i

DESIGN AND DEVELOPEMENT OF PNEUMATIC MINI DISC

OIL PALM FRUIT STALK CUTTER

MUHAMMAD AFANDI BIN DARWIS

B040810284

A report submitted in partial fulfilment of the requirements

of the award of the degree of

Bachelor of Mechanical Engineering (Design and Innovation)

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka (UTeM)

JUNE 2012

ii

CANDIDATE’S DECLARATION

“I hereby declare that the work in this thesis/project is my own except for quotations

and summaries which have been duly acknowledged. The thesis/project has not been

accepted for any degree and is not concurrently submitted in candidate of any other

degree.”

Signature : .....................................................

Name : MUHAMMAD AFANDI BIN DARWIS

ID Number : B040810284

Date : 22 JUNE 2012

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“To family and friends”

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ACKNOWLEDGEMENTS

Apart from the efforts of myself, the success of Pneumatic Mini Disc Oil

Palm Cutter depends largely on the encouragement and guidelines of many others. I

would like to take this opportunity to express my humble gratitude to the people who

have been instrumental in the successful completion of this project.

I would like to show my greatest appreciation to Prof. Madya Dr Ir Abdul

Talib bin Din. I can't say thank you enough for his tremendous support and help. I

feel motivated and encouraged every time I attend his meeting. Without his

encouragement and guidance this project would not have materialized.

The guidance and support received from all the members who contributed

and who are contributing to this project, was vital for the success of the project. I am

grateful for their constant support and help.

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ABSTRAK

Kekurangan tenaga buruh dalam industri sawit telah mencetuskan

kebimbangan banyak pihak terutamanya dalam memastikan dapatan keuntungan

melalui pengimbangan produktiviti dan kos pengeluaran. Kaedah tradisional dalam

penuaian buah tandan segar yang menggunakan sabit mengambil masa yang lama

dan menjejaskan kecekapan pengeluaran. Laporan ini adalah kolaborasi daripada

beberapa bab yang berkisar tentang semua aspek penting dalam merekabentuk alat

pemotong pneumatik. Bab pertama adalah merujuk kepada bahagian pengenalan

yang meliputi penyataan masalah, objektif dan skop permasalahan. Bab kedua

laporan ini memaparkan tentang teori-teori dan dapatan daripada penyelidikan

terdahulu berkenaan alat pemotong tandan segar. Ciri-ciri fizikal pokok kelapa sawit

dinyatakan dengan jelas sebagai garis panduan untuk memastikan produk akhir dapat

digunakan dengan berkesan. Bahagian seterusnya adalah berkaitan dengan teknik

atau metodologi yang terdapat dalam penyelidikan. Dapatan juga telah dinyatakan

dalam selingan supaya pemilihan data yang sesuai boleh dibuat. Satu alat penuaian

baru, yang direka khas untuk menuai buah tandan segar, akan direka dan

dibangunkan dengan menggunakan mekanisme pneumatik. Produk ini adalah

diharapkan meningkatkan lagi produktiviti dalam bidang penuaian.

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ABSTRACT

Shortage of labour recently has forced all parties involved in the oil palm

industry to find ways and means to at least maintain the profit through balancing the

productivity and the production cost. The traditional sickle method of harvesting oil

palm fresh fruit bunch takes a lot of time and reduces production efficiency. This

report writing contains several chapters that will cover all important aspects related

in designing a pneumatic mini disc cutter. The first chapter is an introduction to the

study which includes the problem statement, objectives and scope of the relevant

discipline of study and will be referred to throughout this research. The second

chapter is a description of the theory and the results of previous studies ever

conducted in relation to the study of fresh fruit bunch cutting tools. The physical

quantity of the oil palm itself has also been clearly explained to ensure the end

product can be utilize efficiently in harvesting process. The next section is related to

the actual composing technique or perhaps methodology found in the research. In

this section, some with the methods used are described in detail. The finding has also

been stated in the process so that appropriate data selection can be made. A new

harvesting tool, specifically designed for oil palm trees, is about to be designed and

developed, by means of using pneumatic system, to increase productivity in the field

harvesting.

