ORGANIZATION CHART

1
 CHAPTER I

IDENTIFICATION OF NEED

1.0 Introduction

Our group name is ‘HAND’, want to redesign a rostrum specially to use in

Dewan Tunku Ibrahim,UTHM. This rostrum has been improved in design by fitting
assembly of mechanical mechanism to adjust height where it can be use for all people
with different height from children to adult.

1.1 Problem statement

This project invented because most of the rostrum in market is made in

standard height about 150 cm height. Usually Asian people especially woman and
young lady has a height between 150 – 170 cm. Its not suitable for them to have a
speech in usual rostrum in market because the rostrum is higher than that person itself.
Usually whether school, university or firm have some of rostrum with different size
and height where it will use depends on certain function. However, the problem is still
the same where it cannot be adjusted according to height of the person that gives the
speech. In the term of ergonomics, the position of the person is wrong if the rostrum
height is not adequate with the person height. It will cause back sick could be
happened.

1.2 Scope

Our scope for this project is to produce the adjustable rostrum height is about
113 cm minimum and 130 cm maximum.

1.3 Objective

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 To produce an adjustable rostrum for Dewan Tunku Ibrahim, UTHM.

1.4 Expected Result

Our expected result for this an invention is it can be function well to move in
minimum and maximum height level range. The movement could be slowly and
smooth. The level height of the rostrum will be adjusted automatically with push the
button.

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1.5 Design Stage

Chart 1.0 : Design Stage

4
1.6 Project Planning

CHAPTER 1 Primary Goal

Identification Of Need Product Design
Specifications
• background
of the problems
• objective
• scope
• project
• Gathering CHAPTER 2
information about Background Research
material and methods
• Ergonomic
Concept Generation
• Brainstormin
g
CHAPTER 3 • Ishikawa
Conceptual Design Diagram
Concept Evaluation
Matrix Evaluation
Methodology
Design Review

• Dimensional CHAPTER 4
Modeling Embodiment Design
• Material
Selection
• Analysis/

CHAPTER 5 • Detail
Final Design Drawings
• Manufacturin
g Process
• Evaluate Cost
• Design

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1.7 Gantt Chart

NO. CONTENT MONTH/WEEK

1/1 1/2 1/3 1/4 2/1 2/2 2/3 2/4 3/1 3/2 3/3 3/4
1 GROUP SELECTION

2 SEPARATE GROUP DUTIES

3 OBJECTIVE/CREATED IDEA

4 SEARCHING INFORMATIONS

5 SKECTHING THE CONCEPT

6 ANALYSE DEPEND THE CONCEPT

7 DECIDE THE DESIGN

8 SKECTHING AND DIMENSIONING

THE MODEL
9 ANALYSE THE MOTION OF MODEL

10 MATERIAL SELECTION

11 EXECUTING THE PROJECT

12 PROJECT PRESENTATION

LEGEND :
TARGET FORECAST
REAL FORECAST

6
 CHAPTER II

BACKGROUND RESEARCH

2.0 Introduction

This chapter consists of reviews made on several reports that are relevant to this study.
This selection of this technical report is to focus on the field of the uses of adjustable height
rostrum. This study can be collaborated with the inventing for a new design of rostrum. The new
invention will be considered about the rationale of making that adjustable height. The new
innovation of rostrum is made from some of materials. Usage of variety material will make the
rostrum looks simple but interesting. The important things are it must be safety user and easy to
use.

2.1 Ergonomics

Ergonomics is the scientific discipline concerned with designing according to human

needs, and the profession that applies theory, principles, data and methods to design in order to
optimize human well-being and overall system performance. The field is also called human
engineering, and human factors. Ergonomic research is performed by those who study human
capabilities in relationship to their work demands. Information derived from these studies

7
contributes to the design and evaluation of tasks, jobs, products, environments and systems in
order to make them compatible with the needs, abilities and limitations of people.

2.1.1 Five Aspects Of Ergonomics

5 aspects

Comfort Easy to Productivity Safety Aesthetics

use

Chart 2.1 : Five Aspects Of Ergonomics

Based on these aspects of ergonomics, examples are given of how products or

systems could benefit from redesign based on ergonomic principles.

