Chapter 3 - Hydraulic
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Transcript of Chapter 3 - Hydraulic
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Chapter 3
Research Design and Methodology
3.0 Research Methodology
This chapter presents the principles and methodologies involved by the proponents in
order to realize a research plan and creation of the proposed design improvement for the
hydraulic press for the Jatropha oil extraction. Furthermore, the step-by-step procedure used in
the design will be discussed.
3.1 Methods of Research
The proponent used experimental method in combination with data gathering technique.
Data gathering technique included library research, survey of people involved in the subject
matter and internet research. Data gathering was used to determine the proper design of the press
and to ensure the reliability of the prototype to test the efficiency and effectiveness of the
proposed hydraulic press. A set of experiments was performed in an accurate and precise way.
3.2 Development of the System
This part discussed the methodologies and principles used by the proponents in designing
the prototype, in accordance to the data gathered.
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Design Consideration
The procedure for the design of the hydraulic press started with assessing the existing
design used in DOST. Through observation of its operation, we realized some constraints in the
design as well as its processing time. We have also gained the fact that the proposed 6% oil
content by weight of the Jatropha seed was not fully recovered from the pressing process. Our
experience in DOST Jatropha facility gave us our first data on what to improve on the hydraulic
press. Presented below is the data we acquired from the three trials we observed when Engr.
Mallinllin showed us a demo using their hydraulic press.
Table 3.1 Data of DOST hydraulic press Jatropha oil extraction
TRIAL Mass of seed Operation Time Volume of oil
recovered
% oil content
recovered
1 200g 29mins 15mL 38.25%
2 200g 25mins 17mL 43.35%
3 200g 22mins 18mL 45.9%
To compute for % oil content per 250g of seed we used the following equations:
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Trial 1
Trial 2
Trial 3
The first trial showed us a result of 38.25% oil recovered from pressing the 250g Jatropha
seed. Also, 25 minutes was consumed during its operation. The second trial proved to be more
efficient than the first trial since it gave us a higher yield of 43.35% and the same weight but its
operation time took longer than the previous trial. The last trial showed us a remarkable
improvement in oil recovery since the percentage of oil recovered is 45.9% having the same
weight but in a lesser operating time of 22 minutes. Although there is an increasing percentage
of oil recovery it is still not enough to prove the theoretical oil content of the Jatropha seed.
These data just shows that the expected 6% oil content by weight recovered is not accomplished
in the demonstration. Thus we take note of the results and information we acquired, as a basis on
improving the design for oil extraction process using a manual hydraulic press.
The proceeding pictures shown are the actual design provided by the DOST for Jatropha
oil extraction.
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Figure 3.1: Photos taken in
DOST Jatropha Research facility
(top-left: Engr. Mallinllin
demonstrating a demo operation
of the Hydraulic press; top-right:
the pressing tool and the
pressing chamber: bottom-left:
Hydraulic set-up; bottom-right:
proponent holding the pressing
chamber after the pressing)
The hydraulic press that was used in DOST provided us oil yield but based on our
observation the procedure when the pressing was conducted was stressful. Certain problems
arises as we were conducting the demo such as difficulty in the return of the spring, difficulty in
adjusting the stroke and aligning the pressing tool, and a stressful work since sometimes it takes
three pressing procedure is needed in order to release seed oil. All of these observations came to
our mind that we need to design a better hydraulic press.
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3.3 Methods of Developing the System
This section provided the step-by-step procedure of the proponents in designing the
proposed hydraulic press. This section included explanation how a hydraulic press works, heat
band function, design parameters and material selection, the construction of the actual prototype,
and the final design specifications.
3.3.1 Principles Used in the Design
The basic operation used in the design doesnt go far from what we have witnessed from
the Hydraulic press in DOST. But in order to realize our objective, the design that the proponents
created, provided a much easier operation, more efficient in terms of time and oil yield, durable
and cheap to fabricate and maintain for a small scale operation.
