UNIVERSITI TEKNOLOGI MALAYSIA -...

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DECLARATION OF THESIS / UNDERGRADUATE PROJECT PAPER AND COPYRIGHT

Author’s full name : CHONG LIP GANG

Date of birth : 1st DECEMBER 1989

Title : DESIGN OF LIGHT WEIGHT STRUCTUE FOR VERTICAL PLANTING SYSTEM

Academic Session: 2012/2013

I declare that this thesis is classified as :

I acknowledged that Universiti Teknologi Malaysia reserves the right as follows:

1. The thesis is the property of Universiti Teknologi Malaysia.

2. The Library of Universiti Teknologi Malaysia has the right to make copies for the purpose

of research only.

3. The Library has the right to make copies of the thesis for academic exchange.

Certified by :

SIGNATURE SIGNATURE OF SUPERVISOR

891201-08-5859 EN. IDRIS ISHAK (NEW IC NO. /PASSPORT NO.) NAME OF SUPERVISOR

Date : 23 JUNE 2013 Date : 23 JUNE 2013

NOTES : * If the thesis is CONFIDENTAL or RESTRICTED, please attach with the letter from

the organization with period and reasons for confidentiality or restriction.

UNIVERSITI TEKNOLOGI MALAYSIA

CONFIDENTIAL (Contains confidential information under the Official Secret

Act 1972)*

RESTRICTED (Contains restricted information as specified by the

organization where research was done)*

OPEN ACCESS I agree that my thesis to be published as online open access

(full text)

√

UTM(FKM)-1/02

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

VALIDATION OF E-THESIS PREPARATION

Title of the thesis : DESIGN OF LIGHT WEIGHT STRUCTURE FOR VERTICAL PLANTING

SYSTEM

Degree: BACHELOR OF ENGINEERING (MECHANICAL-MATERIALS)

Faculty: FACULTY OF MECHANICAL ENGINEERING

Year: 2012/2013

I CHONG LIP GANG

(CAPITAL LETTER)

declare and verify that the copy of e-thesis submitted is in accordance to the Electronic Thesis and

Dissertation’s Manual, Faculty of Mechanical Engineering, UTM

_____________________

(Signature of the student)

______________________

(Signature of supervisor as a witness)

Permanent address:

2672, KAMPUNG TERSUSUN

KLEDANG UTAMA,

31100, SUNGAI SIPUT (U), PERAK

Name of Supervisor:

EN. IDRIS ISHAK

DR. SHUKUR ABU HASSAN

Faculty:

FACULTY OF MECHANICAL ENGINEERING

Note: This form must be submitted to FKM, UTM together with the CD.

“We hereby declare that we have read this report and in our opinion

this thesis is sufficient in term of scope and quality for the

award of the degree of Bachelor of Engineering (Mechanical – Materials).”

Signature : …………………………

Name of Supervisor 1 : En Idris Ishak

Date : 23 JUNE 2013


Name of Supervisor 2 : Dr Shukur Abu Hassan

Date : 23 JUNE 2013

DESIGN OF LIGHT WEIGHT STRUCTURE FOR

VERTICAL PLANTING SYSTEM

CHONG LIP GANG

A report submitted in fulfilment of the

requirements for the award of the degree of

Bachelor of Engineering (Mechanical – Materials)

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

JUNE 2013

ii

I declare that this thesis entitled “Design of Light Weight Structure for Vertical

Planting System” is the result of my own study except as cited in the references. The

thesis has not been accepted for any degree and is not concurrently submitted in

candidature of any other degree.


Nam of Candidate : Chong Lip Gang

Date : 23 JUNE 2013

iii

To my family and beloved

who supported me all the way through…

iv

ACKNOWLEDGEMENT

There are many persons have contributed towards my understanding and

thoughts in preparing this thesis. I would like to express my sincere gratitude to my

supervisor, En Idris Ishak and Dr Shukur Abu Hassan for their advice,

encouragement and guidance. Without their continued support and interest, this

thesis would not have been the same as presented here.

I also want to express my sincere thanks to my friends and family for their

continuous support and assistance during the study. Without support from one of

them, none of this would have been possible. Besides that, my sincere appreciation

also extends to Universiti Teknologi Malaysia (UTM) for providing facility and

sufficient equipments and tools for this study.

To all of them, this thesis is earnestly dedicated.

v

ABSTRACT

Sustainable development was defined as „meet present needs without

compromising the ability of future generations to meet their need.‟ The issue of

sustainability is getting more attention in almost all the country around the world,

agriculture sector became one of the sectors that will face tough challenge in future

development. Furthermore, food crisis has become the attention of the human being

all over the world. The frequent happens of natural disaster have caused the decrease

of yield. In Malaysia, the total amount that spends on importing food was keep

increasing each year. Land reclamation for agriculture, using innovation method to

increase yield are the tasks that we can do. Vertical planting structure may be one of

solution for sustainable agriculture. Design of light weight structure of vertical

planting structure was discussed in this thesis. In addition, the design was analyzed,

simulated and improved by Computer Aided Design (CAD) software Solidworks. At

the end, a light weight structure of vertical planting structure was design and ready

for further development like rain water harvesting system, hydroponic system or

renewable energy harvesting system.

vi

ABSTRAK

Pembangunan lestari bermaksud memenuhi permintaan pada masa kini tanpa

mengekploitasi hak-hak generasi akan datang untuk memenuhi permintaannya. Isu-

isu pembangunan lestari telah diuar-uarkan pada semua negara di seluruh dunia dan

sektor pertanian adalah salah satu sektor yang akan menghadapi cabaran pada

pembangunan akan datang. Tambahan pula, krisis makanan juga menarik perhatian

orang ramai di seluruh dunia. Kekerapan berlakunya bencana alam telah

mengurangkan hasilan makanan di seluruh dunia. Di Malaysia, jumlah wang yang

digunakan untuk mengimpot makanan dari luar negara adalah meningkat setiap

tahun. Menerokai kawasan baru, penggunaan innovasi untuk meningkatkan hasil

pertanian adalah langkah-langkah yang boleh diambil. Penciptaan struktur ringan

untuk penanaman berkonsep tegak adalah salah satu solusi untuk pembangunan

pertanian lestari. Dalam tesis ini, process reka bentuk dibincang and dianalisis

dengan penggunaan Computer Aided Design (CAD), Solidworks. Akhirnya, satu

struktur ringan untuk penanaman berkonsep tegak telah direka-cipta dan siap untuk

pembangunan sistem pemgumpulan air hujan, sistem hidroponik, atau sistem tenaga

boleh diperbaharui.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENTS iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF SYMBOLS xiv

LIST OF APPENDICES xv

1 PROJECT INTRODUCTION 1

1.1 Introduction 1

1.2 Project Background 1

1.3 Problem Statement 3

1.4 Objectives 3

1.5 Scope of Study 3

1.6 Significant of Study 4

1.6.1 Vegetables Demand in Malaysia 4

1.6.2 Economic Impact of Agriculture Sector 5

1.7 Research Planning 6

viii

1.8 Expected Research Outcomes 8

1.9 Thesis Writing Framework 8

2 LITERATURE REVIEW 10

2.1 Introduction 10

2.2 Design Philosophy 10

2.2.1 Role of Concurrent Engineering in Design 11

2.2.2 Design for Manufacturing 13

2.2.3 Design for Assembly 14

2.2.4 Design for Environment 14

2.3 Soilless Culture-Hydroponic 15

2.3.1 History of Hydroponic 15

2.3.2 Advantage of Hydroponic 16

2.3.3 Hydroponic Methodology 17

2.3.3.1 Ebb & Flow Garden System 17

2.3.3.2 Drip Feed 17

2.3.3.3 Aeroponics 18

2.3.3.4 Nutrient Film Technique 18

2.3.3.5 Deep Water Culture 18

2.4 Vertical Planting 21

2.5 Vertical Farming Products Comparison 22

2.6 Aerofarms Aeroponic Farming (AAF) 22

2.7 Tower Garden Growing System (TGGS) 23

2.8 Vertical Aeroponic Growing System (VAGS) 23

3 RESEARCH METHODOLOGY 26

3.1 Introduction 26

3.1.1 Problem Identification 27

3.1.2 Design Analysis 28

3.1.3 Engineering Analysis 29

4 CONCEPT AND DESIGN SELECTION 30

4.1 Introduction 30

4.2 Concept Generation 30

ix

4.2.1 Proposed Design 1 30



4.3 Design Selection 34

4.4 Design Finalize 35

4.4.1 Beam and Column 35

4.4.2 Joining Method 36

4.4.3 Stacking Feature 36

4.4.4 Lifting Feature 37

4.5 Final Concept 38

5 ENGINEERING ANALYSIS 39

5.1 Introduction 39

5.2 Materials Selection 39

5.3 Detail Computer Aided Drawing 41

5.4 Engineering Analysis 42

5.4.1 Loading Define 43

5.4.2 Stress Analysis 43

5.4.2.1 Tensile Stress 44

5.4.2.2 Compressive Stress 44

5.4.3 Buckling Analysis 46

5.4.4 Deflection and Displacement Analysis 47

5.4.5 Bolt and Member Analysis 48

5.5 CAD Software Simulation 49

6 CONCLUSION AND RECOMMENDATIONS 54

6.1 Conclusion 54

6.2 Recommendations 55

REFERENCES 56

APPENDICES A-L 58-88

x

LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 The comparison of Vertical Farming Product/System 24

4.1 The Matrix Assessment Table for the selection of final

design concept 34

5.1 Candidates Materials for Materials Selection Process 40

5.2 Rigid Requirement of the Materials Selection Process 40

5.3 The Performance Index (γ) of each candidate materials 40

5.4 Bill of Materials 41

5.5 Properties of Glass Fiber Reinforced Polymer (GFRP) 42

xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Food trade of Malaysia from year 2008 to prediction

year 2011 4

1.2 Distribution of imported food in year 2010 5

1.3 The research flow chart of project for PSM 1 & 2 7

2.1 Overall engineering cost 12

2.2 Graph of cost of changes versus the design phase 12

2.3 Ebb & Flow Garden Growing System 19

2.4 Drip Feed System 19

2.5 Aeroponics 20

2.6 Nutrient Film Technique 20

2.7 Deep Water Culture 21

2.8 The Aerofarms Aeroponic Farming 22

2.9 Tower Garden Growing System 23

2.10 Vertical Aeroponic Growing System 24

3.1 Project research methodology 26

3.2 Problem identification flow chart 27

3.3 The process flow for design analysis 28

xii

3.4 Engineering analysis flow chart 29

4.1 The proposed design 1 for the light weight vertical

planting structure 31

4.2 Joints that use in proposed design 1 32

4.3 Proposed design 2 which uses the concept of shipping

container 32

4.4 The view of interior structure of the proposed design 2 32

4.5 Proposed design 3 for vertical planting system 33

4.6 The skeleton structure of the vertical planting structure that

built by structural beam 33

4.7 Design of beams 35

4.8 Design of joint 36

4.9 Design of stacking feature 37

4.10 Design of lifting feature 37

4.11 The isometric view of the final design 38

4.12 The stacking assembly of the vertical planting structure 38

5.1 Vertical planting structure components 41

5.2 The tensile force that act on the box column of the vertical

planting structure 44

5.3 The stacking assembly of the vertical planting structure 45

5.4 The upper and lower parts of the vertical planting structure 46

5.5 Box column 102x102x6.4 (2500) from the vertical planting

structure 46

5.6 Box beam 102x102x6.4 (2398) from the vertical planting

structure 48

xiii

5.7 Joint connection of the vertical planting structure 49

5.8 The stress distribution of the lower part of box column

while under compression loading 50

5.9 The stress distribution of the top part of box column while

under tensile loading 50

5.10 Displacement of box column while under compression

loading 51

5.11 Deflection of box beam while under a point load condition 52

5.12 The stress distribution of corner joint plate 52

5.13 The stress distribution of middle joint plate 53

xiv

LIST OF SYMBOLS

𝜎𝑇 - Tensile Stress

𝐹 - Force

𝐴 - Area

𝑃𝑐𝑟 - Critical Axial Load

𝜋 - Pi (3.142)