1. Safety:

The AHR is stable and will not collapse where all the sharpen edge has been on
them could be larger so that a deburred.

2. Comfort:

This AHR provided a comfortable level of height according to different normal

height of Asian person.

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 3. Easy of use:

The AHR have a simple switch button to make upward or downward movement.

4. Productivity/performance:

The AHR give a smooth movement when the adjustable process done by pressing
the switch button.

5. Aesthetics:

The AHR used an acrylic as a selected material for body and top base which it has
a transparent view.

2.2 Material

Materials are substances or components with certain physical properties which are used
as inputs to production or manufacturing. Basically materials are the pieces required to make
something else.

A material can be anything: a finished product in its own right or an unprocessed raw
material. Raw materials are first extracted or harvested from the earth and divided into a form
that can be easily transported and stored, then processed to produce semi-finished materials.
These can be input into a new cycle of production and finishing processes to create finished
materials, ready for distribution, construction, and consumption.

9
 An example of a raw material is cotton, which is harvested from plants, and can then be
processed into thread (also considered a raw material), which can then be woven into cloth, a
semi-finished material. Cutting and sewing the fabric turns it into a garment, which is a finished
material. Steelmaking is another example—raw materials in the form of ore are mined, refined
and processed into steel, a semi-finished material. Steel is then used as an input in many other
industries to make finished products.

Material for this project consist a lot of material and kind of material. In this project,
we’ve choose several material to use in some part of our product such as casing, table, and rod to
build the adjustable rostrum. The material that we planned to are :-

Adjustable rostrum

Casing Table Body

Mild steel Wood Wood

Zinc Glass Iron
Plastic Acrylic Aluminium

2.2.1 Acrylic

Acrylic is a useful, clear plastic that resembles glass, but has properties that make it
superior to glass in many ways. Common brands of high-grade acrylic include Polycast, Lucite
and Plexiglass.

There are two basic types of acrylic: extruded and cell cast. Extruded or "continuous cast"
acrylic is made by a less expensive process, is softer, can scratch easier and may contain
impurities. Cell cast acrylic is a higher quality acrylic and U.S. domestic cell cast is a good
choice for applications that require the best. Imported cell cast acrylic is often manufactured to
lesser standards.

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 Acrylic is used to make various products, such as shower doors, bath enclosures,
windows and skylights. It is chosen over glass for many reasons. It is many times stronger than
glass, making it much more impact resistant and therefore safer. Falling against an acrylic
shower door will not likely break it. Baseballs that crash through glass windows will, in most
cases, bounce off acrylic windows. Acrylic also insulates better than glass, potentially saving on
heating bills.

Another great advantage of acrylic is that it is only half as heavy as glass. This makes
working with acrylic much easier. It can also be sawed, whereas glass must be scored.

Adding to this favorable array of properties, a transparency rate of 93% makes acrylic the
clearest material known. Very thick glass will have a green tint, while acrylic remains clear.

A unique property of plastic is its ability to be shaped. Bow-front aquariums are beautiful
examples of acrylic's wonderful properties. There are also no seams in acrylic structures, as
chemical welding at the molecular level actually "melts" seams into one piece of solid material.
Seams that are welded and polished are invisible.

There are some misconceptions about acrylic, namely that it yellows, turns brittle and
cracks over time. Though this might be true of very cheap forms of plastic, it is not so with
acrylic. For example, the fighter planes of WWII have acrylic bubble-tops. Airplane windows are
also acrylic. If taken care of, acrylic remains new looking regardless of age or exposure to sun.
Some people worry that acrylic scratches too easily, but unlike glass, scratches can be easily
buffed out of acrylic.

For all of its advantages, there are two disadvantages of acrylic: it is more expensive than
glass, and if exposed to a direct flame it will melt and eventually burn.

Today acrylic is used more than ever. Virtually all major public aquariums now build
display tanks out of acrylic. You will also find acrylic in malls, institutions, prisons, hospitals
and commercial buildings. Acrylic just over one inch thick (32mm) is bullet resistant. The
Presidential motorcade, the Pope's booth-vehicle, teller enclosures and drive-through window
enclosures all feature bullet-resistant acrylic.