3.3.2 Basic principle of the Hydraulic press used for Jatropha oil extraction
The basic principle that encompasses the Jatropha oil extraction using hydraulic press
includes simple understanding of physics. The seed was filled in a filter cloth or a sack and then
is put into a pressing chamber, made from a perforated cylinder, which was then pressed using
the hydraulic jack with the aid of a pressing tool. In order to prevent misalignment a guide post
was attached to the hydraulic jack plate. The compressive force induced by the hydraulic jack
created pressure on the seed which at a point of pressure the oil from the seed was released.
Extension springs was used to create a returning force to pull back the hydraulic jack piston
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when the pressure relief valve is released. The compressed cake, however, will be pulled out
manually by pushing the sack or filter cloth with a hammer tool.
3.3.3 Heat Band function
The heat band is a type of heating element that provides heat to another surface. Heat
band is mostly used in cylindrical shapes such as pipes, tubes and cylinder shaped-metals that
needed heat addition. According to the data gathered from P.Beerens, a cooker is a helpful
addition to increase oil yield. The heat band will be controlled using a thermo-controller in order
to obtain the right temperature needed.
3.3.4 Design Methodology
This section shows how the proponents design the proposed hydraulic press using
considerations on available raw materials and calculations to verify the acceptability of the
design parameters that we will use.
1. Consideration on amount of seed per batch.
The proponents started the design by considering the desired mass of jatropha
seeds to be pressed. We decided that 1/2 kg of seeds must be the mass per batch and
to increase the oil extraction we grounded the seed using a blender.
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The proponents computed the pressed volume that a mass of 1/2kg grounded
Jatropha seeds can have. Using the data in chapter 2, the solid density of jatropha
seeds is 1020 kg/m3. Using formula V =
we can get:
V =
= 4.902 x 10-4
m3
2. Design consideration for Hydraulic Jack
According to P.Beerens research on Jatropha
oil extraction, he stated that the design pressure
required for pressing jatropha seed to expel oil was
between 3MPa to 40Mpa. By computing the force
capacity, we computed how much pressure the
hydraulic jack can produce. Using the equation of
pressure P = we got the pressure that can becreated. For the calcuated area, we used the
formula provided by M.Modh from Ganpat
University, India, where in his paper he designed a small press chamber for an oil
expeller which is A = D h and for the force, we used
F = (Capacity x x 9.81 m/s2
)
F = (15 ton x
x 9.81 m/s2)F = 146 150 N
Fig. 3.2: Hydraulic press
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3. Design consideration for Pressing Chamber
After the hydraulic jack capacity was chosen, the proponents designed the
dimension for the chamber. To determine the height of the chamber, we measured the
actual height measured by putting the grounded seed at the tube. There are only three
size of pipe available during our canvassing these are 138mm, 248mm, and 158mm.
The proponents decided to choose the 158mm diameter mild steel pipe. After filling
up the pipe the actual height of kg grounded seed measured 145mm, so for the
height of the chamber we concluded to make it to 160mm for clearances and to
prevent spillage. From the computed pressed volume, we determined the height
produced during the pressing of the grounded seeds.
Since the cylinder has a 158mm diameter, using the equation h =
we gotthe pressed height established by 1/2 kg of seed.
D
H c
h
Fig. 3.3: Pressing Chamber
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h = = 25.09mm
In order to check for the validity of the material that will be used, we calculated
the pressure that can be created using the 15 ton hydraulic jack.
P =
= 11.82 N/mm2 or MPa
The calculated pressure for 15 tons was 11.82 MPa and the proponents decided to
use a mild steel pipe that is readily available for purchase. The mild steel pipe had an
ultimate strength 841 MPa and according to R.W.I Brachman and R.P Krushelnitzky,
the factor of safet that can be used on perforated pipes is 3.0. Perforation of the
chamber was required in order to provide holes where the seed can expel oil during
the pressing process even though from the experience we got in DOST most of the oil
was released below the chamber.
