. hispida ptant '1

1

.3 Problem Statement

1.4 Objectives

I 10 11

IX

CHAPTER 2 2.0 LITERATURE REVIEW 2.1 lntroductions

12

2.2 Mechanization Potential on Harvesting

IJ

2.2.1 Hoe (Cangkul)

14

2.2.2 Con@plual Design for Manual Hand Tool

'15

2.2.3 Conceptual Design of Semi-Automated Machines

17

2.2.4 Conceptual Design of Automated Machine (Robot

't9

Hardware)

2.3 Finite Element Method (FEM)

21

2.3.1 Simulation Analysis for Designed Product

22

2.3.2 SolidWorks Simulation

22

2.4 Summary of Literature Review

24

CHAPTER 3 3.0 METHODOLOGY 3. 1 Overview

25

3.2 Determination of Harvesting Force

29

3.3 Conceptual Design for lnnovative Hand Tool Harvester

30

3.4 Concept Design Using Parametric Software

31

3.4. 1 SolidWorks Simulation Program

32

3.4 2 Simulation Process on Stress Analysis

32

3.5 Material Properties Used in Simulation

34

X

3.5.1 Elastic Modulus

34

3.5.2 Poisson's Ratio

34

3.5.3 Shear Modulus

35

3.5.4 Mass Density

36

3.5.5 Tensile Strength

Jb

3.5.6 Thermal Expansion

37

3.5.7 Thermal Conductivity

37

3.5.8 Specific Heat

3B

3.6 Material and Fabrication Process

47

CHAPTER 4 4.0 RESULTS AND DISCUSSION 4.1 Field Test

48

4.2 Simulation Result for Max and Min Stress,

50

Displacement and Strain Force (Straight, Bent and Fulcrum Hand Tools)

4.3 Design and Modelling of Hand Tools

62

4.4 Proposed Materials of Hand Tools

66

4.5 Simulation Result on Proposed Materials of Hand Tools

67

4.6 Relationship between Weight and Force Requirement for

75

Harvesting D. hisprda Tubers 4.7 Discussion on Tool Design and Simulation Analysis

80

xt

CHAPTER 5 5.0

coNcLUsroN

81

REFERENCES

82

PUBLICATION

86

APPENDICES

92

BIODATA OF THE AUTHOR

'106

xll

LIST OF FIGURES

PAGE

Figure 1.1: The tubers and stem for D. hispida

6

Figure 1 .2: Classifications of D. hispida dennst 1: leaf 2: male

I

flowering shoot and 3:cluster of tubers Figure 2.1: Flow chart process for designing and fabrication level

14

Figure 2.2: Hoe (Cangkut)

15

Figure 2.3: lnnovative hand tool designed for cassava

'16

Figure 2.4: Semi automated machine also was developed for

17

harvesting lhe ubi kayu Figure 2.5: Prototype cassava harvester with reciprocating share

18

Figure 2.6: The Dyna-Digger power shovel used by nurserymen and

19

land scrapers alike Figure 2.7: The complete diagram and picture of cocoa pod harvester

tv

Figure 3.'l : Flow chart of process using parametric software

1-7

Figure 3.2: IMADA digital force measurement gauges

ZO

Figure 3.3: Hand-held test stand

28

Figure 3.4: Harvesting the tubers using developed innovative hand

28

tool Figure 3.5: Force determination using IMADA and bent type tool

29

Figure 3.6: Conceptual design for manual harvester

JI

Figure 3.7: Step to perform analysis in SolidWorks simulation

JJ

Figure 3.8: Bent type hand tool

20

xt

I

Figure 3.9: SolidWorks SimulationXpress Analysis

40

Figure 3.10: Fixture dialog box fixing in SolidWorks

40

Figure 3.1 1 : Selected faces for the hand tool

40

Figure 3.12: Force of 50N applied to the handle of the hand tool

41

Figure 3.1 3: Side view of the load

41

Figure 3.14: Full view of the SolidWorks SimulationXpress design

42

Process Figure 3.15: How to change a model's material

43

Figure 3.16: Materials window dialog box

43

Figure 3.17: Result of SolidWorks Simulationxpress on static

44

Displacement Figure 3.18: Result of SolidWorks SimulationXpress on stress

45

Figure 3.19: Part of the process flow in SolidWorks SimulationXpress

46

Figure 3.20: SimulationXpress Study tree

46

Figure 4.1 : Penetrating the hand tool near D. hispida lree

51

using straight type hand tool Figure 4.2: Penetrating the hand tool near D. hispida lree

51

using bent type hand tool Figure 4.3: Penetrating and harvesting D. hispida plant using

52

fulcrum type hand tool Figure 4.4: Stress distribution on shaight type hand tool

54

Figure 4.5: Stress distribution on bent type hand tool

55

Figure 4.6: Stress distribution on fulcrum type hand tool

56

Figure 4.7'. Displacement value at top holder of straight type hand tool

5B

Figure 4.8: Displacement points at top holder of bent type hand tool

59

Figure 4.9: Displacement points at top holder of fulcrum type hand tool

60

Figure 4.10: Straight type hand tool

62

Figure 4.'11: Bent type hand tool

63

Figure 4.12: Fulcrum type hand tool

64

Figure 4.13: Design of bent type hand tool showing foot stand and

65

fork; a) Front view b) Side view Figure 4.14: Aluminum Alloy (201.0-T7 lnsulated Mold Casting)

69

stress (max at below & min at top) Figure 4.15: Aluminum Alloy (201.0-T7 lnsulated Mold Casting)

70

Factor of Safety (F.O.S) Figure 4.16: Cast Carbon Steel for stress (max. at the bottom & min.