𝐸 - Tensile Modulus

𝐼 - Moment of Inertia

𝐾 - Effective Length Factor

𝐿 - Effective Length

𝛿 - Relative Displacement

𝑃 - Compression Force

xv

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Product Design Specification 58

B Morphology Chart 60

C Materials Selection 61

D Detail Engineering Drawing 63

E Loading Define 74

F Stress Analysis 75

G Buckling Analysis 78

H Deflection Analysis 79

I Displacement Analysis 83

J Bolt Analysis 84

K Member Analysis 87

L Gantt Chart 88

1

CHAPTER 1

PROJECT INTRODUCTION

1.1 Introduction

This chapter is discussed a brief explanations about the backgrounds of the

project including the objective, scope of study and the project framework of the final

year project. The aim of the project is to design a light weight structure for vertical

planting system as an alternative method for vegetables growing.

1.2 Project Background

Malaysia is a country which is located near the equatorial with a tropical

climate which is very suitable for agriculture activities. Malaysia has a very large

area of land which covers 33 million hectare. In these large area of land, only 6.6

million [1] hectare or equivalent to twenty percent are allocate for agriculture

purpose. Thus, the rest of the areas are used as residential area, industrial, and others.

It is easy to clear a land for agriculture because there still exist a large area of

land which not yet been explored in Malaysia. With the rise in population of

Malaysia, open an agriculture area is not a sustainable method because the land is

still not enough for agriculture to support the population of our country.

2

In the year of 1987, sustainable development was defined as „meet present

needs without compromising the ability of future generations to meet their need‟ [2]

and with the issue of sustainability getting more attention in almost all of the country

around the world, agriculture sector will become one of the sectors that will face

tough challenges in the future development. According to Deputy Chief Minister

Datuk Seri Yahya Hussin in The Star (2010) “higher input in agriculture on an

industrial scale can elevate food production but it also contributes to global warming,

destruction, biological imbalance, loss of land fertility and use of much water.”

There is a very close relationship between the agriculture and environment,

methods that are environmental friendly should be given priority to ensure the

sustainable food supply for the country. In order to minimize the agriculture impact

to the environment, the minister of agriculture of that period of time, had suggested

growing paddy on the roof top of the building and it was successful. Nevertheless,

there is none of the farmer dare to practice this modern technique due to the huge

initial investment of the modern farming technique.

In other to boost agriculture sectors, government has introduced New

Economic Model (NEM). The ability to ensure the continuous food supply in the

context of New Economic Model (NEM) was identified as one of the challenge to

country in order to become a high income country. Therefore, increasing the income

of the farmer and stabilize the food price in the market would be the main challenge

to us. In less than eight years to transforming our country to a high income country,

there is not much different of agriculture technique that is use in Malaysia although

the use of machine, modern method have started to penetrate in this sector. In

connection with this situation, government has identified four strategies [4] to

revitalize agriculture sector, there are:-

i. Enlarge the application of Information and Communication Technology

(ICT)

ii. Develop high quality human capital

iii. Increase the effectiveness of institution involvement in agriculture sector

iv. Application of innovation and technology in agriculture sector

3

In this project, the design of vertical planting system will become an

innovation in the modern farming technique. With the high demand of the vegetable

in Malaysia, an implementation of vertical planting technique will be the solution to

it. Currently, hydroponic are one of the solution to increase the yield of vegetables. A

green house is a simple structure that built to grow vegetables. The built of green

house need to clean up a large area of land, yet the yield is limited. This green house

still can be improved in term of the structure and the yield with a limited area of land.

Thus, the light weight vertical planting structure can be a solution for farmer,

entrepreneur or country to generate higher income in the future.

1.3 Problem Statement

High demand for vegetable is causing our country to spend a lot on importing

food. This shows that the current farming method is not enough to supply the

vegetables demand of our country.

1.4 Objectives

The objective of this project is to design a light weight structure for vertical

planting system with compliance to design for environment concept.

1.5 Scope of Study

The scopes of this project include developing the specifications and propose

design for a light weight structure for vertical planting system. The scope of the

vertical planting should be limited to the growing of herbs, leafy vegetables or

fruiting vegetables in Malaysia. The best solution among the proposed concept for

vertical farming will be chosen based on requirement and detailed engineering

4

drawing will be generated. The safety factor of the structure will be calculated and

the product will be optimized by Computer Aided Design (CAD).

1.6 Significant of Study

1.6.1 Vegetables Demand in Malaysia

Although Malaysia has a large area of land that used for agriculture activities

but it is still not enough to fulfil the demand in our country. At the year of 2011, the

food import‟s value had achieved RM27.93 billion [5] from January until October.

By prediction, the total food import of the year may achieve RM34.45 billion [6].

Figure 1.1 Food trade of Malaysia from year 2008 to prediction year 2011 [6]

Figure 1.1 shows that there is an imbalance between the food export and

import. The money that spent on food importing was always higher than the amount

of export from the year 2009 to 2011. During the year of 2010, Malaysia still remains

as a net food importer. The money spent on importing food had achieved RM30.19

billion [6], which exceeded RM3.51 billion compare to the year of 2009. From

Figure 1.2, with the total food import value of RM30.19 billion, the import of coffee,

tea, cocoa and spices occupying 16.96%, follows by cereal and cereal preparations

2008 2009 2010 2011

Export 17.76 15.71 18.1 20.5

Import 27.92 26.68 30.19 34.45

0

10

20

30

40

Val

ue

(R

M B

illio

n)

Food Trade of Malaysia From 2008-2011(Predict)

5

which contribute to 11.80%. For vegetables, the total import in year 2010 is RM2.72

billion, which contributes 9% of overall import value.

Figure 1.2 Distribution of imported food in year 2010 [6]

In the year of 2011, populations in Malaysia are estimated have increase to

28.55 million [6] people and this lead to the high demand in getting food supply.

Over depend on the import of food from other countries have put us in a weak

situation as we are not able to tackle the food crisis in the coming decade [7]. In short,

farmers in Malaysia should ready to accept the uses of latest technology and

environmental friendly method in growing crop.

1.6.2 Economic Impact of Agriculture Sector

In these recent years, the food crisis has become the attention of human being

all over the world. The frequent happens of natural disaster like flood, drought,

earthquake, and hurricane have caused the decrease of yield. The era of cheap food

price is over. From the June 2010 till February 2011, the total of yield from the

Cereal & Cereal Preparations

12%

Coffee, Tea, Coco & Spices

16%

Vegetables9%

Fruit5%

Meat & meat Preparation

6%

Sugar, Sugar Preparation &

Honey10%

Others42%

Distributions of Imported Food in Year 2010

6

countries like China, Russia, and Brazil has decrease significantly due to the draught.

At the same time, Pakistan and Australia also strike with flood [8].

In other point of views, food crisis could be the huge market potential for us

to explore. Land reclamation for agriculture, using innovation method to increase

yield are the tasks that we can do. Even some of the countries like Syria, Oman, and

Dubai already started using science knowledge to create an ecosystem that suitable

for growing crops. There are much of actions that we can take to resist the food crisis

and explore the unlimited market potential like developing vertical planting system

in our country.

1.7 Research Planning

The project was divided into 2 phases which each phases were consume 1

semester to complete. Phase 1 of the project was concentrate on information

searching, background studies, and research planning. Then, the project was continue

with phase 2 of the project which the procedures are concept generation, final

concept evaluation, engineering analysis and conclusion or recommendations for

further studies of the project. At the end, a structure with detail dimensions was

expected as the result of the project. In short, the phase 1 was concentrated on the

aspect of design while the phase 2 was focus on design analysis. Figure 1.3 shows

the entire procedure flow chart of the design of light weight structure for vertical

planting system:

7

Figure 1.3 The research flow chart of project for PSM 1 & 2

8

1.8 Expected Research Outcomes

At the end of this project, a design of a light weight structure for vertical

planting system will be developed. This project focus on the design of the structure,

but the other supporting components selection will be added in as the support of the

study.

1.9 Thesis Writing Framework

The thesis consist of six chapters, each chapter was lead the project from the

background of the problems to the details of the design and the recommendations for

further study. The details of each chapter are planned as below:-

Chapter one is the introduction of the whole project by identify the system

design requirement. The project background is discussed in this chapter

which includes the scope of study, significant of study, objective, and

research planning.

Chapter two is discussing on the literature of the related studies. The

literatures were divided into two categories which are theory and field studies.

The theories that apply are including the philosophy of design and some

design theory. For the field studies, it is related to the agriculture methods and

the studies of current product in the market.

Chapter three provides the research methodology that used in the whole

project. In this chapter, the details of each design steps were determined.

Chapter four is about the concept design and design selection. Three

concepts will be evaluated and critics in order to fulfil the design criteria and

the concept were finalized.

Chapter five is the engineering analysis of the final concept. The details of

the design like the dimensions of the product will be finalize in this stage and

modelling process was done by using Computer Aided Design (CAD)

software. Safety factor of each component was calculated and optimized.

9

Chapter six is the conclusion and recommendations of the project. The

chapter is discussing the outcome of the project. Besides that,

recommendations were made for further improve of the design.

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

This chapter discusses about the apply theory of use like design philosophy,

the role of concurrent engineering in the design field, and some theories of design.

Besides that, some apply field of studies like the definition of vertical planting and

some available products in the market were studied.