For the calculated allowable stress, we used the equation a = .
a =
= 280.33 MPa
For the calculation of the stress inside the chamber, we used the equation S s =
where the pressure inside the chamber was 11.82 MPa and the locally
available size of the inside diameter and the outside diameter of the pipe were 158mm
and 170mm respectively.
Ps = 11.82 MPa = 11.82 N/mm2
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Ss = = 86.79 N/mm2 or MPa
Since 86.79MPa < 280.33MPa the selected pipe dimension was acceptable.
4. Design consideration for Press Tool
The design of the press tool depended on the inner diameter of the press chamber
which was 158mm. We considered an allowance of 2mm on the creation of the piston
head to create a smooth stroke when pressing. The material that was used for the
piston head was a steel plate having 10mm thickness. The length of the press tool
shaft considered the stroke needed for the height of a 0.5kg grounded Jatropha seed.
L= 160mm25.32mm = 134.68mm
The press tool was decided to be adjustable so in order to do so, we decided to use
a two 32mm threaded stainless steel shaft together with a 76.2mm mild steel shaft
with threads reaching 50mm deep at both ends with countering direction. The upper
thread was clockwise oriented and the lower end was counter-clockwise oriented.
Using the computed length required for the press body, we decided to cut the
threaded rods at 70mm and the adjuster shaft at 120mm giving an initial length of
140mm and can be extended for another 100mm.
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`
For the computation of the acceptability of the material used, we used the
equation P =and compared it with its allowable stress using allowable =
The same formula from determining the stress of a material using surface area
which was shown in M.Modh formula of stress in mild steel is used to determine the
stress involved in these materials. Where: A =; D= diameter of material; L=length of material; Pss = pressure produced by the press tool shaft; Pms=pressure
Ls.s
Lo.s
Lm.s
Ds.s
Do.s
Dm.s
Fig. 3.4: Press Tool
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produced by the press tool mild steelshaft; Pcp=pressure induced to the circular plate
which is the press tool head and the press tool base; for the factor of safety it is based
on B.K Sarkars book, Strength of materials, Stress and Strains for Mild steels
which is between 2 and 6. In this context we will use 6 to maximize the safety of the
design since high pressure is involved in this process.
;
;
;
Factor of safety = 6
Pss =
= 20.91 N/mm2 or MPa
= = 91.66 MPa
Pms =
= 20.91 N/mm
2or MPa
= = 140.17 MPa
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Pth =
= 30.03 N/mm2 or MPa
=
= 41.67 MPa
For threaded stainless steel we had 20.91MPa < 91.66 MPa;
For mild steel, 20.91 MPa < 140.17 MPa;
And for press tool head and base, 30.03MPa < 41.67MPa.
Since the stainless steel threaded rod, mild steel adjuster and the press head
stresses were below their allowable stresses we conclude that the materials are
acceptable.
By joining all the length of the materials to be used, where the body of the press
tool shaft was 130mm, the press head of 60mm and 10mm for the press base, it would
sum up to:
Lpress tool = 130mm + 60mm + 10mm = 200mm
Therefore the total length of the actual press tool is 200mm.
5. Design consideration for Spring and Spring holder
To be able to have a fast return of jack piston when the pressure value is relieved,
a spring was appointed by the proponents to force return the jack piston into the battle
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frame. For determining if the locally available spring was acceptable, we used the
equation Fs = kx. If the returning force of the spring is greater than the force of the
jack then it is considered acceptable. Since the motion of the spring was longitudinal,
we used:
k =
where E = elastic modulus = 200 GPa = 200 000 N/mm2
A = circular area = (D2)
L = free length = 240mm
D = 5mm
s= Ds
Lf
Fig. 3.5: Tensile Spring
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k = = 16 362.46N/mm
Fs = Kx
According to spring data that we have gathered from the spring calculator
program of www.planetspring.com and the www.centuryspring.com spring data table the
maximum elongation of the spring to be used was 170mm.