71

at the top) Figure 4.17: Cast Carbon Steel for Factor of Safety (F.O.S)

72

Figure 4.18: Plain Carbon Steel for stress (max. at the bottom & min.

t3

at the top) Figure 4.19: Plain Carbon Steel for Factor of Safety (F.O.S)

74

Figure 4.20: The relationship between weight and force requirement

75

for harvesting of tubers of D. hispida Figure 4.21 : Soil Texture Triangle

79

LIST OF TABLES Table 1.1: The principle edibte species oI D. hispida

PAGE J

Table 4.1 : Tools set for manual harvesting of D. hispida

49

f

53

able 4.2: Simulated stress and displacement the straight,

bent and fulcrum hand tools Table 4.3: Material, mass, volume and density of design for

bb

innovative hand tool Table 4.4: The material properties of hand tool harvester material

67

LIST OF ABBREVIATION D.

hispida

Dioscorea hispida

CAD

Computer Aided Design

FE

Finite Element

FEM

Finite Element Method

FEA

Finite Element Analysis

FRIM

Forest Research lnstitute Malaysia

FAO

Food and Agriculture Organization

PDE

Partial Differential Equation

PROSEA

Plant Resources Of South-East Asia

TIG

Tungsten lnert Gas

UniSZA

Universiti Sultan Zainal Abidin

UPEN

Unit Perancangan Ekonomi Negeri

CHAPTER

1

1.0 INTRODUCTION

1.1 Background The advancement of technology should be introduced in most important area;

agriculture,

as for the benefit of mankind. The righteous book,

Al-Quran

mentioning about agriculture and plant within eighty three sentences shows it

significance (Fauzi, 2008). Dioscorea hispida (D. hispida) is one of the yam (Discorea spp ) species and is characterized as a climbing plants with glamorous

leaves and twining stems, which helix readily around the stem. D. hispida is commonly found in secondary forest and grows under shaded areas or near streams which is known by the local as lJbi Gadong (Nashriyah et a1.,2010). Yam (also called name in Spanish and lgname in French) belongs to the genus Dioscorea (family Dioscorea). An estimated of 300-600 species are available, there are just over half-dozen principal species that are grown for consumption, while others are grown for medicinal purposes. Yams originated in the Far East

and spread westwards. They have since evolved independently in the Eastern and Western Hemispheres, and today yams are grown widely throughout the tropics.

L

ln the West African yam zone, which is the major producer on a global basis, D.

rotundata,

D. alata, and D. esculenta are the most common species.

The

production and utilisation of yam is declining in most producing areas, mainly due

to the high labour demand and the delicate nature of the harvested crop. The small-scale farmers who produce the majority of crop need to mechanize, which

will reduce drudgery and improve productivity at all levels (on-farm and postproduction operations). The objective of this chapter is described to outline, the

techniques and procedures for harvesting, handling and storing yams. Some mechanical properties of yams will also be presented to assist in the design and selection of appropriate handling and processing systems. Yams are second to Cassaya as the most important tropical root crop. yams are

a staple crop in many parts of Africa and Southeast Asia. ln the South pacific, yam is a sfgnificant food crop, accounting for over 20o/o, 8.1o/o, and 4.6% of the total dietary calorie intake in the Kingdom of Tonga, Solomon lslands, and papua

New Guinea, respectively. Table 1.'l show the principle edible species of

D.

hispida.

2

Table 1.1: The principle edible species of D. hispida

Country

Famous Name

Malaysia

Ubi arak, gadongan, gadong mabuk

English

Asiatic bitter yam, intoxicating yam

lndonesia

Gadong (General), sikapa (Bali, Sulawesi), ondo (Ambon)

Philippines

Nami (Tagatog), Qayus (biasaya), karut (ilokano)

Burma(Myanmar)

Kywe

Cambodia

D6mio:ng Kduoch (western)

Loas

Hwa ko:y (northern)

Thailand

Kloi (central), kloi-nok (northern), kloi-hua nieo (nakhon Rafchchasima)

Vietnam

CIUr]n[ee] Source: Vernacular Names ofsoulh-East Asia (Flach and M.Rumawasl 1996)

3

Besides their importance as food source, yams also play a significant role in the

socio-cultural lives of some producing regions like the celebrated New Yam Festival in West Africa,

a practice that has also extended to overseas

where

there is a significant population of the tribes that observe it. ln some parts of South-eastern Nigeria,

the meals offered to gods and ancestors

consist

principally of mashed yam. Yams can be stored relatively longer in comparison with other tropical fresh produce, and therefore a stored yam represents a stored wealth which can be sold all-year-round by the farmer or marketer. ln parts of lgboland in South-eastern Nigeria, it is customary for the parents of a bride to offer her yams for planting as a resource to assist them in raising a family.