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TABLE OF CONTENTS

CANDIDATE’S DECLARATION II

ABSTRAK V

ABSTRACT VI

TABLE OF CONTENTS VII

LIST OF FIGURES XI

LIST OF TABLES XIV

LIST OF SYMBOLS XV

CHAPTER 1 1

INTRODUCTION 1

1.0 INTRODUCTION 1

1.1 BACKGROUND 2

1.2 PROBLEM STATEMENTS 4

1.3 OBJECTIVES 5

1.4 SCOPES 6

CHAPTER 2 7

LITERATURE REVIEW 7

2.0 INTRODUCTION 7

2.1 BACKGROUND 8 2.1.1 Palm Oil Industry in Malaysia 8 2.1.2 Oil Palm Mechanization 10

2.2 INTRODUCTION TO THE OIL PALM 12 2.2.1 Historical Background 12

2.3 CHARACTERISTICS OF OIL PALM 13 2.3.1 Canopy 14

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2.3.2 Fruit and Bunches 15 2.3.3 Stem 16 2.3.4 Root System 17

2.4 HARVESTING 19 2.4.1 The Technology 19

CHAPTER 3 21

METHODOLOGY 21

3.0 INTRODUCTION 21

3.1 EXPANSION OF PROBLEM STATEMENT 22

3.2 FLOWCHART 24 3.3.1 Flow chart 25

3.4 PROCESS FLOW EXPLANATIONS 26 3.4.1 Identify problem statement 26 3.4.2 Literature review 26 3.4.3 Idea development 28 3.4.4 Concept Generation 29

3.5 DATA COLLECTION 29 3.5.1 Product Comparison 30 3.5.2 Study on Previous Research 30 3.5.3 Survey 31

3.6 HOUSE OF QUALITY 31 3.6.1 Voice of Customers 33 3.6.2 Technical Requirement 33 3.6.3 Planning Matrix 34 3.6.4 Interrelation Matrix 34 3.6.5 Technical Correlation Matrix 35

3.7 PRODUCTION DESIGN SPECIFICATION (PDS) 37

3.8 MOPHOLOGICAL CHART 38 3.8.1 Exterior Shape Design 39 3.8.2 Impeller 39 3.8.3 Disc Holder 39 3.8.4 Cutting Disc 39 3.8.5 Pressurized Air Distributor 39

3.9 CONCEPT GENERATION 40

3.10 DESIGN LIMITATION FACTORS 41

3.11 OBJECTIVE TREE 42

3.12 SCORING METHOD 43

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3.13 FINAL CONCEPT 44

CHAPTER 4 45

PROTOTYPING 45

4.0 INTRODUCTION 45

4.1 PROTOTYPE DEVELOPMENT PROCESS 46

4.2 DETAIL DESIGN 47 4.2.1 Lower Casing 47 4.2.2 Upper Casing 48 4.2.3 Axial Impeller 50 4.2.3 Air Distributor 50 4.2.4 Impeller Sub 50

4.3 FUSED DEPOSITION MODELLING 51 4.3.1 Processes 53 4.3.2 Technical Details 53

4.4 SILICONE MOLDS 54 4.4.1 Procedure Steps 55 4.4.1.1 The Inspection of Master Pattern 55 4.4.1.2 Box Construction 56 4.4.2 Making the male mold 59 4.4.2.1 The Silicone Mixing Process 59 4.4.2.2 Inhibition of cure 61 4.4.3 Typical Properties 61 4.4.4 Making the female mold 61 4.4.4.1 Sprue Setting 62