2.2 Design Philosophy

Design can be define as an activity that using theories of scientific, technical

information and imagination in solving a problem. Design is not a process or

activities that suddenly comes to a person mind, while design is a process that

consume a lot of time and energy before it comes to a real product, which include the

process of ideal generation, testing and modification until it achieve the desired

specifications. A new product always been introduce to the market are based on two

main reasons which are the market demand and the changes of technology. Market

demand is one of the reasons because the user needs new innovation or invention in

solving their problem. Besides that, the advanced technology always substitutes the

old technology to improve the efficiency of a product.

11

2.2.1 Role of Concurrent Engineering (CE) in Design

Concurrent engineering, also refer as parallel engineering or simultaneous

engineering have broaden the focus of processing, functional requirement, operating

limits of the product to account for the „customer‟ as one of the aspect that

previously not to consider in the design phase. Compare to conventional engineering,

lack of communication between designer and manufacturer may slow down the

overall product development time and increase the cost.

The studies by Institute for Defense Analysis [9] on the experience with

military aircraft had reveals that the modifications and maintenance of the product

are the main cause of increasing in overall engineering cost. Except the operational

cost, only 10% of the engineering cost is spent on design stage, around 25% is taken

by manufacturing process and remain of 65% are the expenses for modification and

maintenance of the design which as shown in Figure 2.1.

From the studies of Institute for Defense Analysis, we can know that the role

of designer at the beginning of the design process is important. Any decision and

specification that made in the design phase will influence the remains of the life-

cycle. Refer to Figure 2.2, the graph shows the extra expenses on the changes of

design in each stage. During the initial stage (concept design phase), the changes of

design would not cost so much, but the extra cost that spent on the changes of design

may increase as the design phase keep moving forward. When the design phase

comes to the production stage, it is no longer suitable for changing. According to

Salzberg and Watkins [11], the lack of information in the conceptual design phase is

the factor that contributes to the rises of the design problem in the manufacturing

process. Traditionally, designers work as „over-the-wall approach‟ which the

designer design the product, and pass the concept to the manufacturing engineer,

who need to solve various manufacturing problems as they are not involve in the

initial design stage. However, the concurrent engineering can avoid this problem and

helps them to study the proposed design in the point of view of manufacturing

constraint and cost before it comes to production phase.

12

Figure 2.1 Overall engineering cost [9]

Figure 2.2 Graph of cost of changes versus the design phase [10]

In other perspective views, practices of concurrent engineering in a

companies‟ product introduction may obliterate the innovation and creativity of

designer. A limitation in manufacturing process always become constrain of design.

In the aspect of engineering, problem solving is the core of this discipline.

Application of concurrent engineering will lead engineer or designer to parry

problems rather than solving it. As consequence, the creativity of designer is limited

and the companies will lose its competitive in the market. As quoted from James

Dyson “We want people who are creative and courageous – unconditioned fresh-

thinkers. We don‟t strap people in a suit and plank them behind a desk, we like to

10%

25%

65%

Overall Engineering Cost

Design Stage

Manufacutring

Maintenance & modification

13

give people the chance to make a difference.” Dyson is a company with an

outstanding commitment in developing innovative solutions to daily problems. From

James Dyson‟s point of view, design engineer should not limit by any constraint to

keep the engineer‟s creative and innovative mind.

2.2.2 Design for Manufacturing

Manufacturing of parts or products mean the conversion of raw materials into

a usable, functional shape. Each of the process that involve the change in shape,

properties of raw materials is called manufacturing process. In producing a product

or component, each manufacturing operation consumes time and labour cost. Design

for Manufacturing is a systematic process to maximize the use of manufacturing

process in the design of component [12]. If the design of components considers the

manufacturing process in the design phase, it may minimize the overall

manufacturing operation, in other term; it can reduce the manufacturing cost. The list

below show the some of the guidelines of product design for manufacturing:-

i. Avoid the slow manufacturing process and design the components for

high speed continuous processes

ii. Simplify the design details and avoid expensive operations that not really

need to achieve specification

iii. Avoid the use of small tolerances in the manufacturing a component

iv. Design the component that can be machined with minimum number of

standard tool

v. Use standards procedure in manufacturing components if possible

vi. Design the components in uniform wall thickness and cross-sectional

14

2.2.3 Design for Assembly

Design for Assembly is a systematic procedure to maximize the use of

components in the design of a product [12]. The procedure of maximizing the uses of

component also means the simplification of the product so that the overall cost of

assembly is reduced. Design for Assembly is important in the beginning of design

phase as it need to analyze the part component and the whole product for the

assembly problem to achieve the target on easy, low-cost and functionality. There are

some basic guidelines for Design for Assembly:-

i. Minimize components count by incorporating maximum functions into

single component

ii. Modularize multiple parts into single subassemblies

iii. Standardize to reduce the part variety

iv. Design the mating features for easy insertion

v. Provide orienting features on un-symmetries

vi. Eliminate fasteners

2.2.4 Design for Environment

The concept of Design for Environment firstly introduced in the early of

1990s to built environmental awareness into the product development efforts. Design

for Environment also may refer to Eco-design, Life Cycle Design, Design for Eco-

efficiency and Sustainable Design. According to Joseph Fiksel:

“ Design for Environment is the systematic consideration of design performance

with respect to environmental, health, safety, and sustainability objectives over the

full product and process life cycle” [13].

Typically, there are obviously a broad range of guidelines and practices that

can be considered. In short, the Design for Environment are divided into four

principles strategies:-

15

i. Design for Dematerialization refers to the reducing of the total amount of

materials as well the corresponding energy requirements, for a product and its

associated processes throughout their life cycle.

ii. Design for Detoxification refers to reduce and eliminate the poisonous, toxic,

and hazardous product or by-product that affects the humans or the

environment.

iii. Design for Revalorization refers to recover, recycle, or otherwise reuse the

residual materials and energy that generated at each stage of the product life

cycle, thus eliminating waste and reducing virgin resource requirements.

iv. Design for Capital Protection and Renewal seeks to ensure the safety,

integrity, vitality, productivity, and continuity of the human, natural, and

economic resources that are needed to sustain the product life cycle.

2.3 Soilless Culture - Hydroponic

In last few decades, the world of agriculture has shifted dramatically with the

rise in human population and the living standard, the demand for food is getting

higher. The consequence of this situation had lead to the changes of agriculture

method, from conventional soil growing to a soilless culture - hydroponic.

2.3.1 History of Hydroponic

The word „Hydroponics‟ was coined by Dr. W.F. Gericke [14], a professor

from University of California in year 1934 to describe the cultivation of both edible

and ornamental plants in a solution of water and dissolved nutrients without the

presence of soil medium. The word „Hydroponics‟ is derived parallel relationship

with the word “Geoponics”, the Greek word meaning “Earth Working”, or literally

“agriculture”.

16

The earliest published work on hydroponics was in year of 1627, this concept

has actually been developed as early as the pyramids time when the citizen had

successfully built one of the Seven Wonders of the World - Hanging Garden of

Babylon.

2.3.2 Advantages of Hydroponics

By practicing hydroponic methods, plants are grown healthier than soil

grown counterparts since the plant received a balanced diet and do not come into

contact with the soil borne pests and diseases. High efficient hydroponics system can

prevent the evaporation of solution and hence conserve the nutrients and the water

needed by the plants to grow. Meanwhile, unlike the conventional agriculture

methods, hydroponic crops can grow closer without starving for nutrient in a

confined space. This is commercially important since healthier crops can be grown in

larger amount at once (higher productivity). Furthermore, hydroponically grown

cultivation can cut-off the soil preparation cost, insecticides, fungicides and losses

due to drought and ground flooding.

In other point of views, plants normally waste huge amount of energy to

develop their roots to search for the sufficient nutrient and water under the ground.

However, this energy can be conserved in hydroponic crops since the nutrient and

water are supplied directly to their roots. As a result, the conserved energy can be

redirected to the production of more foliage, flowers, fruits and vegetable.

Moreover, hydroponics farming has been known as the eco-friendly farming

method due to its low consumption of water and fertilizer usage compared to the

conventional growing method. In traditional farming, forests or the old grown

cultivation on a land are burnt into ashes to produce soil enriched with nutrient for

the next production of crops. This has raised a lot of environmental issues that can be

actually avoided. The nutrient used for hydroponics farming is non-toxic and hence it

creates no harm to the natural ecosystem.

17

2.3.3 Hydroponic Methodology

There are several types of hydroponic system that commonly practice by

farmers. Each hydroponic system has its own advantages and limitation in growing

vegetables. The detail of each hydroponic system was discussed in section below.

2.3.3.1 Ebb & Flow Garden System

Ebb & Flow Garden System as shown in Figure 2.4 is a method which the

plants are being flooding with nutrient rich solution and then drain back into the

reservoir. The Ebb and Flow Garden System also refer as Flood & Drain System.

With the simplicity, inexpensive apparatus and set up cost, this method becomes a

favourite among hydroponic grower. The cycle of flooding and draining will be

repeated until the plants are grown. The flooding and draining cycle will be repeated

several times a day by a submersible pump that has been placed on a timer. When the

pump is switch on, aerated fertilizer solution will be pump to the tray that filled with

plants. Then, aerated fertilizer solution will flow back into the reservoir without any

waste of nutrient and water when the pump is turn off.

2.3.3.2 Drip Feed

In Drip Feed method as shown in Figure 2.5, the plants are fed by inject

fertilizer solution directly to the growing medium. This is done by a pump and

injection system using water pressure or using the gravity with a water tank above

the plants. This technique is one of the most popular methods of grow plants as this

method can distribute nutrient solution evenly through a series of drip lines to a large

plant site. The method is suitable for a larger system or larger area of irrigation.

18

2.3.3.3 Aeroponics

In Aeroponics methods, growing plants are suspended in the air as shown in

Figure 2.6. The nutrient solution will be spray direct to the roots. This technique is

suitable for growing root vegetables. The grower can harvest the plant roots without

removing the plant. The overall set up cost and operation cost are relatively higher

than other hydroponics methods as the zero growing medium is used. Without

growing medium, the plants need moist at all the times by running the pump

continuously or extremely high frequency which will lead to the increase of

electricity usage. Therefore, the Aeroponic method is rarely applied for the

commercial use.

2.3.3.4 Nutrient Film Technique

Nutrient Film Technique fed the plants by constantly flow a thin film of

nutrient solution across the plant roots in the tray of pipe. This method has the same

problem as the Aeroponic, which the roots of the plant may dry out in a very short

time once the pump failure or shut down. This problem may be solving by increase

the growing medium by adding Perlite or lava stones to keep moisture. This method

is relatively simple in term of components compare to drip feed and suitable for

growing leafy vegetables and herbs at the commercial production level as shown in

Figure 2.7.

2.3.3.5 Deep Water Culture (DWC)

Deep Water Culture is one of the hydroponic methods that roots are

submerged in nutrient solution with air are provided by air pump or air stone. This

method is simple and can ensure the high level of humidity in the root zone. There is

limitation of this method, if the source of oxygen in the nutrient solution is low, the

19

plants are hardly to maintain vigour, but this can be solved by the proper design of

the system. Deep Water Culture method are popular because of high productive and

is popular for growing herbs and lettuce as shown in Figure 2.8.