D. hispida is Asiatic Bilter yam, similar to the African Dioscorea

dumetorum.

Large tubers are near to the soil surface, which are very toxic and are used for hunting or criminal purposes; the toxin can be removed, and the tubers are used as a famine food in the tropical East.

The global production of yam was estimated by Food and

Agriculture

Organization (FAO) at 40 million metric tons in 2004, about 75% from West Africa, especially Nigeria. Yam are also widely grown in Southeast Asia, the Pacific and becoming replaced by cassava and sweet potatoes, both of which are

often able to produce more food with less labour input. Nutritionally the yams are more useful than cassava, particularly in protein. They contain about 28% starch and about 5 mg/1009 Vitamin C, carotene is present in varielies with yellow flesh. There are about 600 species of Dioscorea (Tony, 2006). 4

D. hispida is a poisonous plant where scientific studies have shown that its tuber

contains toxic poison. lt can only be consumed after the poison of dloscorn is removed. lt is normally found in wildlife, forest and could act as an alternative for

the daily food. D. hrspida which entitled Ubi Gadong in Malaysia is one of the most economically important agriculture in yam species, which serves as a fast

food for a millions of people in tropical and subtropical countries (Hahn, 1995; Udensi. 2008; Hudzari et a|.,2011). ln harvesting aspect, the innovative hand

tools were conceptually designed

to

replace

the old method on

manual

harvesting of D. hispida.lt is by using a hoe, namely cangkul which required high

force especially due to cutting of the scattered roots of tubers. The farmer would normally harvest the D. hispida by using a hoe and needs to plough in around the stem a bit larger than the tuber. Sometimes the farmer may need to cut the root of the fruit and by using a hoe, he needs to push manually. This process might need to be repeated a few times before the tuber could be harvested. Figure

1.1

shows the tuber of D. hispida. This plant is classified as a wild creeping and climbing plant which can grow up to 20 meters in height (Hahn, 1995).

5

Stem

Scattered roots

Tubers

I

Figure 1.1: The tubers and stem lor D. hispida

1.2 Morphological on D. hispida Morphology is a branch of biology dealing with the study of the form and structure

of organisms and their specific structural features (Hahn, 1995). Generally a tool

is required since harvesting D. hispida tubers are time tedious. A tool is any instrument used in doing work. A hand tool generally refers to any tool operated

by hand that makes use of muscle power rather than electricity or other power sources. This is contradicted with

a

power tool, which is operated by some

source of power other than human power (Ray, 2010).

6

1

.2.1 Type of Harvest

When the leaves turn yellow and the vine completely dry up, the crop is ready for lifting, which will be in about 8 - 9 months after planting. D. hispida matures early

as compared to other species. There is a practice of double harvesting removing

the tuber after two months of growth and allowing

i.e.

subsequent

production of more tubers. However, double harvesting is not economical as compared to single harvesting, while harvesting should be done so as not to cut or damage the tubers as this causes vetting of tuber (Ray, 2010).

1.2.2 The Root System The function of plant roots is to absorb water and nutrients from the soil, to anchor the aerial (above ground) plant parts, and sometimes also to store food. The young root that rushes out from the seed is called the radicle. Depending on

the species, this can either persist and become a deep growing primary root ot tap roots, or it can be replaced by a more fibrous root system of secondary roots. Adventitious roots are neither primary nor secondary roots, nor do they arise from them, but are roots which develop in an abnormal position from stems or leaves. Root hairs on the younger roots absorb water by osmosis and a nutrient by active

selective absorption. This second process requires energy provided by root respiration, which requires oxygen.

lf the soil is waterlogged, oxygen is

unavailable and the roots cannot respire, and so nutrients cannot be absorbed (Tony, 2006).

7

1.2.3 D. hispidaPlant A tuber is an enlarged, swollen tip of underground stem (or rhizome). Tubers have buds, or nodes, in the axils or rudimentary consent or scales. The tubers are renewed annually from a superficial corn, which they grow as lobes where in outline are spherical, sometimes slightly elongated and pale yellow to light grey. The flesh is white to lemon-yellow. The stem is twining to the left, firm, measuring

9 mm or more in

diameter, usually prickly, drying bright yellowish and with

glabrescent, the builbils are absent. The leaves are hifoliolate, herbaceous to cretaceous and pubescent.

Figure 1.2 shows Classifications

of D. hispida dennsf. The middle leaflet

is

oblong-elliptical (rarely obviate or tripartite), measuring up to 30 cm x 28 cm and acuminate. The lateral leaflets are in equilateral where the outer is

a half 3-

nerved. The petiole is usually longer than the middle leaflet and usually with small prickles on the back. The petioles are up to 1 cm long.