4.5 PART CASTING 63 4.5.1 The Polyurethane Mixture 63 4.5.2 Solidify Forming 64

4.6 LATHE MACHINING 65

4.7 MAKING SCREW HOLES USING DRILL PRESS 68

4.8 CUTTING THE MATERIAL USING BANDSAW 69

4.9 ASSEMBLY PROCESS 71

4.10 FINISHING 74 4.10.1 Spraying 74

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CHAPTER 5 75

ANALYSIS AND DISCUSSION 75

5.0 INTRODUCTION 75

5.1 ANALYSIS 76 5.1.1 Manual Static Analysis 76 5.1.2 Computer Simulation 77 5.1.2.1 Result on the upper casing 77 5.1.2.2 Result on the lower casing 78

5.2 SELF CLEANING MECHANISM 80

5.3 ROTATION OF CUTTING DISC 81

5.4 CALCULATION ON THE WEIGHT OF THE SILICONE USED 81

5.5 CALCULATION ON THE WEIGHT OF POLYURETHANE USED 82 5.5.1 Lower Casing 82 5.5.2 Upper Casing 82

5.6 THE MATERIAL 83

5.7 FUSED DEPOSITION MODELLING 83

5.8 THE DESIGN 83

CHAPTER 6 84

CONCLUSION 84

BIBLIOGRAPHY 85

APPENDIX 88

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LIST OF FIGURES

CHAPTER 2

Figure 2. 1: Malaysia had produced 41.3% of world palm oil production in 2008 8

Figure 2. 2: Export trend of major oil until 2008 (MPOB, 2008) 9

Figure 2. 3: The Six Wheeler (MPOB, 2008) 11

Figure 2. 4: The grabber (MPOB, 2008) 11

Figure 2. 5: Leaf emission rate varies with palm age (MPOB, 2008) 14

Figure 2. 6: Canopy form of oil palm leaves (MPOB, 2008 14

Figure 2. 7: The spikelets (MPOB, 2008) 15

Figure 2. 8: Fresh fruit bunch (MPOB, 2008) 15

Figure 2. 9: Short oil palm trees stem (MPOB, 2008 16

Figure 2. 10: Cylindrical shape stem of oil palm (MPOB, 2008 17

Figure 2. 11: Thick superficial adventitious mat of oil palm root (MPOB, 2008) 18