Figure 2.3 Ebb & Flow Garden Growing System

Figure 2.4 Drip Feed System

20

Figure 2.5 Aeroponics

Figure 2.6 Nutrient Film Technique.

21

Figure 2.7 Deep Water Culture

2.4 Vertical Planting

Indoor farming is not a new practice since the greenhouse production of

vegetables has been in vogue for a long time. Now, an entirely new development of

indoor farming has to be invented with applying advanced technology to

accommodate the demand of food in the future. Plant the food vertically can be the

solution for it! Vertical Farming was first suggested in the year 1999 by Dickson

Despommier, a professor of environmental health at Columbia University in New

York City [17]. In urban city, high rise building was built to solve the problem of

lack of land; it is the same concept that applies in vertical farming. New era of

agriculture will shift from country side to high population urban city, and even in the

high rise building in the business area.

In an ideal situation, vertical farming can bring a lot of advantages to

environment, social and human. The major advantages are as follows:-

i. Increase the yield by precise climate control

ii. Safe from natural disaster that will cause reduce in yield

iii. Reduce environment pollution

22

iv. Encourage ecosystem recovery

v. Reduce Carbon Footprint

vi. Generate renewable energy from biomass

2.5 Vertical Farming Products Comparison

There are many products available in the market. In this section, the products

that related to vertical farming were being chosen and analyzed. The information will

be tabulated in table form for easy comparison between each product.

2.5.1 Aerofarms Aeroponic Farming (AAF)

The plants are grown without sunlight and soil is the special characteristic of

Aerofarms. Without the needs of sunlight, it can provide yield year round and in any

location. This Aerofarms Aeroponic Farming is designed in modular form, which

can be vertically stackable with an external support structure. Aerofarms able to

generate profit and applied in commercial scale production in urban city.

Figure 2.8 The Aerofarms Aeroponic Farming [18]

23

2.5.2 Tower Garden Growing System (TGGS)

The Tower Garden Growing System is a product that promotes vertical

farming. Tower Garden Growing System applied Aeroponic method which the

nutrient solution will be directly fed to the roots. This five feet tall Aeroponic

vertical garden with components of net pots, pump and drain tube allow growing of

20 plants together with a shorter time to harvest compare to conventional farming

method.

Figure 2.9 Tower Garden Growing System [19]

2.5.3 Vertical Aeroponic Growing System (VAGS)

The Vertical Aeroponic Growing System contains a Bio-shelter Structure

which provides a suitable growing environment to the plants. There are many

vertical aeroponic growing tubes utilize in the system to increase the yield of plant in

a limit area. This Vertical Aeroponic Growing System can achieve 6 to 7 times the

output of a conventional greenhouse [20]. The types of plant that can be grown in

this system include garden vegetables, berries, flower, and herbs.

24

Figure 2.10 Vertical Aeroponic Growing System [20]

Table 2.1: The comparison of Vertical Farming Product/System

Criteria AAF TGGS VAGS

Size Modular Size

with can combine

into large system

5 feet height Module: 12ft x

6ft x 10ft

Practical size:

1000sq.ft

Components Light Emitting

Diode (LED)

Cloth Medium

Pump

Support Structure

Solution

Chamber

Net pots

Wall Frame

Pump

Tomato Cage

Bio-shelter

Grid-beam

support

structure

Vertical rotation

equipment

Advantages Nutrient Re-

circulation

Indoor Growing,

Pesticide free

Low

Contamination

Risk

Modularity Size

for speedy

installation

Fits easily on

urban house,

balconies

Suitable for

outdoor and

indoor

Height can be

increase

Suitable for

almost all the

vegetables

Non-stop

production

cycle

Low dependent

on human

power

Nutrient supply

in closed circuit

Weakness Suitable for

growing, not

Standalone

unit

Extra cost on

Bio-shelter

25

design for

harvesting

The inner part of

the module

hardly reach by

hand

Extra support

structure are

needed

Not suitable

for

commercial

scale

production

May be

collapse in

windy season

High

Maintenance

cost on

rotational

component

CHAPTER 3

RESEARCH METHODOLOGY

3.1 Introduction

In this chapter, project methodology was discussed in details. The

methodology for the project was divided into 4 parts which were preliminary data

analysis, design analysis, engineering analysis and simulation. Figure 3.1 shows the

brief research methodology for the project. Each part was discussed further in the

following sections.

Figure 3.1 Project research methodology

Start

Problem Identification

Design Analysis

Engineering Analysis

End

27

3.1.1 Problem Identification

Problem identification was the first step of the research methodology.

Information that gains from the literature review was categories into few categories

which were problem backgrounds, engineering, and design.

At the beginning of the problem identification, the related information was

extract from the journal, newspaper or magazine. Then, the process continues with

the semi structure interview session with the personnel from Malaysia Agriculture

Research and Development Institute (MARDI) in Cameron Highland. With all the

information in hand, it was analyzed by statistical method. Statistical method is a

method of analyzing or representing some sort of data, these include histogram, pie

chart and tables. At the end, a list of product design specifications was prepared for

the concept generation.

Figure 3.2 Problem identification flow chart

28

3.1.2 Design Analysis

After the preliminary data analysis, the results that obtained were used to

generate the product design specification. As shows in Figure 3.3, concept generation

was done by idea generation by associate studies and using Morphology Chart as a

tool. Creative idea always comes from the ability of identify the same characteristic

of the available product in the market.

First, the overall ideas were sketched on the paper. Each concept was

evaluated to ensure it fulfils the design criteria. Then, all the concepts were brought

to the personnel with agricultural background for an interview. During the interview

session, each concept was explained. The feedback from them was used as one of

criteria for choosing the best concept. At the end of design analysis, the best concept

was determined by Matrix Assessment Method.

Figure 3.3 The process flow for design analysis

29

3.1.3 Engineering Analysis

Figure 3.4 shows the process flow for the engineering analysis. From the final

concept, detailed dimension was determined. A modelling process was started by

using Computer Aided Design (CAD) called Solidworks. Solidworks is a powerful

tool for Three Dimensional (3-D) modelling. After modelling process, a materials

selection process was come in for proper materials selection of the product.

Weighted Property Method was used as a tool for materials selection as this method

is easy and can shown the different characteristic of materials on the performance

need of the product. With proper materials selection, each component’s stress

distribution and safety factor was calculated and stimulated by Solidworks

SimulationXpress. If the safety of the component is not achieved, the process will

loop back to the modelling process to modify the design of the components. At the

end, detailed dimension and simulation of each component was ready.

Figure 3.4 Engineering analysis flow chart

CHAPTER 4

CONCEPT AND DESIGN SELECTION

4.1 Introduction

In this chapter, the development of final design of light weight structure for

vertical planting system was discussed. Each proposed designs were evaluated and

the best proposed design was proceed to next phase.

4.2 Concept Generation

There were 3 proposed designs of light weight vertical structure for vertical

planting system. Ideas of these 3 proposed design was come from the Morphology

chart as attached in Appendix B. Each proposed design has its own special features

and characteristics.

4.2.1 Proposed Design 1

The overall concept for the proposed design 1 was shown in Figure 4.1. The

main structure column or beam was square in shape since this can contribute to

higher second moment of area compare to other shape. Besides that, the simple

square shape beam can be joint easily compare to other shape like round shape. In

31

order to design the structure into easy assembly, there was standard joint for all

connection as shown in Figure 4.2. Each joint was secure by using screws or bolts for

stronger connection. For the roof structure, the design of triangle shape can provide

natural ventilation of the structure. On the other aspect, the hydroponic system that

proposed in this design was Ebb & Flow Garden Growing System. This hydroponic

system is the most common system that applied for commercial purpose because of

its high production rate with precise control of water flow.


The proposed design 2 was based on the concept of shipping container as

shown in Figure 4.3. The Box shape designs of structure able each crucible to stack

together like shipping containers in the port. From Figure 4.4, the box shape design

of the vertical planting structure was design with Nutrient Film Technique

hydroponic system where it offers a lighter weight to the structure. Each crucible was

design with simple connection mechanism that allows user to enlarge or reduce the

size of it. For the exterior structure design, the transparent flat roof top offers the

maximum sunlight as primary source for plant’s photosynthesis. Besides that, the

exterior wall offer extra protection of plants toward different weather in Malaysia.

Figure 4.1 The proposed design 1 for the light weight vertical planting structure

32

Figure 4.2 Joints that use in proposed design 1

Figure 4.3 Proposed Design 2 which uses the concept of shipping container

Figure 4.4 The view of interior structure of the proposed design 2

33


The proposed design 3 is shown in Figure 4.5. The idea of propose design 3

was based on the construction of building structure using structural beam. With the

reference from the industrial beam joining method, bolts and nuts are the joining

methods for the structure. The hydroponic system that use in the proposed design 3

was Aeroponic which offer the minimum usage of water to grow vegetables. Besides

that, the flat slope design of roof top offers a suitable platform for the installation of

solar cell as the secondary source of electrical power. Furthermore, the flat slope

design of rooftop can be used as rain water collection area for rain water harvesting

system. From the proposed design 3, the planting columns are design versatile so

that the total production can be adjusted according to the needs.

Figure 4.5 Proposed design 3 for vertical planting system

Figure 4.6 The skeleton structure for the vertical planting system that built by

structural beam

34

4.3 Design Selection

Each proposed design was evaluated and critics in order to fulfil the

requirement as stated in the product design specification (PDS). There were 3

proposed concepts in total and all these concepts were evaluated by using Matrix

Assessment Table as shown in Table 4.1.

All 3 proposed design were judged by 9 criteria which are ease of assembly,

ease of disassembly, time consume for assembly and disassembly, total types of

components, ability in weather proof, aesthetic, flexibility and land condition

requirement. Each criterion was given by different weight in evaluation according to

the importance of the criteria.

Each criterion in the table was judged by comparison among 3 proposed

concepts. The concept that fulfils the requirement the best were given 1 mark, while

the weakest were given -1 mark. Then, the marks were multiply with the weight that

assign to each criterion and sum up. The proposed concepts with highest marks were

chosen to design finalizing.

From the Matrix Assessment Table below, proposed concept 2 were chosen

to proceed to design finalizing. This result was coincidentally same as the survey

result from the Malaysian Agriculture Research and Development Institute (MARDI).

Personnel from MARDI were chosen proposed concept 2 as the proper concept of

vertical planting structure.