x = elongation = 170mm
Fs = 16 362.46N/mm x 170mm = 2 781 618.2 NAnd FJ = = 147 150 N
Since Fs > FJ we therefore concluded that the spring was accepted
For the spring holder, a high threaded rod was welded, having a diameter of 12mm
and joined to a steel nut having a hole of 7 mm just right to fit the wire diameter of
the spring which was 5mm. Four holes at the jack plate and another four at the top
plate were used to fit in the spring holder. Another nut was torqued to the other end to
serve as its stopper and have the ability to adjust whenever the spring will be
changed. For computing of the spring holder strength, we used the formula of the
weld strength formula.
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Pw=0.5Ue
Where Pw= weld strength; Ue= minimum tensile strength of the electrode.
According to www.bssa.org.uk Ue of stainless steel electrode is 520MPa. Substituting
the variables to the equation:
Pw=0.5(520MPa)
Pw=260MPa
For determining the load capacity of the spring holder, we used the formula from
www.roymech.co.uk for weld strength.
Where
hw
bw
Fig. 3.6: Spring holder
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We used b= 12mm and h= 15mm
Substituting the variable to the equation we got
=46 800N
Since FJ = 147 150 N and there were four spring holders at each corner, the force was
distributed evenly at the spring holders.
For the computation of the force induced at each spring holder by the force of the 16-
ton jack, we used the formula:
Fig. 3.7: Spring Set-up
1
4
3
2
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Since we can say the design of spring holder was sufficient to hold the spring.
6. Design consideration for Press Frame
The press frame design was composed of four rigid pillars and three steel plates.
The pillars also acted as guide posts for the vertical movement of the jack plate. The
steel plate that was considered as the jack plate therefore the jack plate was placed in
the middle of the base and top plate.
For the four pillars, a stainless steel shafts that were locally available were used.
The available pillars size that were used were 50mm in diameter, the plates those
were 3pcs were 300mm x 300m x 10mm and one piece plate was 400mm x 400mm x
19mm. For the determination of the length of the pillars, the proponents considered
first the height of the pressing chamber, the hydraulic jack, pressing tool, the
hydraulic jack extender and thickness of the plates. For the calculation the length of
cut for the shafts, we added length of the said considerations.
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Total length = height of hydraulic jack spring + height of press chamber + max height
of extender + press tool height
Spring length with spring holder = 240mm
Press chamber = 160mm
Extender = 100mm
Press tool = 200mmm
Total length = 240 +160 + 100 + 200 = 700mm
We used 850 mm to accommodate the thread at both ends of the shaft. Each
thread of the shaft had a length of 70 mm and a pitch of 6 threads per inch. The major
400mm x 400mm x 19mm
300mm x 300mm x 10mm
300mm x 300mm x 10mm
300mm x 300mm x 10mm
700mm
Fig. 3.8: Press Frame Set-up
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diameter of the shaft thread was measured 32mm and for the calculation for the load
capacity, we used the ASME equation for threads. Using the following equations:
Note: since the ASME equation was designed for English units we converted all S.I
units to English units.
FL =
Where A = * +Dp = Dm -
H
H = tan 60 (P/2)
P = 1/5
Dm = 1 inch
P
Dm
Fig. 3.9: Shaft Thread
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H = tan 60 (/2) =
Dp = 1.25 - = 1.12 in
Dp = 1.12 in
A = [ ]
= 0.8742 in
2
Convert 0.8742 in2
to S.I unit
A =0.8742 in2x = 564.03 mm2
The factor of safety to be used according to ASME equation reference is 1.25 and tensile
strength of stainless steel was 550N/mm2.
FL = ( ) = 248 173.2 N
Since Fjack= 147 150 N
and 248 173.2 N > 147 150 N
Since the thread load capacity was greater than the force produced by the jack, we therefore
conclude that it was allowable to take the 15 ton hydraulic jack force. Also, according to our
research the nut that can be used for the thread must have a higher tensile strength than the
material of the thread. We used a high tensile nut having a tensile strength of 930MPa which was
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acceptable since it had an allowed tensile stress was higher than the tensile strength of stainless
steel which was 550MPa.