Figure 2. 12: The fibrous superficial root system (MPOB, 2008) 18

Figure 2. 13: Traditional harvesting method using sickle cutter (MPOB, 2008 19

Figure 2. 14: Latest technology developed by MPOB known as CANTAS™ 20

CHAPTER 3

Figure 3. 1: Flow Chart 25

Figure 3. 2: Basic structure of House of Quality 32

Figure 3. 3: House of Quality of Pneumatic Mini Disc Cutter 35

Figure 3. 4: Morphological Chart 38

Figure 3. 5: Objective Tree 42

Figure 3. 6: Final Concept 44

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CHAPTER 4

Figure 4. 1: Prototype Developement Process 46

Figure 4. 2: Isometric View of Exterior Look 48

Figure 4. 3: Isometric View of Interior Look 48

Figure 4. 4: Isometric View of Exterior Look 49

Figure 4. 5: Isometric View of Interior Look 49

Figure 4. 6: Isometric View of Axial Impeller 50

Figure 4. 7: Isometric View of Impeller Sub 51

Figure 4. 8: Fused Deposition Modelling Machine 52

Figure 4. 9: Interior Look of FDM Machine 52

Figure 4. 10: The for segments of upper casing 54

Figure 4. 11: Joint segments 54

Figure 4. 12: Box construction 56

Figure 4. 13: Modelling Clay Base 57

Figure 4. 14: Leakage Inspection 57

Figure 4. 15: The completed model is kept on flat and safe place 58

Figure 4. 16: Completed Male Mold 59

Figure 4. 17: Mixing Machine 60

Figure 4. 18: The Silicone 60

Figure 4. 19: Pouring hardener intothe silicone 60

Figure 4. 20: Completed female mold 62

Figure 4. 21: Setting up sprue on upper casing 62

Figure 4. 22: Setting up sprue on the lower casing 63

Figure 4. 23: Cured Lower Casing Part 64

Figure 4. 24: Cured Upper Casing Part 64

Figure 4. 25: Lathe machine is used in producing impeller sub 65

Figure 4. 26: Safety precaution in handling lathe machine 65

Figure 4. 27: Continuous measurement 66

Figure 4. 28: Drill Press Machine 68

Figure 4. 29: Bandsaw Machine 69

Figure 4. 30: Inner besring insertion 71

Figure 4. 31: Back bearing insertion 71

Figure 4. 32: Bearing insertion in upper casing 71

Figure 4. 33: Axial impeller respective slots 72

Figure 4. 34: Supporting pad with axial impeller 72

Figure 4. 35: Pressuruzed air distributor 73

Figure 4. 36: Installing pressurized air distributor 73

Figure 4. 37: Complete product 73

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CHAPTER 5

Figure 5. 1: Force Distribution in Static Analysis 76

Figure 5. 2: Von Mises Stress in Upper Casing 77

Figure 5. 3: Deformation Analysis in Upper Casing 78

Figure 5. 4: Von Mises Stress in Lower Casing 78

Figure 5. 5: Deformation Analysis in Lower Casing 79

Figure 5. 6: Air Distribution Along the Hose 80

Figure 5. 7: Self-Cleaning Working Principle 80

Figure 5. 8: Rotation of Cutting Disc 81

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LIST OF TABLES

CHAPTER 2

Table 2. 1: The increasing need of labour throughout years until 2008 10

CHAPTER 3

Table 3. 1: Product Design Specification (PDS) 37

Table 3. 2: Concept Generation 40

Table 3. 3: Scoring Method 43

CHAPTER 4

Table 4. 1: Technical Detail on Fused Deposition Modelling 53

Table 4. 2: Typical properties of silicone mixture 61

CHAPTER 5

Table 5. 1: Mechanical properties of Aluminium Alloy 77

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LIST OF SYMBOLS

FP = Pulling Force (N)

FR = Reaction Force (N)

FC = Cutting Force (N)

W = Weight (N)

x = Maximum distance where the force can be apllied(mm)

Ʃ = The sum of

δx = Change in distance (mm)

η = Safety factor

sut = Ultimate tensile strength (Nm2)

σmax = Maximum stress (Nm2)

W = Wide (cm)

H = Height (cm)

L = Long (cm)

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CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

Projek Sarjana Muda (PSM) is one of the most important aspects of local

university to evaluate their degree level students. Through PSM, students will be able

to apply all the knowledge they had learnt in related field of engineering.

Engineering is first and foremost the application of knowledge. However, the

application must be carried out with judgement, to ensure that the resultant system is

effective and efficient, and that it is of benefit. The PSM is one of the primary the

mechanisms used by the local university to provide students with an opportunity to

gain experience in the practical, effective, efficient, and beneficial application of

what you have been studying for the past several years. Naturally, student will

continue to gain engineering experience after they graduate but the final year project

will always be their first exposure to the full rigour of engineering practice. It is

essential that the students learn from this exposure and practise all of the engineering

methodologies involved. It is particularly important that they learn not just to apply

what they know, but to apply it with judgement, with the ability to assess what they

are doing and to be critical of it.

This chapter will cover several subtopics in project area which consist of

project background, the objectives, the scopes and the problem statement.

2

1.1 BACKGROUND

Harvesting costs signify near 45% associated with total expenses in adult

plantations. This activity is usually initiated whenever palms tend to be between 23

and 36 months. Precocity as well as early yields rely on environmental problems, the

range, the quality from the nursery plantation, care throughout planting, as well as

early administration. The initial bunches produced are little in size and consist no

much oil, and they are normally not harvested.

In regards to a week prior to the first commercial harvesting, the palms tend

to be cleaned (sanitary pruning) associated with old lifeless leaves as well as

bunches. No green leaves ought to be cut, since a new palm needs them all. During

earlier harvesting rounds it is suggested to “steal” the bunch by means of cutting the

fresh bunch without having to cut any leaf. This practice might be done till bunches

can be found to the height of 1 meter within the soil area.