Table 4.1: The Matrix Assessment Table for the selection of final design concept

No Criteria Weight Concept

1

Concept

2

Concept

3

References

1 Assembly Easily 10 1 0 -1

2 Disassembly Easily 7 -1 0 1 D

3 Assembly Fast 8 0 1 -1 A

4 Disassembly Fast 3 -1 0 1 T

5 Total types of

Components

4 -1 0 1 U

6 Weather Proof 7 0 -1 1 M

35

7 Aesthetic 4 0 1 -1

8 Flexibility 7 0 1 -1

9 Land Condition 5 1 -1 0

Total '+' 2 4 3 0

Total '-' 2 2 5 0

Overall Total 0 2 -2 0

Grand Total 1 7 -8 0

4.4 Design Finalize

Although proposed concept 2 were the best concept among 3, further

improvements were done to make it better. The improvements were focused on the

certain aspect as discussed in section below.

4.4.1 Beam and Column

During the proposed design stage, the beam and column of the vertical

planting structure was design into complex shape which may offer flexibility in

structure but flexibility does not offer an easier way to join between each other. Since

the final design was focused on the simple cube shape structure, flexibility in

structure is not required. At last, the complex shape of beam as shown in Figure 4.7a

were improved to square shape beam as shown in Figure 4.7b.

(a) (b)

Figure 4.7 Design of beams

36

4.4.2 Joining Method

The original design of beam as shown in Figure 4.8a, the connection between

the joint and the beam was secured by extra components. With this design, it

increases the complexity of the overall structure. In order to simplify the design, the

joining method was changed to standard mechanical joint, which were bolt and nuts

like shown in Figure 4.8b.

(a) (b)

Figure 4.8 Design of joint

4.4.3 Stacking Feature

Stacking assembly was an important character for the proposed concept 2 to

achieve the concept of vertical planting. In the proposed design 2, the structure was

designed on simple stacking which cause slip and collapse may happened easily

when the base structure is not in perfect horizontal. In the final design, a smaller

beam as shown in Figure 4.9b was add on it so that the structure can have more

stable connection between each other.

37

(a) (b)

Figure 4.9 Design of stacking feature

4.4.4 Lifting Feature

When the structure need to lift to higher place, a simple joint is needed to

perform the task. From the proposed design 2, the concept used was lifting the

skeleton structure to the higher place and assembly the accessories parts on the spot.

After the consideration, the design was improved. A circular tube was added into the

box beam which use to connection of stacking. While lifting procedure was needed, a

hanger can add on it like shown in Figure 4.10 and the structure is ready to lift.

Figure 4.10 Design of lifting feature

38

4.5 Final Concept

From the design analysis, 3 proposed design were undergoes evaluation via

Table Assessment Matrix. Proposed concept 2 are the best solution among the 3 and

this concept were undergoes several improvement as discussed at section before. At

last, the final design of the light weight structure of vertical planting system as shown

in Figure 4.11 was ready to proceed to engineering analysis.

Figure 4.11 The isometric view of the final design

Figure 4.12 The stacking assembly of the vertical planting structure

CHAPTER 5

ENGINEERING ANALYSIS

5.1 Introduction

Materials and safety of the light weight vertical planting structure were the

concern of the design. In this chapter, detail materials selection processes were

discussed. Besides that, several types of analysis on the critical point of the structure

were discussed in detail to ensure the structure that design is safe and reliable.

5.2 Materials Selection

The interaction between the materials properties and its application and the

need to adopt concurrent engineering approach is important to increase the

performance of the design. Therefore, a formal rating method is needed to determine

how well the materials in Table 5.1 were meets the rigid requirements as stated in

Table 5.2. The formal method that will be discussed here is the Weight Properties

Method. This method rates the materials by giving greater weight to the more

important requirement by Digital Logic Method as show in Appendix C. From Table

5.1, materials that were identified as defender are the common materials that used in

structural design. However, few challengers were included into the list as alternative

materials.

40

Table 5.1: Candidate Materials for Materials Selection Process

No Defenders Challengers

1 Aluminium 6061-T6 Glass Fibre Reinforced Polymer (E class fibre system)

2 Steel ASTM A36 Carbon Fibre Reinforced Polymer

3 Stainless Steel 304

Table 5.2: Rigid Requirement of the Materials Selection Process

No Rigid

Requirement Reason Objective

1 Yield Strength High strength for higher performance Maximum

2 Density Reduce the overall weight of the

structure Minimum

3 Cost Reduce materials cost Minimum

4 Corrosion

Resistance

Need to expose to weather and

corrosive environment Maximum

5 Carbon Dioxide

Burden

Parallel with the theory of Design For

Environment Minimum

From the calculation as attached in Appendix C, performance index of each

materials were shown in Table 5.3. The material with highest performance index (γ)

has been chosen as the most suitable material for the design requirement. By

referring to Table 5.3, it shows that Glass Fibre Reinforced Polymer (GFRP) has the

highest performance index compare to other candidate materials, which is 70.76. In

other words, GFRP appeared to be the most suitable materials for the light weight

vertical planting structure design.

Table 5.3: Performance Index (γ) of each candidate materials

41

5.3 Detail Computer Aided Drawing

Final design of the light weight structure for vertical planting system was

generated by using Computer Aided Design (CAD) – Solidworks. Each component

in the structure was drawn into three Dimensional (3D) modelling and converts it

into two Dimensional (2D) engineering drawing and attached in Appendix D. For

easy explanation in coming sections, each component was labelled as shown in

Figure 5.1 and Table 5.4.

Figure 5.1 Vertical planting structure components

Table 5.4: Bill of Materials

ITEM NO. PART NUMBER QUANTITY

1 Box Beam 102x102x6.4 (2398) 38

2 Box Column 102x102x6.4 (2500) 8

3 Angle Connector 96

4 Corner Joint Plate 16

5 Middle Joint Plate 8

6 Preferred Wide FW 0.375 640

7 HNUT 0.375-24-D-N 320

8 Hex Bolt-ai 320

42

5.4 Engineering Analysis

Final design of the light weight structure for vertical planting system was

analyzed to ensure the safety of design and prevent failure of components. From the

material selection process, GFRP is the most suitable material for the vertical

planting system application. By referring to the data sheet from the GFRP supplier,

relevant data like physical properties of the GFRP were extracted as shown in Table

5.5.

Table 5.5: Properties of Glass Fibre Reinforced Polymer (GFRP) [21]

Property Value

Poisson’s Ratio 0.33

Tensile Strength 290MPa

Tensile modulus 18GPa

Flexural Modulus 250MPa

Compressive Strength 125MPa

Impact Strength 100KJ/m²

In order to simplify the engineering analysis, several assumptions were made:

i. Engineering analysis was done under static condition.

ii. The acceleration of gravity, g is 9.81𝑚/𝑠2.

iii. All the loads are distributed equally to each column of the structure.

iv. Both end of the column is considered as fixed end, where K=0.5 for

buckling analysis.

v. Average weight of a person is assumed as 70kg and act as point load.

vi. GFRP is considered as isotropic material, where the mechanical

properties at axes X, Y, Z is the same.

43

5.4.1 Loading Define

Total load of the structure was divided into two categories, which were dead

load and live load. Dead load refers to the weight that remain unchanged or the

weight that caused by the structure itself, it can comes from the weight of the

component, hydroponic system, bolts, nuts, and others. On the other hands, the live

load refers to the weight like human weight, water, and vegetables weight that is not

constant. For engineering analysis, the total of dead load and live load were used as

the critical load that acts toward the structure. From the estimation from Solidworks

and the calculation as attached in Appendix E, the total load of each unit of vertical

planting structure is 1924.20kg, which equivalent to 18876.38N.

5.4.2 Stress Analysis

All the components in the vertical planting structure were analyzed based on

two failure theories, which were Maximum-Normal-Stress Theory and Distortion

Energy Theory. Maximum-Normal-Stress is suitable to apply for all brittle materials

where failure occurs whenever one of the three principles stresses equals or larger

than the strength of materials [22]. However, Distortion Energy Theory is suitable

for ductile materials where yielding occurs when the distortion strain energy per unit

volume reaches or exceeds the limit in simple tension or compression on the same

materials [22].

In stress analysis, the weight of the structure will act as load to the base

structure. The entire load was distributed to the box column of the vertical planting

structure equally. Two types of stress analysis were done on the vertical planting

structure, which were tensile analysis and compression analysis.

44

5.4.2.1 Tensile Stress

When the structure was lifted for stacking assembly, the lifting procedure will

give a tensile force to the box column as shown in Figure 5.2. Tensile force from the

hanger and the weight of the structure caused the box column in tension situation.

The stress that applied to the box column can be calculated by the formula as below:

𝜎𝑇 =𝐹

𝐴

From calculation as attach in Appendix F, the tensile force created a stress of

3.21MPa to the box column with a thickness of 6.3mm. Based on the Maximum-

Normal-Stress Theory, the overall safety factor of the column in tensile stress was 90.

Figure 5.2 The tensile force that act on the box column of the vertical planting

structure

5.4.2.2 Compressive Stress

From the product design specification, the structure was designed for a

maximum level of three, which means that extra two unit of vertical planting

structure will stack on the ground vertical planting unit as shown in Figure 5.3.

45

Figure 5.3 The stacking assembly of the vertical planting structure

By total up the weight of above structure, this will create a total load of

37752.76N act on the base structure. By assuming load were distribute equally to

eight columns of the structure, each box column from the base structure will received

a compression load of 4719.09N from above structure. Then, base structure was

categorized into two parts which were upper parts and lower parts as shown in Figure

5.4. These were giving an extra loading to box column in different section. The

calculation was based on the Maximum Normal Stress Theory and attached in

Appendix F; the columns were safe from compression loading with a safety factor of

43.

46

Figure 5.4 The upper and lower parts of the vertical planting structure

5.4.3 Buckling Analysis

Figure 5.5 Box column 102x102x6.4 (2500) from the vertical planting structure

When a long slender members as shown in Figure 5.5 subjected to an axial

compression like the situation that faced by the box column in the vertical planting

structure, lateral deflection or buckling can occurs. Buckling of column can lead to a

47

sudden failure of a structure. Critical axial load of the box column can be calculated

by the formula as below:

𝑃𝑐𝑟 =𝜋2𝐸𝐼

(𝐾𝐿)2

From the calculation as attached in Appendix G, the maximum load that can

apply to the box column before buckling was 186.48kN, which equivalent to

76.2MPa. Since the critical stress of the box column was smaller than the yield stress,

it is conclude that the box column will only failed by buckling before the

compression. Based on Maximum Normal Stress Theory, the safety factor of the

column in the vertical planting structure was 26.

5.4.4 Deflection and Displacement Analysis

The allowable deflection and displacement of beam was set in less than 5mm

and 2mm respectively. Box beams as shown in Figure 5.6 were undergoes deflection

analysis and box columns as shown in Figure 5.5 were undergoes displacement

analysis. As attached in Appendix H, it was assumed that the box beam was applied

with a load of a human with 70kg in the centre of beam. Maximum deflection

happened at the centre of beam with a maximum deflection of 2.3mm which was

within the specifications. A further analysis was done to the beam with a dimension

of 76mm x76mm, the results shown the deflections of this type of beam was out of

specification which is 5.93mm. As the result, the beam of size 76mm x 76mm was

not suitable for this structure. Thus, beam with size of 102mm x 102mm was chosen.