7. Design consideration for Press Frame Stand
The stand was simply discussed in this section since its only purpose was to
elevate and hold in place the press frame. Using angle bars with dimension 1 x 3/16
for the construction. The press frame measures a height of 610mm or roughly 2 feet
from top plate to base plate. We used the stand to elevate the working space where
the operator has easy access on the operation of pressing. The elevated height that the
proponents used for the stand was 545mm to give a total height of press of 1200mm
or 4ft. The stand was forced as an A-frame to prevent bending, the preferred angular
presentation from the ground is 75 Therefore, using a free body diagram, wecomputed the length angle bar to be cut.
15
R 545mm R = = 564.23mm
75
Figure 3.10 Free Body Diagram for Stand Frame Leg
75
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15
362.35mm 300mm x = = 73.02mm
Length of joint bar a = 300mm + 2(73.02mm) = 446.04mm
Figure 3.11 Free Body Diagram for Stand Frame Braces
545mm
75
Fig. 3.12: Stand Frame
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8. Design consideration for Pre-heater
The proponents decided to buy a heat band that would have a temperature control
range from 0-100oC since we need to heat the pressure chamber at 50
oC, 60
oC, 70
oC.
The diameter of the heat band must also fit the diameter of the chamber therefore the
diameter of the heat band is 170mm and the length must not cover the holes of the
pressing chamber, so we concluded 76mm is the length. The available temperature
controller range from 0-300oC and was analogue. The available heat band had the
following parameters 1200 watts and 220 volts. No further computation has been
made since we are only focusing on reaching the desired temperature range and the
time for pre-heating depends on the temperature controller performance.
170mm
76mm
Fig. 3.13: Heat Band
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9. Design consideration for Electric Control Box
a. In the event of electrical malfunction of the band heater controller, we decided to put
up a control box in order to have a safety switch in turning on and off of the thermo-
controller. Shown below was the circuit diagram that the proponents have created.
Figure 3.14: Control Box Diagram for Pre-heater System
In the diagram above, there were five component of the pre-heater circuit. First,
the source of the electricity was from the electric plug where it was inserted to normal
household electric socket holding a 220V capacity. The wire then goes to the power
switch terminal where we considered the three phase switch since it has a safer control on
power than household switches. The two wire from the plug was connected to both side
end of the power switch terminal. A wire connected from the left end of the power switch
terminal that was then connected to the temperature controller terminal P. At terminal 2
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from the controller a wire is connected to a 220V pilot lamp and the other end of it was
then connected to the one of the heat band terminal. The other terminal of the heat band
was then wired to connect at the right side of the power switch terminal. The operation
goes when the plug was inserted to the power source then by pressing ON of the power
switch the electric current will flow into the heat band and the temperature controller.
The temperature was based on the temperature rating adjusted using the temperature
controller. Once the temperature rating was turned on, the pilot lamp will be lighten up.
When the desired temperature was accomplished, the temperature controller cut off the
current flow and the pilot lamp turned off. To turn off the circuit, just press the OFF
switch at the power switch in cases of circuit malfunction of the temperature controller.
The box was dimensioned depending on the sizes of the electrical parts whereas
the suggested dimension is 300mm x 140mm x 65 mm. and holes were drilled according
the alignment of the parts
.
Fig. 3.15: Control Box
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Figure 3.16: Control Box Design
10.Design consideration for Oil Canal.
In order to prevent oil spillage, the proponents designed a stainless steel canal
surrounding the pressing chamber. Since the flow rate of the oil was slow, we
designed the canal wall to be 45mm tall and a diameter of 240mm and then centered
at the mid-point of the pressing chamber. A hole was also drilled to the base plate
inside the canal wall having a diameter of 25.4mm, a nipple steel tube and coupling
tube was attached to the base plate as the exit tube. Note that the hole with the nipple
tube is the outlet for oil where a bucket will catch the drops of oil. An oil brush was
also necessary for us to be able to sweep all oil content extracted during the process.