8

The male inflorescence is a spikeJike, branch on leafless, 2-3-compounded, measures up to 50 cm long, with closely packed or spaced sessile flowers and

with 6 fertile stamens. The female inflorescence is solitary from the upper leaf axils, pendulous and with flowers spaced. The fruit is a large woody capsule, honey coloured, with 3-winger and face upwards. The wing measuring 40-60 mm x'10-12 mm and sometimes freed in dehiscence margin. The seed is winged.

?

/

I

I

Source: PROSEA / FRIM (2009)

Figure 1.2: Classifications of D. hispida dennst 1: leaf 2: male flowering shoot and 3: cluster of tubers

9

1.3 Problem Statement

An innovative hand tool is required to replace the traditional method

for

harvesting D. hispida. ln the remote areas, normally the farmer uses a hoe where

it required high force to operate, especially in cutting the scattered roots of

D.

hrsprda tubers. The farmer, when harvestin g D. hispida, used a hoe to plough soil

around the stem at a radius a bit larger than the tuber area. Sometimes the

farmer had to cut the roots of the tuber and using

a

hoe, they had to push

manually. ln short, hoe is not suitable because it takes much time working and required more energy. Although, normal hoe having straight designed of stick which make the farmer getting back pain body compared with bent type' lt took is about 30 minutes to harvest and average D. hispida tubers. The pulley force for

an average tuber is 10 kg. The purpose of this research is to design, analyze,

and fabricate the hand tool harvester. The new hand tools will ease the harvesting operation, making it more efficient to harvest the tuber. The material

with special characteristic on properties of strength and weight will make proposed hand tool more user friendly.

10

1.4 Objective

The objectives of this studY are:-

i. ii. iii. iv.

To improve the design of the traditional harvester for D. hispida lubet. To determine and analyze the material for the harvester. To study finite element analysis result via solid modelling software. To fabricate a portable prototype hand-held harvester that is light and strong.

LI

CHAPTER 2

2.0 LITERATURE REVIEW

2.1 lntroduction Gadong (D. hispida Dennst.) is one of the unpopular members of tubers which are available in almost all parts of lndonesia's archipelago. This tuber crop

is an important source of

carbohydrates

as an alternative energy

source'

Moreover, it has been used as staple foods, especially by people in the tropical

and sub-tropical regions (Liu ef a/., 2006). This study could be classified under mechanization potential on harvesting. ln general, this study involves the use of common tools to harvest tubers which are the concept of hoe, has been taken.

The conceptual design for manual hand tool refers to development for Cassava (Manihot esculenta)

ot ubi kayu using manual lifting which involve pulling the

stem above the soil surface. While for the conceptual design of semi-automated

machine

is

studied from the machine

for harvesting the

Cassava, which

composed of a digger to pull the roots out from the soil and a conveyor belt that

brings the Cassava from its stem and carries conceptual design

it into a

container. For the

of automated machine was developed for harvesting

the

cocoa fruit and then grabs it before unloading process which the robot hardware applies and power shovel that is suggested for harvesting D. hispida. The finite element theory involves simulation analysis for the designed product.

t2

2.2 Mechanization Potential on Harvesting Current research attention focuses on several areas. Mechanization is a concept

and cannot be measured directly. Appropriate indicators must be selected to determine levels of mechanization for eg. Variables that atlow describing and monitoring the processes. Wan lshak, (2010), states and tendencies of system at

the farm, regional, national and world wide level (Morteza et al., 2010). producing

a

ln

hand-held harvesting tool, we need to design' produce a virtual

model and finally fabricate. Sarah, (2008) stated the process for constructing the

final product includes preliminary design, schematic design and desired. Figure

2.1 shows the flow chart process from designing to fabricating. To design and model the hand-held harvester for D. hispida,

a few variables need to

be

considered, i.e. the grain size and characteristics of the soil, and weight of the

tuber. The product need to be light enough for easy handling on site. The selected material to be used must fulfill the desired output of the product, in this case, to harvest D. hlspida tubers. Davoodi et al., (2010) stated that composite material had some advantages in mechanical strength and act as a medium to high reinforcement carbon plastic and thermoplastic during design and fabrication

stage. Due to these desired properties, the material is chosen for designing the final product.

13

PRTLIM]NAItY

SCHEMATIC

D[516N

co\isln!anoN

DES16N

DfSIGN

OCV:IOPMFMT

)oaalMtMIs

PROGRAM

--C)i

I I I

-l---L

EUILDING

O

O iC,

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Figure 2.1: Flow chart process for designing to fabrication level

2.2.1 Hoe (Cangkutl

A hoe is an ancient and versatile agricultural tool used to move small amounts of

soil (Hartzell and Hal, 1987). Figure 2.2 shows example of hoe (cangkut). Common goals include weed control by agitating the surface of the soil around

plants, piling soil around the base of plants (hilling), creating narrow furrows (drills) and shallow trenches for planting seeds and bulbs, to chop weeds, roots

and crop residues, and even to dig or move soil, such as when harvesting root crops like potatoes and D. hispida. ln Malaysia, normally the farmer will harvest D. hispida using hoe. The farmer needs to dig around the tree with the mass of

the tuber. Sometime the farmer needs to cut the root of the tuber and from outside of the plant the farmer will use the hoe to push the D. hispida up, in some cases these methods needs to be repeated.