The displacement analysis was carried out for the box column. Displacement

of the box column can be calculated by the formula as below:

𝛿 = ∑𝑃𝐿

𝐴𝐸

48

By dividing the box column into few sections as the attachment in Appendix

I, the total displacement of the column was 2.96𝑥10−4𝑚 which is within the

specification of less than 2mm.

Figure 5.6 Box beam 102x102x6.4 (2398) from the vertical planting structure

5.4.5 Bolt and Member Analysis

There were two types of joint in the vertical planting structure as shown in

Figure 5.7. Each component was connected together by bolts and nuts. From the bolt

analysis in Appendix J, the austenite stainless steel bolt with a diameter of 5mm and

coarse-pitch was chosen initially. The bolts had a safety factor of 18 by applying

Distortion Energy Theory. However, from the calculation that attached in Appendix

K, the bolt with 5mm diameter was created a shear load of 55.15MPa to the corner

joint plate. By this, the safety factor of the plate was 2, which was too low.

In order to increase the safety factor of plate, the increase of the area of stress

is one of the solutions. The area of stress was increased by increasing the diameter of

bolt to 10mm. By this, the shear stress was reduced to 27.6MPa and the safety factor

49

of plate was increase to 4. Re-calculation of the safety factor of bolt was done and it

shown a significant increase from 18 to 75.

Figure 5.7 Joint connection of the vertical planting structure

5.5 CAD Software Simulation

Some components were analyzed using Solidworks SimulationXpress.

Information that can extract from the simulation was von-Mises stress and

displacement. Figures in this section show the simulation result of Box Beam, Box

Column, Corner Joint Plate, and Middle Joint Plate.

Figure 5.8 shows the stress distribution of the box column when under

compression loading. From Figure 5.8, there was a large area of the cyan colour Box

column surface. It means that the stress distribution on the part was around 3MPa.

This results is almost the same as the manual calculation that done before.

50

Figure 5.8 The stress distribution of lower part of box column while under

compression loading

Figure 5.9 shows a tensile loading of the box column when the structure was

lifted to a higher place. From the Figure 5.9, the area that in orange colour indicates

the highest stress distribution. The highest tensile stress that obtained from the

simulation was around 4MPa, which is almost the same as the result from manual

calculation.

Figure 5.9 The stress distribution of the top part of box column while under tensile

loading

51

Figure 5.10 shows the displacement of the column when under compression

loading. The displacement was the largest on the top section of the column, which

the area was shown in red colour. The maximum displacement of the column from

this simulation was around 0.23mm, which was exactly the same as the manual

calculation.

Figure 5.11 shows the deflection of beam when a point load of 70kg act at the

centre of beam. From the Figure 5.11, it shows that maximum deflection happens at

the centre of beam where the area of beam is in red colour. The maximum deflection

of beam that got from simulation was 0.9mm. This value is different from the manual

calculation. The reason behind it was the different assumptions were made during the

analysis. The beam was assumed as simply supported beam in manual calculation,

but cantilever beam (Fixed end) during the simulation.

Figure 5.10 Displacement of box column while under compression loading

52

Figure 5.11 Deflection of box beam while under a point load condition

Figure 5.12 The stress distribution of corner joint plate

Figure 5.12 shows the stress distribution of corner joint plate when loading

applied on it. The load was come from the bolts and box beam. From the Figure 5.12,

the area that in green colour indicated the high stress area. From the indicator on the

right hand side of the figure, the green colour represents a stress of around 25MPa.

This value was almost the same as result from manual calculation.

53

Figure 5.13 The stress distribution of middle joint plate

Figure 5.13 shows the stress distribution of middle joint plate when load

applied on it. The loads came from the bolts and beam, same as the situation of

corner joint plate. From the Figure 5.13, there was an area of the plate was in cyan

colour, it indicates that the stress was mainly distribute at the centre region of the

plate. The cyan colour shows a stress of around 40MPa. This value was almost the

same as the results that get from manual calculation.

As conclusion, all the components in the structure were once again been

proved by simulation. The results that extract from the simulation were almost the

same as the results from calculation. With this, the reliable of these results were

increased.

CHAPTER 6

CONCLUSION AND RECOMMENDATIONS

6.1 Conclusion

As conclusion, a structure for vertical planting system was proposed. Besides

the light weight as the main characteristic of the vertical structure, the structure was

design into portable and assembles. Each vertical planting structure can assemble to

form a larger farm. By this vertical planting system, the growing of vegetables can be

done within a smaller area compare to conventional farming method. By this, the

vertical planting structure can reduce the impact of agriculture to environment.

Besides that, this innovation can maximize the yield of vegetables without increase

the burden to the environment.

The vertical planting structure was design parallel to the theory of Design for

Environment. Design for Energy and Material Conservation is one of the sub-topics

in the theory of Design for Environment. From this topic, utilizing fewer resources to

deliver equivalent or greater performance and increase the product service life can

reduce the usage of materials and energy. In this vertical planting structure, the main

material of the structure was Glass Fibre Reinforced Polymer (GFRP) with offer an

extra long usage life and higher performance to normal structural alloys as stated in

the theory of Design for Environment.

55

6.2 Recommendations

The design of light weight structure of vertical planting system can be further

improved. The recommendations for further studies are:-

i. Improvement on joining method for the vertical planting structure.

ii. Improvement on the structure for the wider application of more

species of plants like fruiting vegetables, legumes or fruits.

iii. Further development of piping and electrical circuit for the vertical

planting structure like rain water harvesting system and renewable

energy system.

56

REFERENCES

1. Rohaniza Idris. (2012, Jan 29). Ladang Langit. Berita Minggu, p.1 -3.

2. Ooi. (2011). Making Efforts In Sustainability Count. Jurutera, 11, 6 -10.

3. Sustained supply-Keeping it under control. (2010, May 12). The Star. p.1.

4. Kementerian Pertanian & Industri Asas Tani Malaysia, Empat Faktor Tangani

Cabaran Bekalan Makanan,2012

<http://www.moa.gov.my/web/guest/4cabaran_bekalanmakanan>, (Retrieved

December 7, 2012)

5. Malaysia belanja RM92j sehari import makanan. (2012, July 13). Berita Harian.

p.19.

6. Ministry of Agriculture and Agro-based Industry, Malaysia. Agrofood Statistics

2011. Malaysia: Strategic Planning and international Division. 2012

7. Metra Syahril Mohamed. (2012, July 13). Import makanan cecah RM92j sehari.

Utusan Malaysia. p.26.

8. Wealth Creation On Agriculture Innovation. (2012, August 10). Business and

Financial. p.58-60.

9. Components, C. o. E. T. f. U. L.-C. E. o. S., C. o. Engineering, et al. (1991).

Enabling Technologies for Unified Life-Cycle Engineering of Structural

Components. Washington, DC: The National Academies Press.

10. John R. Hartley. Concurrent Engineering: Shortening Lead Times, Raising

Quality, and Lowering Costs. Portland, Oregon: Productivity Press. 1992

11. Salzberg. S and Watkins. M. Managing information for concurrent engineering:

challenges and barriers. In S. Culley. Research in Engineering Design. London:

Springer-Verlag. 35-52; 1990

12. K.L. Edwards. (2003). Towards more strategic product design for manufacture

and assembly: priorities for concurrent engineering. Materials and Design; 23:

61-656

13. Joseph Fiksel. Design for Environment. 2nd

ed. New York: McGraw-Hill. 2012

57

14. Stewart Kenyon. Hydroponics for the Home Gardener. Canada: Key Porter

Books. 1992

15. Discovery Hydroponics

<http://discoverhydroponics.com/wp-content/uploads/2011/03/Aeroponics-

Squash.jpg>, (Retrieved December 8, 2012)

16. Aquaponiceaay.com

<http://aquaponicseasy.com/images%20for%20aquaponics/deepwater%20culture

%20or%20raft%20system%20aquaponics.jpg>, (Retrieved December 7, 2012)

17. Time Magazine, Vertical Farming

<http://www.time.com/time/magazine/article/0,9171,1865974,00.html>,

(Retrieved December 8, 2012)

18. Aerofarm

<http://aerofarms.com/why/technology/>, (Retrieved December 3, 2012)

19. Tower Garden

<https://www.towergarden.com/online-store/tower-garden-growing-system>,

(Retrieved December 3, 2012)

20. Reinhold Ziegler (2005).Vertical Aeroponic Growing System. Synergy

International Inc.

21. Dura Composites Ltd (2009) Fiberglass Pultruded Sections: Dura profile

[Brochure]. United Kingdom: Dura Composites

22. Richard Budynas and Keith Nisbett. Shigley’s Mechanical Engineering Design.

6th

ed. New York: McGraw-Hill. 2011

https://www.towergarden.com/online-store/tower-garden-growing-system

Appendix A

Product Design Specifications 58

1. User

The system shall target entrepreneur as customer (money is not a constraint

as long term investment)

2. Farming Technique

The technique used in the system must be soilless (hydroponic)

3. Types of Vegetables

The system should can plant leafy vegetable, Brassicas or herbs

4. Weather

The system can cope with the Malaysia’s weather like sunny, raining, and

windy season.

5. Geography

The system should suitable with majority agriculture’s land condition (Hill,

mountain, flat, and valley) in peninsular of Malaysia.

The system should suitable with the Malaysia soil condition (sandy, muddy,

rock, soil)

6. Structure

The structure must be able to built for 1 floor or maximum of 3 floors

The structure must be in modular form, which can be used a single unit or

many unit for high yield.

7. Loading

The structure must be able withstand torsion, tension, bending moment, shear,

and buckling

Each component must be safe. (Safety factor > 3)

The displacement of the component must small (Displacement < 2mm)

8. Joint

The joining of each components must be mechanical joint

The assembly and disassembly process must be easy, which can be done by 3

or less people.

9. Ergonomic

The weight of each component must be able carry by a human

The height of each floor must be able to fit a human height

The in the structure must be large enough for a human to move

Appendix A

Product Design Specifications 59

The working environment in the structure must be safe for human.

10. Materials

The material that used should be corrosion resistance

The material must be able to withstand high loads

The material must be able withstand the UV light

11. Shape

The shape of the parts should be high efficiency (Weight to load ratio)

12. Accessories

The components that design should have a space for accessories installation

(piping and electrical wire)

Appendix B

Morphology Chart 60

* T

he

cust

om

shap

e is

as

bel

ow

:

Cust

om

1

Cust

om

2

Cust

om

3

Cust

om

4

Cust

om

5

Appendix C

Materials Selection 61

Parallel to the objective of the design, a suitable material needs to be selected

as the main materials of the structure. Selecting the most suitable materials among

alternatives requires reliable decision. First, each rigid requirement will give its own

weighting factor (α) by comparison between each requirement. Then, the scaling

factors (β) were calculated according to the objective of each requirement.