O
OF
Thermo-controller
Pilot Lam
IN OUT
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45mm
25.4mm
Base Plate
Oil Canal Wall
Exit Tube
Fig. 3.17: Oil Canal and Exit tube Set-up
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3.5 Details of the Prototype
During the design phase of the proposed hydraulic press, the proponents made a
visualization of the prototype by means of using AUTOCAD 2012 Software Application. The
model created in the AUTOCAD provided as a basis for the fabrication of the parts and assembly
of the prototype.
Figure 3.18: Front View CAD Presentation of Hydraulic Press for Jatropha Seed Oil Extraction
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Figure 3.19: Isometric View CAD Presentation of Hydraulic Press for Jatropha Seed Oil
Extraction
Spring Holder
Top Plate
Press Frame Pillar
Spring
Hydraulic Jack
Hydraulic Jack Plate
Press Chamber
Pre-heater
Oil Canal
Base Plate
Stand Frame
Control Box
Oil Exit Tube
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3.6 Design Specification
Hydraulic oil press for jathropa oil extraction
Size = 480mm x 460mm x 1200mm
Hydraulic Jack = 15 ton
Pressing Chamber = , Pillar size = Base plate = Jack plate = Top plate 1 = Top plate 2 =
High Tensile Spring = outside diameter-35 mm, wire diameter5 mm,
Free Length = 200 mm
32mm Nut = 8 pcs
High Tensile spring holder = , 8 pcsHeat band = , 1200 watts , 220VControl Box = 300mm x 140mm x 65 mm
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3.7 Construction Procedure
This section explained how the prototype was constructed in the EMEM Machine Shop
in Balibago, Sta.Rosa City. Using a lathe machine, hacksaw, drilling machine, acetylene welding
machine and an arc welding machine, they succeeded in the construction of the proposed
hydraulic press.
1. First we measured the length of the stroke of the jack piston. After determining the length
required for the press they cut the stainless steel shaft using, a grinder, into four 850mm
in length,
2. Using a lathe machine the machine shop operator was instructed to create threads on both
sides of the stainless steel shafts.
3. When threading was completed, the three 300mm x 300mm steel top plate was drilled in
order to provide a hole fitting the diameter of the thread along with the single plate with
400mm x 400mm x 19mm dimensions. However, we instructed the operator to increase
the hole for the jack plate to provide ease in its movement where the pillars acts also as
its guide post.
4. After drilling holes for the guide post, we instructed to drill 6mm holes for the spring
holder the spring holder is constructed using a threaded rod and welding a rigid nut to it.
Eight spring holders were created along with the four holes on the jack stand plate and
four holes on the top plate.
5. For the construction of the piston or the pressing tool, we instructed the machine shop
operator to cut 70 mm thread steel rod and another 70 mm stainless steel shaft, both
having a diameter of 32mm. Later, we instructed to thread the stainless steel shaft
opposite to the thread of the thread rod with 65mm thread depth. A mild steel shaft
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having a diameter of 76mm and a length of 120mm was holed using a drill machine with
a diameter of 30mm. It was then thread from both ends with opposite direction to each
thread, the length of thread at each end is 50mm. At the center, four holes with 40mm
diameter was drilled which later will act as the hole for the adjuster rod. Two circular
plates is cut from the 10mm steel plate having a diameter of 160mm. One of the plate is
welded to the stainless steel plate and the other at the threaded rod. The upper circular
plate is holed with 10mm at four sides, later this would act as the hole for the bolts that
will attach it to the jack plate. An additional holder was also welded to the press head for
easier adjusting of the press body.