1,4

I i

l

I

'-t.r

Figure 2.2: Hoe (Cangkul) 2.2.2 Conceptual Design for Manual Hand Tool

A

manual hand tool was also developed by the Agricultural Mechanization

Development programmed; Philippines for Cassava (Manihot esculenta) or "Ubl Kayu" (FAO,201'1). Manual lifting of cassava usually involve pulling the stem at a

height of about 300 mm above the soil surface. The detachment of the aerial parts of the plant is to allow for effective grip by the hands. However, under firm

rooting conditions, manual tools such as machetes, hoe or digging fork are employed to dig the soil in the root zone to reduce the soil restraining. Force is necessary to lift out the tubers. lt is often impractical to lift tubers by simply pulling

from compacted or desiccated soils because they tend to break off the stalk. (Agboola, 1997 and Osobu, 1985). As in figure 2.3 (i), it is used with a hoist which

is positioning the blade under the plant's base, holding the stem of the root with the two jaws and using the pedal action of this tool to draw up the Cassava. 15

To facilitate this kind of operation, it is useful if the tifter in Figure 2.3 (ii): the cassava is attached by means of a chain mounted to one end of the lifter while at the other end there is a handle to pull up the plant. The cassava is very similar to the D. hispida. Their tubers normally grow on the surface. But the root or tuber for ubi kayu is hard and big compared to D. hispida.

\

\ \

\

l

I

\.

Chain I

Lifter

Blade

Lifter

(i) (ii)

Figure 2.3: lnnovative hand tool designed for Cassaya 1b

2.2.3 Conceptual Design of Semi-Automated Machines

The mechanism produced in harvester design will be later used for integration in the development of semi-automated machine. As in Figure 2.4, this machine will operate on both sides of planting and harvesting stage. The kubota tractor available at Universiti Sultan Zainal Abidin (UniSZA) will be used for this purpose.

The implement will be bought from outside of the country as they have already achieved advancement in harvesting etc. potato harvesting machine. The semiautomated machine also was developed for harvesting lhe ubi kayu (FAO, 201 1).

As in Figure 2.4, this harvester is composed of two parts: a digger to pull the roots out from the soil and a conveyor belt that brings the Cassava from its stem and carries it into a container. The semi auto machine for Cassava harvesting in Malaysia also was reported by Md. Akhir and Sukra (2010). The digger part will

penetrate the soil and push up the Cassava while the rotating blade and the conveyor will isolate the fruit with soil.

To

traclor

PTO

Rotatingglade5

Source: \r/v/w.guoxinmachine.en (201

1

)

Figure 2.4: Semi automated machine also was developed for harvesting the ubi kayu L1

The modification on the front side of the machine is required for adoption to the physiological of the D. hispida. As shown in Figure 2.5, the image for modification purpose start at intake web part.

*

Crc! 'l,irr -

rl

,rl;k,:

i1

---,r

irst .

r-l

i:;iin

''

Se$nc

-

Ile,ia:.rr Phking :atle

T$er,'clod

'i,*t

$ec "l,ll'l [,,e1 seltralgr \ ---

1: !

.1.r.

l,le

I

[r,ri:;

f::l.-r

rr:,iir ltrrt

C

;a- -_l

:/ H;,r,nr

*l:..ril,

Return wcb to elevator

Source: Pringle

etal,

(2009), potatoes postharvesl, CABI pubtishing

Figure 2.5: Prototype cassava harvester with reciprocating share

Figure 2.6 shows Dyna-digger a power shover that is suggested for harvesting D.

hispida. commerciaily, it is used for digging and transpranting the trees semiautomatically.

lt's specification is engineered precisely with only top

quality

materials, 2-cycre Tecumseh engine, compretery assembred expect for shover

attachment, body 12.6cm long (not inctuding blade) shipping weight 95.6Kg pounds, Detachabre 7.ogcm brade is standard 9.4cm and i.r.gcm brade avairabre, 18

quick change additionar attachments avairabre brade rengths is 7.09cm,9.4cm and 11.8cm, 2.36cm coring toor for post hore type digging, tamper attachment for packing.

J

Source: http:/Ir/w!v.dynadiggr.com/index.html

2O

j

1

Figure 2.6: The Dyna-Digger power shover used by nurserymen and randscapers

2.2.4 Conceptual Design of Automated Machine (Robot Hardware)

The automated machine was developed for harvesting the cocoa fruit and then

grabs

it

before unloading process. Robot hardware applies the process for

innovative hand tool harvester. There are

4

pneumatic cylinders for linear

movement and 1 pneumatic motor for robot turning. rt is arso equipped with the 19

solenoid valve, air pressure pump, pneumatic wiring and personal computer with

a digital camera. The computer triggered the inpuuoutput card by 5 volts power and then this card stood passing through 24 volts from power source to trigger solenoid valve to release air pressure for robot movements. As in Figure 2.7, the

diagram and picture development

is

shown for complete robot system. The previous

of the "robot eye" system for

agriculture arm machine was

successfully designed and fabricated by Hudzari (2002).