Table 1: Weighting Factor (α) of each rigid requirement by Digital Logic Method

From Table 1, each Relative Emphasis Coefficient is given the weight by

comparison between 2 goals. The more important goal was given ‘1’ while the less

important was given ‘0’. Then, the Relative Emphasis Coefficient is calculating by

convert the positive decision of each goal to equivalent proportion.

Table 2: Scaling Factor (β) of each candidate materials

For a given property, the scaling factor (β) for each candidate materials was

calculated as below. The result of scaling factor of each materials and properties are

as shown in Table 2.

Appendix C

Materials Selection 62

For properties with the objective of maximum requirement:

𝛽 =𝑛𝑢𝑚𝑒𝑟𝑖𝑐𝑎𝑙 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑝𝑟𝑜𝑝𝑒𝑟𝑡𝑦

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑙𝑢𝑒 𝑖𝑛 𝑡ℎ𝑒 𝑙𝑖𝑠𝑡𝑥100

For properties with the objective of minimum requirement:

𝛽 =𝐿𝑜𝑤𝑒𝑠𝑡 𝑣𝑎𝑙𝑢𝑒 𝑖𝑛 𝑡ℎ𝑒 𝑙𝑖𝑠𝑡

𝑁𝑢𝑚𝑒𝑟𝑖𝑐𝑎𝑙 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑝𝑟𝑜𝑝𝑒𝑟𝑡𝑦𝑥100

At the end of the materials selection process, the performance index (γ) of

each material was calculated by the formula as below:

𝛾 = ∑𝛼𝛽

Table 3: Performance Index (γ)

As conclusion, the material with highest performance index is the selected

material which fulfill the requirement the most. From Table 3, the GFRP is the most

suitable material for the design of light weight structure for vertical planting system.

Appendix D

Detail Engineering Drawing 63

Appendix D


Appendix E

Loading Define 74

Live Load

No Items Weight/unit

(g)

Quantity Total

Weight

(kg)

Mass (N)

1 Human 70000.00 4 280.00 2746.80

2 Vegetable 100.00 1944 194.40 1907.06

3 Water 1000.00 316.8 68.43 671.29

Total 474.40 5325.15

Dead Load

No Items Weight/unit

(g)

Quantity Total

Weight

(kg)

Mass (N)

FRAME

1 Box Beam 11018.00 38 418.68 4107.29

2 Box Column 13228.00 8 105.82 1038.13

3 Corner Joint Plate 412.67 16 6.60 64.77

4 Middle Joint Plate 626.83 8 5.01 49.19

5 Angle 328.87 104 34.20 335.53

6 Bolts & Nuts 107.45 320 34.38 337.31

Hydroponic

Accessories

7 PVC Channel 854.11 216 184.49 1809.82

8 Channel Column 3700.34 36 133.21 130.92

9 Channel Support

(Center)

185.35 72 13.35 130.92

10 Channel Support

(Left)

185.35 72 13.35 130.92

11 Channel Support

(Right)

185.35 72 13.35 130.92

Other Accessories

12 Grid 22435.01 12 269.22 2641.05

13 Panel Hold Downs 40.82 48 1.96 19.22

14 Fin Support 1251.4 12 15.02 147.31

15 Fin 496.51 43 21.35 209.44

16 Roof 37125 3 111.38 1092.59

Total 1381.37 13551.23

Total Load = Live Load + Dead Load

= 5325.15N + 13551.23N

= 18876.38N

= 18.876kN

Conclusion: Total weight of a vertical farming unit is 18.76kN.

Appendix F

Stress Analysis 75

Compression Analysis

The vertical planting structure was divided into 2 parts:-

1. Upper Part: Roof structure

2. Lower Part: Hydroponic channel, beam, grid, and etc

Total weight of 2 vertical planting structures,

𝑇𝑜𝑡𝑎𝑙 𝑊𝑒𝑖𝑔𝑕𝑡 = 18876.38𝑁 𝑥 2

= 37752.76 𝑁

This weight was assumed distribute equally to 8 columns of the vertical

planting structure,

𝐿𝑜𝑎𝑑 𝑡𝑕𝑎𝑡 𝑎𝑐𝑡 𝑜𝑛 𝑒𝑎𝑐𝑕 𝑐𝑜𝑙𝑢𝑚𝑛 =37752.76

8

= 4719.09𝑁

No Component Quantity Weight per unit (g) Total (kg)

1 Corner Joint 8 412.67 3.30

2 Middle Joint 4 626.83 2.51

3 Square Beam

(2398)

19 11018 209.34

4 Angle Joint 50 328.87 16.44

5 Bolt & Nut 168 107.45 18.05

6 Roof 3 37125 111.38

Total 361.02

Total weight for the upper part of the structure was 361.02kg, which

equivalent to 3541.61N. This load was assumed transfer equally to 8 columns. Each

column was receiving a compressive load of 442.7N.

𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑙𝑜𝑤𝑒𝑟 𝑝𝑎𝑟𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑠𝑡𝑟𝑢𝑐𝑡𝑢𝑟𝑒 = 18876.38 − 3541.61 − 864.85

= 14469.92

load was assumed distribute equally to 8 columns, where each column was

receiving a compressive load of 1808.74N

Appendix F

Stress Analysis 76

The free body diagram of the column is as below:

↑ 𝑎𝑠 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 ∑𝐹𝑦 = 0

0 = −4719.09 − 442.7 − 108.09 − 1808.76 + 𝐹𝑅

𝐹𝑅 = 7078.64𝑁

Maximum compression zone was at section CD

where 𝐹 = 7078.64𝑁

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 = 1022 − 89.22

= 2447.36𝑚𝑚2

= 2.447𝑥10−3𝑚2

𝑆𝑡𝑟𝑒𝑠𝑠 = 7078.64

2.447𝑥10−3

= 2.89𝑥106𝑃𝑎

𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 =𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑆𝑡𝑟𝑒𝑠𝑠

𝑆𝑡𝑟𝑒𝑠𝑠

=125𝑀𝑃𝑎

2.89𝑀𝑃𝑎

= 43.2

≈ 43

The column is safe from compression load with a safety factor of 43.

Appendix F

Stress Analysis 77

Tensile Analysis

Total weight of 1 unit vertical planting structure= 18876.378𝑁

When the unit is lift up by crane, each column will

attach to a steel cable. Each column will applied a

tensile force of

𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝐹𝑜𝑟𝑐𝑒 𝑜𝑓 𝐸𝑎𝑐𝑕 𝐶𝑜𝑙𝑢𝑚𝑛 = 18876.38

8

= 2359.55𝑁

This tensile force will create a stress to the column

with a thickness of 6.3mm

𝑆𝑡𝑟𝑒𝑠𝑠 = 2359.55

(89.22 − 83.22) − 2 50𝑥3

= 3.21𝑀𝑃𝑎

Then, the safety factor was:-

𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 = 290𝑀𝑃𝑎

3.21𝑀𝑃𝑎

= 90.26

≈ 90

The columns are safe from tensile loading with a

safety factor of 90.

Appendix G

Buckling Analysis 78

Both end of the column is pinned end, where

K=1:

Maximum load that can applied to column

before buckling is

𝑃𝐶𝑟 =𝜋2𝐸𝐼

(𝐾𝐿)2

=𝜋2(86126)

(1𝑥2.135)2

= 186.48𝑘𝑁

The force was create an average compression

stress of

𝜎𝐶𝑟 =186.48𝑘𝑁

2.447𝑥10−3

= 76.2𝑀𝑃𝑎

Since 𝜎𝐶𝑟 < 𝜎𝑦 , the beam will fail by buckling

before fail by compression. Allowable stress is

76.2MPa.

𝑁𝑒𝑤 𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝐶𝑜𝑙𝑢𝑚𝑛 = 76.2𝑀𝑃𝑎

2.89𝑀𝑃𝑎

= 26.36

≈ 26

The new safety factor of the column is 26.

Appendix H

Deflection Analysis 79

Deflection Analysis- Box Beam

Free Body Diagram 1

Free body Diagram 2,

𝑀1 = 343.35𝑋1…… (1)

Free body Diagram 3,

𝑀2 = 343.35𝑋2 − 686.7 𝑋2 − 1.199

𝑀2 = −343.35𝑋2 + 823.35…….. (2)

From (1),

𝑀1 = 343.35𝑋1

𝐸𝐼𝑑2𝑣1

𝑑𝑋12 = 343.35𝑋1

𝐸𝐼𝑑𝑣1

𝑑𝑥1=

343.35𝑋12

2+ 𝐶1

Appendix H


𝐸𝐼𝑑𝑣1

𝑑𝑋1= 171.67𝑋1

2 + 𝐶1 ……..(3)

𝐸𝐼𝑣1 =171.67𝑋1

3

3+ 𝐶1𝑋1 + 𝐶2 ……………. (4)

From (2),

𝑀2 = −343.35𝑋2 + 823.35

𝐸𝐼𝑑2𝑣2

𝑑𝑋22 = −343.35𝑋2 + 823.35

𝐸𝐼𝑑𝑣2

𝑑𝑋2=

−343.35𝑋22

2+ 823.35𝑋2 + 𝐶3

𝐸𝐼𝑑𝑣2

𝑑𝑋2= −171.67𝑋2

2 + 823.35𝑋2 + 𝐶3 ….(5)

𝐸𝐼𝑣2 =−171.67𝑋2

3

3+

823.35𝑋22

2+ 𝐶2𝑋2 + 𝐶4

𝐸𝐼𝑣2 = −57.22𝑋23 + 411.675𝑋2

2 + 𝐶3𝑋2 + 𝐶4 ……….(6)

By using boundary condition:

Substitute 𝑋1 = 0, 𝑣1 = 0 , 𝑡𝑕𝑒𝑛 𝑔𝑒𝑡 ,

𝐶3 = 0 …..(7)

When 𝑿𝟏 = 𝑿𝟐 = 𝟏. 𝟏𝟗𝟗 ,

𝑑𝑣1

𝑑𝑋1=

𝑑𝑣2

𝑑𝑋2

Substitute (3) and (4) into the equation above,

171.67(1.199)2 + 𝐶1 = −171.675(1.199)2 + 823.35 1.199 + 𝐶3

246.79 + 𝐶1 = −246.8 + 987.19 + 𝐶3

𝐶1 = 493.61 + 𝐶3 …….(7)

When 𝑿𝟐 = 𝟐. 𝟑𝟗𝟖,

𝑣2 = 0

Substitute 𝑣2 into equation (6),

Appendix H


0 = −57.225 2.398 3 + 411.675 2.398 2 + 𝐶3 2.398 + 𝐶4

0 = 1578.19 + 2.398𝐶3 + 𝐶4

𝐶4 = −1578.19 − 2.398𝐶3 …… (8)