6. Next was the construction of the pressing chamber or the perforated cylinder. Using the
acquired 170mm steel pipe, we advised the operator to cut a length of 160mm and drill
holes of 5mm in diameter with 20mm x 40mm clearance to hole. The total holes drilled
holes were 80.
7. Next was the base plate, a stainless steel plate with thickness of 3mm was welded with
the plate and four holes were drilled on it having the same size as of the top plate.
8. Another hole with size 28mm was drilled to give space for the drain pipe. The drain pipe
was composed of a nipple and a coupling and is welded to the 28mm hole.
9. When the stainless steel plate was welded, the press chamber was aligned to the center
and a guide plate was welded along the half circle at the bottom of press chamber. This
prevents the wiggling of the cylinder.
10.Next is the canal wall having a circumference of 625mm and a height of 25mm which is
welded to the base plate to form a circle large enough to prevent the oil flow to scatter out
from the plate.
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11.A hole is 30mm diameter was drilled to the base plate 50.8mm from the cylinder tube. On
the hole, the 25.4mm nipple tube and 25.4mm coupling tube, made in Thailand, were
welded to it. This will act as the oil hole where it flows down to the catch basin.
12.Locally available parts were bought in the supply stores in order to complete the
prototype such as eight 31.75mm high tensile nuts for the pillar thread and four jst13
springs used for truck brakes assembly.
13.The last part that was constructed was the stand. Using the shape of an a frame, we
instructed the machinist to cut four 50mm x 5mm angle bar with a length of 363mm and
four 50mm x 10mm x 393.78mm to be welded as the stand of the press.
3.8 Material Selection
Our idea in material selection is to be eco-friendly and economically smart. The
proponents selected all the materials from the various sources but we first considered the surplus
shops and junk shops to look for available materials such as steel plates, stainless steel shafts,
steel tube and angle bars, this way we can be able to save a lot in buying materials unlike in
buying on industrial steel supplies where there are no available small cuts to be obtained and
rather buying a full length of each material where it cost a lot more. And If ever we bought brand
new materials, most of the unused portions of the materials will be junked. So to prevent over
spending, we first approached the CRC surplus shop and Balibago, Sta. Rosa City junkshops.
The bolts, nuts and springs were brought brand new since most of the steel materials on
the junkshops and surplus shops were rusted. We considered getting all the bolts, nuts and
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springs from the screws and bolts store in Platero, Binan City along old national road hiway and
in Parian, Calamba along the old national road hiway.
The band heater was bought in Tondo, Manila from the company Heatwave which we
found in sulit.com.ph. The other electrical parts were bought in Ohms electrical shop in Platero,
Binan City.
Since it came from a second hand and junkshops, we carefully selected all usable and
presentable parts available.
3.9 Actual Prototype
TOP PLATE
HYDRAULIC JACK
PRESS TOOL
Pre-Heater
PRESSURE CHAMBER
CONTROL BOX
STAND FRAME
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3.10 Material Costs
Press Frame
Table 3.3: Press Frame Cost
Item Description Cost,Php
Steel Pipe 406
Stainless Steel shaft , 3 meters 2250
Shaft Nut , 8 pcs 475
Spring , 4 pcs 1320
Steel Plates , 5 pcs 1370
Threaded Rod , 4 pcs 96
Rod Nut, 4 pcs 22
Spring Nut Holder, 8 pcs 30
Angle Bar 450
Machine Shop Labor 4000
Miscellaneous 1500
Total Php 11,919
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Pre-heater
Table 3.3 Cooker and Controller Cost
Item Description Cost,Php
Heat Band 900
Temperature Controller 800
Power Switch 125
Royal Wire , 3ft 270
Plug , 10A 40
Control Box 250
Machine Shop Labor 500
Miscellaneous 150
Total Php 3035
Hydraulic Jack, 10 tons= Php 900
Total Cost = 11, 919 + 3035 + 900 = 15854
Jathropa Seed = 30 pesos per kilo
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3.11 Assembly Procedure
Note: Always make sure to wear protective gloves in order to prevent cuts and bruise during
assembly of the press.