Cu!.,

16rp.i

Molo 2

Crndd 2

W3

C),5da I

q,!\ I

t

It el

Figure 2.7: The complete diagram and picture of cocoa pod harvester (Wan lshak and Mohd Hudzari, 2009) 20

2.3 Finite Element Method (FEM)

FEM is

a

numerical technique for finding approximate solutions

to

partial

differential equations (PDE) and their systems, as well as integral equations. ln simple terms, FEM is a method for dividing up a very complicated problem into

small elements that can be solved

in relation to each other. lt's

practical

application often known as finite element analysis (FEA) (Sapuan et aI.,2006). The main feature of FEM is the entire solution domain is divided into small finite segments (hence the name finlte element). over each element, the behavior is described by the displacement of the elements and the material law. All elements

are assembled together and the requirement of continuity and equilibrium are satisfled between neighboring elements. provided that the boundary conditions of

the actual problem are satisfied, a unique solution can be obtained to the overall system of hour algebra equation. stress is generally defined as the average for

force (F) per unit area (A).The sorution matrix is sparsery popurated (Becker, 2004).

21

2.3.1 Simulation Analysis for Designed Product

simulation program is very useful on designing work before fabrication the final product (Sapuan et al, 200n.

lt is necessary to

simulate the practicality and

workability of the conceptual design of hand-held harvester for designing and fabricating level. The concurrent engineering environment used as a conceptual

arena, is created by any or all technologies enabling collaborative efforts in the

building process. The technology engineering concept will

be applied i.e.

extraction of the design layout of the machine, schematic and wireframe of the model, modification in computer aided design (cAD) environment, simulation and

finally the complete drawing for fabrication purposes (Darius and Azmi, 2003). Designers and engineers primarily use structural simulation to determine the

strength and stiffness

of a

product by reporting component stress and

deformations (Sapuan et al., 2007).

2.3.2 SolidWorks Simulation

cAD software, soridworks, enabres every designer and engineer to carry out structural simulation on parts and assemblies with finite element analysis (FEA)

while they work to improve and validate performance and reduce the need for costly prototypes or design changes later on (Becker,2oo4). structural simulation

covers a wide range of FEA problems from the performance of a part under a

constant load to the stress analysis of

a moving assembly under dynamic

loading, all of which can be determined using solidworks simulation tools. 22

solidworks simulation uses the displacement formulation of the FEM to calculate component displacements, strains, and stresses under internal and external loads.

solidworks Simulation uses FEA methods to calculate the displacements and stresses in the product due to operational loads such as: Forces

ii.

Pressures

iii.

Accelerations Temperatures Contact between components

Loads can be imported from thermal, flow, and motion. Simulation studies to perform metaphysics analysis. The solidworks and finite element is suitable using for innovative hand tool harvester.

23

2.4 Summary of Literature Review

From literature review existing design for harvesting crop from a remole site is

not ergonomic, heavy, inefficient and difficult to carry. The summary on the literature review was focus on research using new toor simuration computer program and innovating the existing agricurturar equipment. conceptuar design

on Semi-automated machine and automated machine arso were introduced

in

current research finding which has rerevance for future apprication. The research concentrates on manuar hand toor harvester which imposes on designing, an ergonomic, lightweight, efficient and portability.

24

CHAPTER 3

3.0 METHODOLOGY

3.1 Overview

The reverse engineering concept was applied where it initially involved extraction of the design layout of the tool, development of schematic drawing and wireframe

model, design modification in a CAD environment, design simulation and finally the completed drawing for fabrication purposes (Hudzari et at.,2O11and Darius et

al.,2003). Conceptual designs of the tools were developed and these designs

were important in product development (Sarah, 2008; Sapuan et

al.,2OO6;

Sapuan et a\.,2005; Sapuan and Maleque, 2005). Figure 3.1 shows a flow chart

of the process starting from drafting, modeling, material selection, simulation analysis, prototyping a performances analysis, and lasfly fabrication. Drafting is technical drawing or droughting, is the act and discipline of composing plans that visually communicate how innovative hand tool harvester functions or has to be constructed. Modeling is the construction of geometric model by combining form features hand tool with base model in SolidWorks. Material selection defines the configuration of a material from CAD as it was designed. Simulation analysis is

modeling, exercising and analyzing

a

design's behavior without physically

building the design. The simulator and simulation model have all the necessary 25

attributes of the physical design. Prototyping is an innovative hand tool that enables to create working CAD and SolidWorks that include interactive elements

and dynamic content. Prototyping serves to provide specifications for

a

real,

working system rather than a theoretical one. Performance analysis included in

the purpose of this activity is aimed to aid in the decision making process by creating

a study on the design, assign materials, apply fixtures, apply loads,

mesh the model, run the analysis, and visualize the results. Fabrication meaning

to make, construct the innovative hand tool harvester upon completion of the FEA. To determine the force required to extract the tuber IMADA digital force

measurement gauge with

a fabricated hand-held test stand is used.