When 𝑿𝟏 = 𝑿𝟐 = 𝟏. 𝟏𝟗𝟗,

𝑣1 = 𝑣2

Substitute (4) and (6) into above equation,

57.22 1.199 3 + 𝐶1 1.199

= −57.225 1.199 3 + 411.675 1.199 2 + 1.199𝐶3 + 𝐶4

98.63 + 1.199𝐶1 = −98.64 + 591.82 + 1.199𝐶3 + 𝐶4

Substitute (7) into the equation,

98.63 + 1.199 493.61 + 𝐶3

= −98.64 + 591.82 + 1.199𝐶3 − 1578.19 − 2.398𝐶3

98.63 + 591.84 + 1.199𝐶3 = 493.18 − 1578.79 − 1.199𝐶3

1777.08 = −2.398𝐶3

𝐶3 = −741.07 …..(9)

Substitute (9) into (7),

𝐶1 = 493.61 + −741.07

𝐶1 = −247.46

Substitute (9) into (8),

𝐶4 = −1578.19 − 2.398 −741.07

𝐶4 = 198.89

Thus,

𝑪𝟏 = −𝟐𝟒𝟕.𝟒𝟔 , 𝑪𝟐 = 𝟎 , 𝑪𝟑 = −𝟕𝟒𝟏.𝟎𝟕 , 𝑪𝟒 = 𝟏𝟗𝟖.𝟖𝟗

From (3),

𝐸𝐼𝑑𝑣1

𝑑𝑋1= 171.67𝑋1

2 − 247.46

Appendix H


When maximum deflection happens,

𝑑𝑣1

𝑑𝑋1= 0

0 = 171.67𝑋12 − 247.46

𝑋1 = 1.199 𝑜𝑟 − 1.199

Since 𝑋1 > 0, so the maximum deflection happen at 𝑋1 = 1.199𝑚

Substitute 𝑋1into (4),

𝐸𝐼𝑣1 = 57.22 1.199 3 − 247.46 1.199

= −198.075

𝑣1 =−198.075

86126 , 𝑤𝑕𝑒𝑟𝑒 𝐸𝐼 = 86126

𝑣1 = −2.2998 𝑥 10−3𝑚

= −2.3𝑚𝑚

Comment: Maximum deflection of the beam is 2.3mm when a load of 70kg applied

to 𝑋1 = 1.199𝑚.

If the beam size change from 102𝑚𝑚 𝑥 102𝑚𝑚 to 76𝑚𝑚 𝑥 76𝑚𝑚 ,

𝑣 =−198.075

33366 , 𝑤𝑕𝑒𝑟𝑒 𝐸𝐼 = 33366 𝑓𝑜𝑟 𝑏𝑒𝑎𝑚 76𝑚𝑚 𝑥76𝑚𝑚

𝑣 = −5.93 𝑥 10−3𝑚

= −5.93𝑚𝑚

Comment: The deflection of beam is too large (> 5𝑚𝑚), so the beam of size

76𝑚𝑚 𝑥76𝑚𝑚 are not suitable for this structure. Thus, beam with size of

102𝑚𝑚 𝑥 102𝑚𝑚 was chosen. Due to standardization, all the beams or columns

were using the same size.

Appendix I

Displacement Analysis 83

Displacement Analysis- Box Column

According to the free body diagram,

𝛿𝑇𝑜𝑡𝑎𝑙 = 𝛿𝐴𝐵 + 𝛿𝐵𝐶 + 𝛿𝐶𝐷 + 𝛿𝐷𝐸

𝛿𝐴𝐵 =4719.09

2.447𝑥10−3= 1.93𝑥106𝑃𝑎

휀𝐴𝐵 =1.93𝑀𝑃𝑎

2.3𝑥1010= 8.39𝑥10−5 𝑚 𝑚

𝛿𝐴𝐵 = 8.39𝑥10−5𝑥0.185 = 1.55𝑥10−5𝑚

𝛿𝐵𝐶 =5161.79

2.447𝑥10−3= 2.109𝑥106𝑃𝑎

휀𝐵𝐶 =2.109𝑀𝑃𝑎

2.3𝑥1010= 9.17𝑥10−5 𝑚 𝑚

𝛿𝐵𝐶 = 9.17𝑥10−5𝑥1.250 = 1.146𝑥10−4𝑚

𝛿𝐶𝐷 =5269.88

2.447𝑥10−3= 2.154𝑥106𝑃𝑎

휀𝐶𝐷 =2.154𝑀𝑃𝑎

2.3𝑥1010= 9.36𝑥10−5 𝑚 𝑚

𝛿𝐶𝐷 = 9.36𝑥10−5𝑥1.250 = 1.17𝑥10−4𝑚

𝛿𝐷𝐸 =7078.64

2.447𝑥10−3= 2.893𝑥106𝑃𝑎

휀𝐷𝐸 =2.893𝑀𝑃𝑎

2.3𝑥1010= 1.25𝑥10−4 𝑚 𝑚

𝛿𝐷𝐸 = 1.25𝑥10−4𝑥0.180 = 2.25𝑥10−5𝑚

𝛿𝑇𝑜𝑡𝑎𝑙 = 1.55𝑥10−5 + 1.146𝑥10−4 + 1.17𝑥10−4 + 2.25𝑥10−5 = 2.696𝑥10−4𝑚

Comment: The maximum deflection of the column is 2.696𝑥10−4𝑚, which is within

the limitation. The column is considered safe.

Appendix J

Bolt Analysis 84

Total weight of for lower part of the structure is 15334.77N

This load was assumed distribute to 8 columns equally.

𝐿𝑜𝑎𝑑 𝑜𝑛 𝑒𝑎𝑐𝑕 𝑐𝑜𝑙𝑢𝑚𝑛 =15334.77

8= 1916.85𝑁

For Corner Joint 1,

↑ 𝑎𝑠 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 ∑𝐹𝑦 = 0

0 = −479.21 − 479.21 + 𝐹1 + 𝐹2

𝐹1 + 𝐹2 = 958.42𝑁 , 𝐹1 = 𝐹2

= 479.21𝑁

From Free Body Diagram,

𝑟𝐴 = 74.18 , 𝑟𝐵 = 111.92

𝑟𝑐 = 111.92 , 𝑟𝐷 = 74.18

𝑐𝑙𝑜𝑐𝑘𝑤𝑖𝑠𝑒 𝑎𝑠 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 ∑𝑀 = 0

0 = −479.21 0.09353 − 479.21 0.04153 − 479.21 0.06147 𝑥 2 + 𝑀𝐺

𝑀𝐺 = 123.64𝑁𝑚

This moment will give secondary shear to the bolt.

𝑀𝐺 = 𝐹𝐴"rA+FB"𝑟𝐵 + 𝐹𝐶"𝑟𝐶 + 𝐹𝐷"𝑟𝐷

123.64 = 𝐹𝐴"(0.07418)+FB"(0.1119)+FC"(0.1119)+FD" 0.07418 ……..(1)

Given,

𝐹𝐴"

𝑟𝐴=

𝐹𝐵"

𝑟𝐵

0.119𝐹𝐴"=0.07418FB"

𝐹𝐴" = 0.663𝐹𝐵"

Substitute 𝐹𝐴" into (1),

123.64 = 0.14836(0.663𝐹𝐵") + 0.2238𝐹𝐵"

Appendix J

Bolt Analysis 85

= 0.3222𝐹𝐵"

𝐹𝐵"=383.78N , then FA" = 254.45𝑁

Free Body Diagram:

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝐹𝑜𝑟𝑐𝑒 𝑜𝑓 𝐵𝑜𝑙𝑡 𝐴, 𝐹𝑟𝐴 = 690.062 + 142.432 = 704.61𝑁

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝐹𝑜𝑟𝑐𝑒 𝑜𝑓 𝐵𝑜𝑙𝑡 𝐵, 𝐹𝑟𝐵 = 689.972 + 320.732 = 760.87𝑁

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝐹𝑜𝑟𝑐𝑒 𝑜𝑓 𝐵𝑜𝑙𝑡 𝐵, 𝐹𝑟𝐶 = 799.942 + 210.762 = 827.24𝑁

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝐹𝑜𝑟𝑐𝑒 𝑜𝑓 𝐵𝑜𝑙𝑡 𝐵, 𝐹𝑟𝐷 = 621.642 + 210.852 = 656.42𝑁

Note: Bolt C will received highest shear force. Only the bolt that acts with highest

shear force will be analyzed.

Bolt that chosen is M10 with coarse-pitch series, detail properties are as below:

Material Austenite Stainless Steel

Minor Diameter, 𝐴𝑠 52.3mm²

Yield Strength, 𝑆𝑦 206.7MPa

By applying Distortion Energy (DE) Theory,

𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡𝑕, 𝑆𝑠𝑦 = 0.577 206.7𝑀𝑃𝑎 = 119.27𝑀𝑃𝑎

Shear Stress at bolt C,

𝜏 =𝐹

𝐴𝑠

Appendix J

Bolt Analysis 86

=827.24

52.3 𝑥 10−5

= 1.582𝑀𝑃𝑎

𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑏𝑜𝑙𝑡 =119.27𝑀𝑃𝑎

1.582𝑀𝑃𝑎= 75.4 ≈ 75

Comment: The safety factor of bolt is 75. The safety factor may be too high and

reduce of diameter is needed. The diameter of both is change to 5mm.

If bolt size change to M5, coarse-pitch series with minor diameter 12.7 𝑥 10−5𝑚2

𝜏 =827.24

12.7 𝑥 10−5= 6.514𝑀𝑃𝑎

𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 =119.27𝑀𝑃𝑎

6.514= 18.31 ≈ 18

The safety factor of bolt with diameter 5mm is 18. It is safe.

Appendix K

Member Analysis 87

A bolt with a diameter of M5 was used:

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑆𝑡𝑟𝑒𝑠𝑠 = 0.005 𝑥 0.003

= 1.5 𝑥10−5𝑚2

𝜎 =827.24

1.5 𝑥 10−5= 55.15𝑀𝑃𝑎

𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 =125𝑀𝑃𝑎

55.15𝑀𝑃𝑎= 2.27 ≈ 2

Comment: The safety factor is too low, the diameter of bolt were change to 10mm

diameter and analyze again.

With thickness of corner joint is 3mm, and bolt diameter of 10mm,

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑆𝑡𝑟𝑒𝑠𝑠 = 0.01 𝑥 0.003

= 3 𝑥10−5𝑚2

𝜎 =827.24

3 𝑥 10−5= 27.6𝑀𝑃𝑎

𝑆𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 =125𝑀𝑃𝑎

27.6𝑀𝑃𝑎= 4.5 ≈ 4

Appendix L

Gantt Chart 88

G

an

tt C

ha

rt F

or

UG

P 1

Gan

tt C

ha

rt F

or

UG

P 2

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