1. Insert the pillars into their designated holes in the base plate.
2. Fit in the nut at the bottom thread of the pillar; adjust the nut until it has a righttightness on the base plate.
3. Insert the pressing chamber in the middle of the base plate.
4. Insert the jack plate unto the pillars. Then install the 4 spring holder unto the holes
located near the guide holes.
5. Attach the top plates and tighten the remaining four nut. Also install the springholders into the top plate.
6. Install the springs to the spring holder adjust the nut until the jack plate is levelled.
7. Attach the pressing tool below the jack plate. Insert the flat lead screws to hold the press
tool in the place.
8. Insert the heat band to the pressing chamber. Make sure that the mercury tube is faced in
front of the control box. Then attached the two wires at the electric terminal of the heat
band.
3.12 Press Operation
1. Always wear protective work wear and protective gloves before operation.
2. Check first that the thermo-controller is turned off or to zero. And check that jack piston
is not elevated. Turn on the power switch starting position or non-lifting position.
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3. Insert the ground seed in the pressing chamber.
4. Turn the controller to desired temperature and pre-heat for until the indicator lamp turns
off. Turn off the power switch.
5. Tighten the jack valve and adjust the press tool. Make sure it is aligned flat to the crushed
seeds. Start pumping the lever at the hydraulic jack.
6. Continue pumping until the oil is released from the pressure chamber.
7. Using an oil brush sweep the oil into the outlet hole. Continue sweeping until there is still
oil left from the base plate.
8. After oil is recovered rotate the jack valve slowly from turn counter-clockwise up to 1
turn and wait until the piston is lifted from the pressure chamber. Never attempt to release
the valve quickly since it is dangerous to do so and it may affect the oil seal in the bottle
jack.
9. Remember to check the volume of oil recovered in the basin. Make sure to put it into
another container when 75% full.
10.Remove the thermo-tube from the heat band and carefully remove the pressing chamber
from the press frame.
11.Using a cake bucket and a rigid shaft hammer, pound the cake for removal.
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3.13 Maintenance
The hydraulic jack should be well maintained so that it will function properly and
avoid/prevent efficiency loss.
Most of the parts of our prototype were made of metal which are highly corrosive.
Corrosion monitoring gives vital role for maintenance. Scheduled inspections for corrosion
damage feature prominently to facilitate these pre-emptive actions. The aim is to minimize or
eliminate unnecessary maintenance and inspection activities and to focus maintenance efforts
when and where they are most needed. Moist and wet areas can start to rust the press so it should
be kept away from these areas.
The main part of our prototype is the hydraulic jack. The hydraulic jack is the prime
mover that presses the seeds to produce oil. The exterior of the hydraulic must be always kept
clean because keeping it clean not only removes debris but can identify if any oil comes out from
the cylinder. The ram should be always kept inside the body when not in use because the
unprotected surface can be prone to rust and corrosion. If rust begin to form, gently work the
surface with a piece of emery cloth.
When filling oil any hydraulic jacks, use only approved hydraulic jack oil because
inappropriate oil will cause malfunctioning of the hydraulic jack. The screw plugs, located on the
square metal base of the jack, is the oil fill plug. Never use the brake fluid in place of approved
hydraulic oil because it contains alcohol that will quickly ruin the internal seals.
Most damage occurs by exerting force on an item too heavy for the hydraulic jack s rated
capacity. Exceeding the force capacity can place excessive pressure on these materials, not only
will damage occur in the seals and valves but injury may result to the operator from the jack s
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failure. Springs should also be checked on its proper deflection/stress. Too much load and
elongation of the spring can cause damage the spring itself and may also cause injury and harm
the operator.
The cloth use as bag for the jatropha seeds should always be kept clean so that oil will
come out freely. If the cloth was already worn-out or damaged, have a new one because press
cake will be mixed to the oil.