IMADA

digital force measurement gauge as shown in Figure 3.2 is state-of-the-art, instruments capable of the highly accurate measurements required in quality testing to determine the strength or functionality of a part or product. The purpose

of hand-held test stand as shown in Figure

3.3 is conceptually required for

placement of digital force gauge during experiment in determining the force required for harvesting the tubers of D. hispida. This stand is available to use which brought together with digital gauge. Otherwise, during the experiment, the

gauge was directly stick on to harvester like shown in Figure 3.5. Figure 3.4 shows the image during harvesting the tubers using an innovative hand tool that was developed. This force value will be used in FEA.

25

Drafting Modeling Material Selection

Simulation Analysis

Prototyping

Performance Analysis

Fabrication

Figure 3.1 : Flow chart of process using parametric software 27

Holderforfixture

Displa/screen

, : N

Figure 3.2: IMADA digital force gauges

measurement Figure 3.3: Hand-held test stand

Developed lnnovative Hand

il Dioscorea hispida stem

,t

Scattered roots and tuber

I

Figure 3.4: Harvesting the tubers using developed innovative hand tool

,a

3.2 Determination of Harvesting Force Force measurement was taken using digital force gauge (IMADA) and the bent

type hand tool is used in computer simulation program. The IMADA is hooked at handle as shown in Figure 3.5.

I

D

Bent

type

tool

;

r-l /;

IIVlADA

Figure 3.5: Force determination using IMADA and bent type tool

There are 2 types of force determination:-

1.

Hand hoe test stand.

2.

Bent type hand tool.

29

3.3 Conceptual Design for lnnovative Hand Tool Harvester

This lnnovative hand tool is conceptually designed to replace the old method of manual harvesting of D. hlsprda using hoe or push hoe. lt consists of a designed

bar with a foot press ladder. Figure 3.6 show the conceptual design on three dimensional orientations of the manual harvester using solid modeling software

and the semi-circular rod with four penetration bars at the bottom.

The

penetration bar is designed such that it will penetrate the soil easily while the bottom surface is designed flat so that it will not damage the D. hisprda during manual harvesting process. The hand-held rod was designed with a bent of 45

degrees, enabling the user to pull up the tuber with ease without much body movement. Similar design was fabricated by Mohd Solah et al., (2009) the loose fruit picker with bent hand holder reducing back pain of the worker during palm oil fruits collection.

30

450

1..

R&nt

Figure 3.6: Conceptual design for manual harvester (Hudzari et a|.2011)

3.4 Conceptual Design Using Parametric Software

This parametric CAD software is available at Faculty of Design Arts and Engineering Technology, UniSZA, Gong Badak Campus, Terengganu, Malaysia.

It is necessary to simulate the practicality and workability of the

conceptual

design of hand-held harvester. The concurrent engineering environment is used

which

a

conceptual arena

is

created by any

or all

technologies enabling

collaborative efforts in the building process (Sarah, 2008). The first step is the extraction of the design layout of the machine, second step is then to produce a

31

schematic and wireframe of the model, third step is the modification in a CAD environment, fourth step is the simulation and finally to complete the technical drawing for fabrication purposes (Darius and Azmi, 2003).

3.4.1 SolidWorks Simulation Program SolidWorks Simulation is primarily applicable to mechanical and thermal models.

FEA is useful in predicting a model's response to various influences such as

forces, torques. SolidWorks Simulation is

a

design analysis software fully

integrated in SolidWorks.

3.4.2 Simulation Process on Stress Analysis. Analysis is a process to simulate the design performs in the field. Analysis can help to design better, safer, and cheaper products. lt saves you time and money

by reducing traditional, expensive design cycles. An analytical study represents a

scenario of analysis type, materials, loads and fixtures. solidworks simulation can perform static, frequency, buckling, thermal, drop test, fatigue, optimization,

pressure vessel, nonlinear static, linear and nonlinear dynamic analysis. The results of analysis may slightly vary depending on versions/builds of solidworks

and solidworks simulation. comprehensive analysis tools let you test models digitally for valuable insight early in the design process. static analysis calculates displacements, strains, stresses, and reaction forces. Materials start to fail when

stresses reach a certain limit. The Factor of Safety (F.O.S) Wizard checks the safety of hand tool design.

To simulate the model, SolidWorks Simulation subdivides the model into many small pieces of simple shapes called elements. This process is called meshing. Figure 3.7 shows process on analysis. START

CREATED STUDY

ASSIGN MATERIAL

APPLY FIXTURES

APPLY LOADS

MESH THE MODEL

RUN ANALYSIS

VISUALIZE THE RESULT

END

Figure 3.7: Step to perform analysis in Solidworks Simulation 33

3.5 Material Properties Used in Simulation. 3.5.1 Elastic Modulus An Elastic modulus or modulus of elasticity, is the mathematical description of an object or substance's tendency to be deformed elastically (i.e., non-permanently)

when a force is applied to it. The elastic modulus of an object is defined as the slope of its stress-strain curve in the elastic deformation region (Askeland and Phule, 2006). As such, a stiffer material will have a higher elastic modulus.

{l{,f ,\ :-

slrcss st,l'il iu

(1)

Where lambda (/) is the elastic modulus; slress is the restoring force caused due to the deformation divided by the area to which the force is applied; and sfrarn is

the ratio of the change caused by the stress to the original state of the object. lf stress is measured in Pascal, since strain is a dimensionless quantity, then the units of ,l are Pascal as well (Beer et al., 2009'1.