Bunches might be cut utilizing a narrow chisel (5-8 cm width), having a metal

handle about 1.2 m in length, or a little Malayan knife (sickle-shaped) mounted on a

brief aluminium rod. The purpose is to reduce as much of green leaves as possible.

As the palm grows older, the bunch weight increases, from about 2.5 kg at the

beginning (2-3 years after planning), to 25 or even more kilograms within matured

palms. However, the fruit bunch production decreases with its age.

A matured palm produces 8-13 bunches each year, which signifies about 140-

175 kg associated with FFB (fresh fruit bunches), that will generate 30-38 kilograms.

The optimum potential when it comes to FFB production is usually reached within

commercial plantations once the palms tend to be between four and eight years old.

During this period, yields could be between 15 as well as 40 tonnes of FFB each

year, which signifies 3.3 - 8.8 tonnes of crude palm oil/ha (considering 22%

extraction in the mill). The causes of such differences need to be found upon climate,

earth, agronomic management, and obviously, the variety used.

Harvesting in some way is very challenging in the sense that bunches build

up the majority of its oil throughout a fairly short time (a few days) of development

3

time. If the FFB is harvested too soon (unripe), it will contain less oil than its

potential. If harvested past due, the actual oil is going to be partly deteriorated (free

fatty acid accumulation). The actual ideal level of ripeness is actually evaluated

through the harvester through bunch colour, texture, the change in colour, and the

presence of loose fruits. Ripen fruitlets turn out to be soft, as well as change from a

black coloration to shiny brown and finally to an opaque reddish-brown appearance

at the tip and orange-reddish on the medium section.

The time needed to achieve maturity varies based on palm age, the variety

and environmental conditions, but usually takes between 5.5 and 6 months from the

time of anthesis (pollination). Typically, bunches tend to be harvested within young

palms when 10 or even more loose fruit are discovered. For matured palms, the

amount of loose fruit is decreased to 5. In order to gather peak proportion associated

with bunches using the optimum level of ripeness; harvesting cycles need to be

relatively short: every 8-15 days, depending upon palm grow older and time from the

year (bunch density).

Throughout the very first 5-6 years, harvesting is performed using a metal

chisel (14 cm width or less), welded to a metal hollow rod or attached to a wood pole

(1-3 m long). In matured palms, cropping is performed using so-called Malaysian

knifes (sickle-shaped) mounted on hollowed aluminium rods, that are light and

incredibly flexible. The length of the aluminium pole is increased with palm. The

employee might crop 100-300 large bunches (10-25 kg) per day on an adult planting,

or 400-1, 000 small ones (3-8 kg) in a young plot. Effectiveness depends upon the

power from the worker as well as bunch density.

4

1.2 PROBLEM STATEMENTS

Shortage of labour recently has forced all parties involved in the industry to

find ways and means to at least maintain the profit through balancing the

productivity and the production cost. The traditional sickle method of harvesting oil

palm fresh fruit bunch takes a lot of time and reduces production efficiency. So, it is

clearly there is an immediate need to formulate and develop a technology that can cut

fruit bunches easily and efficiently.

Because of the urgent need, most tools have been developed without

considering the necessary technical information for cutting frond and fruit bunches.

The physical properties of the material, reaction of the material against the cutting

edge, method of cutting, cutting angle and speed of cutting have not really been

considered.

Product that can really satisfy engineering needs comes with really great cost

and unaffordable. CANTAS™ is the latest technology developed by Malaysian Palm

Oil Board (MPOB) and can really increase productivity in FFB harvesting. This

technology, however, is a bit pricy especially for smallholders.