3.5.2 Poisson's Ratio

Poisson's ratio

is the ratio of transverse contraction strain to

extension strain

in the direction of stretching

longitudinal

force. Tensile deformation is

considered positive and compressive deformation is considered negative.

The definition of Poisson's ratio contains

a

minus

sign so that

normal

materials have a positive ratio (Sokolnikoff, 1983).

34

tlrun"

Strain

t

/

tlong itudinal

2)

is defined in elementary form as the change in length divided by the

original length.

e:

ALIL.

(3)

3.5.3 Shear Modulus

The shear modulus is one of several quantities for measuring the stiffness of materials. All of them arise in the generalized Hooke's law:

i)

Young's modulus describes the material,s response to linear shain (like pulling on the ends of a wire or pufting a weight on top of a column).

ii)

The bulk modulus describes the material,s response to uniform pressure (like the pressure at the bottom of the ocean or a deep swimming pool).

iii) The shear modulus describes the material's response to shear strain (like cutting it with dull scissors).

The shear modulus is concerned with the the deformation of a solid when it experiences

a force parallel to one of its surfaces, while its opposite

face

experiences an opposing force (such as friction). ln the case of an object that,s shaped like a rectangular prism, it will deform into a parallelepiped. Anisotropic

materials such as wood, paper and also essentially all single crystals exhibit differing material response to slress or strain when tested in different directions (rUPAC, 1997).

3.5.4 Mass Density The density of a substance is its mass per unit volume. The symbol most often

used for density is

p (the lower case

Greek letter). Mathematically, density is

defined as mass divided by volume (Glenn,201 1).

l)

I'

4)

Where p is the density, m is the mass, and V is the volume. ln some cases (for instance, in the United States oil and gas industry), density is loosely defined as its weight per unit volume, (Oil Gas glossary, 20'10) although this is scientifically inaccurate

-

this quantity is more properly called specific weight.

3.5.5 Tensile Strength

Tensile Strength is the maximum stress that a material can with stand while being stretched or pulled before failing or breaking. Tensile strength is not the same as compressive strength and the values can be quite different. Tensile strength is

defined as a stress, which is measured as force per unit area. For some nonhomogeneous materials (or for assembled components) it can be reported just as

a force or as a force per unit width. ln the Sl system, the unit is the pascal (Pa) nevutons (Black and kosher, 2003). lt is often difficult to precisely define yielding

due to the wide variety of stress-strain curves exhibited by real materials. ln addition, there are several possible ways to define yielding (Dieter, 1986).

36

3.5.6 Thermal Expansion

Thermal expansion is the tendency of matter to change in volume in response to a change in temperature (Paul and Gene,2008). When a substance is heated, its

particles begin moving more and thus usually maintain

a

greater average

separation. The degree of expansion divided by the change in temperature is called the material's coefficient of thermal expansion and generally varies with temperatu re.

3.5.7 Thermal Conductivity

Thermal conductivity (often denoted k, A, or

r) is the property of a material to

conduct heat, k, is an intensive property that indicates its ability to conduct heat.

It is evaluated primarily in terms of Fourier's Law for conduction. Heat transfer occurs at a higher rate across materials of high thermal conductivity than across materials of low thermal conductivity. Correspondingly materials of high thermal

conductivity are widely used

in heat sink

applications and materials

of

low

thermal conductivity are used as thermal insulation. Thermal conductivity of materials is temperature dependent. Thermal is often measured with laser flash

analysis. Alternative measurements are also established. Mixtures may have variable thermal conductivities due to composition (Anthony ef

al,

1989).

37

3.5.8 Specific Heat

The specific heat is the amount of heat per unit mass required to raise the temperature

by one degree Celsius. The relationship between heat

and

temperature change is usually expressed in the form shown below where c is the specific heat. The retationship does not apply if a phase change is encountered, because the heat added or removed during a phase change does not change the temperature. O = cmAT

(5)

Where Q, is the heat added, c is specific heat, m is mass and AT is change in temperature. The specific heat of water is 1 calorie/gram 'C = 4. 186 jouleigram "C which is higher than any other common substance. As a result, water plays a

very important role in temperature regulation. The specific heat per gram for water is much higher than that for a metal, as described in the water-metal example. For most purposes, it is more meaningful to compare the molar specific heats of substances.

38

The bent type hand tool harvester was chosen to be used in Solidworks Simulation on showns in Figure 3.8. Firstly use the model of bent type hand tool in simulation as shown in figure 3.8.

Figure 3.8: Bent type hand tool

To start the simulation from SolidWorks, from main menu bar select "Tools" and choose "Simulationxpress Analysis" as shown in Figure 3.9. Figure 3.10 and

3.

1

'1

shows the dialog box and faces selection containing the selected faces for fixing purposed of the hand tool.

39

File Edit vie,s

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{B ChdrlEr

Dir$xit:fl

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sensors

3..] Annotations

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..

simulationxprers.,,

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