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1.3 OBJECTIVES

The objectives of this project are:

a) To create a power tool that is

a. Cost saving

b. Environmental friendly

c. Safe

d. User friendly

e. Able to be commercialized

f. To run analysis on the best design that can reduce energy

consumption

b) To design a cutting tool that is reliable, efficient and easy to handle

c) To reduce production cost, reduce labour requirement, increase productivity

and improve efficiency of field operations

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1.4 SCOPES

The scopes that need to be covered throughout this project are:

a) To design and develop a pneumatic oil palm fruit stalk cutter using multiple

mini disc cutter

b) The design is developed to replace the traditional sickle cutter

c) To formulate and develop a technology that can cut fruit bunches easily and

efficiently.

d) The design is only focusing on the cutter mechanism itself excluding design

of the pole and the air compressor

e) To design a cutting tool that enhances cutting force with minimal energy

consumption

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CHAPTER 2

LITERATURE REVIEW

2.0 INTRODUCTION

The literature review is really a description from the literature that is highly

relevant to a specific field or even topic. It gives the general idea of what has been

said, who the key writers are, what are the prevailing theories and hypotheses, what

questions are being asked, and what methods and methodologies are appropriate and

useful. As such, it is not in itself primary research, but rather it reports on other

findings.

The literature review might be purely detailed, as within an annotated

bibliography, or it might provide a vital assessment from the literature inside a

particular area, stating in which the weaknesses as well as gaps tend to be,

contrasting the actual views associated with particular writers, or increasing

questions. This type of review will not just be considered as summary but will even

evaluate as well as show associations between various materials, to ensure that key

styles emerge. A descriptive evaluation however should not just checklist and

paraphrase, but ought to add remark and enhance themes as well as trends.

This literature review will generally give an overview or the ‘big picture’ of

what will be conducted throughout this project. These include

i) The information on palm oil tree

ii) Previous research on the technologies regarding to palm oil industry

8

330, 1% 860, 2% 800, 2%

420, 1%

19100, 44% 17735, 41%

1160, 3%

400, 1% 2100, 5%

Cote d'Ivoire

Nigeria

Columbia

Ecuador

Indonesia

Malaysia

Thailand

Papua New Guinea

Others

2.1 BACKGROUND

The oil palm is the most productive species among oleaginous plants.

Malaysia is currently the world's biggest producer of this particular plant. However,

the Malaysian palm oil is now facing competition not only from other oil and fat

industries but also from other palm oil producing countries. Rising competition in the

world market, declining in price, and shortage of labour are some of the factors

influencing the well being and future of oil palm industry.

2.1.1 Palm Oil Industry in Malaysia

In 1960, Malaysia plays only a minor part in producing oil palm with a total

cultivated area of 55 000 hectares and production of 92 700 tonnes per annum. In

1995, however, the total area planted with oil palm increased to about 2.358 million

hectares producing about 7.6 million tonnes of crude palm oil, which was about 64%

of the total world's production. It is estimated that by the year 2005, Malaysia may

produce 10 million tonnes of crude palm oil and 2.5 million tonnes of palm kernel

(Dato' Khalid, 1996).

As the world’s biggest exporter of palm oil, Malaysia accounted for 15.14

million tonnes (26.2%) of the global oils and fats trade in 2007. Its oil palm sector is

Figure 2. 1: Malaysia had produced 41.3% of world palm oil production in 2008

9

also seen as a beacon for sustainable development in agriculture (Yusof, 2007; Chan,

2003).

Although the industry is facing competitions from other edible oils produced

by other countries, and the campaigns by soybeans society not to buy palm oil, it is

expected that the prospect of this industry will be boosted further in the 90's, through

the opening of several new markets especially Myanmar and Vietnam in Asia,

Tunisia, Morocco and a few countries in Africa and South America Demand will

also grow in many developing countries such as India, China and other European

Union countries due to the tight supply condition of other fats and oils in the world

market. In Malaysia, however, the high production cost of palm oil is mainly due to

the high labour cost. Presently, labour cost in the plantation is about 30 to 35% of the

total production cost (Turner and Gillbank, 1982).

Figure 2. 2: Export trend of major oil until 2008 (MPOB, 2008)