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 If upgrading the windows in your house, remodeling your bathroom, or adding a
beautiful aquarium, consider acrylic. It may cost a little more than glass, but its sheer clarity,
light weight and insulating properties make it a superior choice for many applications.

PHYSICAL PROPERTIES

Density 0.0415-0.043 lb/in3

Water Absorption .3-2 %
Moisture Absorption at Equilibrium 0.3-0.33 %
Linear Mold Shrinkage 0.003-0.0065 in/in
Melt Flow 0.9-27 g/10 min

MECHANICAL PROPERTIES

Hardness, Rockwell M 63-97

Tensile Strength, Ultimate 6820-11500 psi
Tensile Strength, Yield 7980-12300 psi
Elongation @ break 1-30 %
Elongation @ Yield 4-5 %
Tensile Modulus 319-551 ksi
Flexural Modulus 435-508 ksi
Flexural Yield Strength 11700-20000 psi
Compressive Yield Strength 14500-17000 psi
Shear Modulus 203 ksi
Izod Impact, Notched 0.225- 0.375 ft-lb/in
Izod Impact, Unnotched 5.06 ft-lb/in
Charpy Impact, Unnotched 9.04-28.6 ft-lb/in2
Charpy Impact, Notched 0.952-1.9 ft-lb/in²
Gardner Impact 0.17-1.03 ft-lb
Tensile Creep Modulus, 1 hour 261000-392000 psi
Tensile Creep Modulus, 1000 hours 174000-261000 psi

ELECTRICAL PROPERTIES

Electrical Resistivity 1E+14-1E+15 ohm-cm

Dielectric Constant 2.8-4
Dielectric Constant, Low Frequency 3-4

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Dielectric Strength 450-1520 kV/in
Dissipation Factor 0.03-0.55
Dissipatin Factor, Low Frequency 0.05-0.55
Surface Resistance 1E+14-1E+16 ohm
Comparative Tracking Index 600 V

THERMAL PROPERTIES

CTE, linear 200 C 33.3-72.2 µ in/in-°F

Heat Capacity 0.349-0.351 BTU/lb-°F
Thermal Conductivity 1.32-1.67 BTU-in/hr-ft²-°F
Melting Point 266°F
Maximum Service Temperature, Air 106-217°F
Deflection Temperature at 0.46 MPa 176-217°F
Deflection Temperature at 1.8 MPa 106-212°F
Vicat Softening Point 117-243°F
Glass Temperature 212-221°F
Flammability, UL94 HB
Oxygen Index 18%

OPTICAL PROPERTIES

Refractive Index 1.49-1.498

Haze 1-96%
Transmission, Visible 80-93%

PROCESSING PROPERTIES

Processing Temperature 469-482°F

2.2.2 Glass

Glass generally refers to a hard, brittle, transparent amorphous solid, such as that used for
windows, many bottles, or eyewear, including, but not limited to, soda-lime glass, borosilicate
glass, acrylic glass, sugar glass, isinglass (Muscovy-glass), or aluminium oxynitride.

13
 In the technical sense, glass is an inorganic product of fusion which has been cooled to a
rigid condition without crystallizing. Many glasses contain silica as their main component and
glass former.

In the scientific sense the term glass is often extended to all amorphous solids (and melts
that easily form amorphous solids), including plastics, resins, or other silica-free amorphous
solids. In addition, besides traditional melting techniques, any other means of preparation are
considered, such as ion implantation, and the sol-gel method. However, glass science commonly
includes only inorganic amorphous solids, while plastics and similar organics are covered by
polymer science, biology and further scientific disciplines.

Glass plays an essential role in science and industry. The optical and physical properties
of glass make it suitable for applications such as flat glass, container glass, optics and
optoelectronics material, laboratory equipment, thermal insulator (glass wool), reinforcement
fiber (glass-reinforced plastic, glass fiber reinforced concrete), and art.

The term glass developed in the late Roman Empire. It was in the Roman glassmaking
center at Trier, Germany, that the late-Latin term glesum originated, probably from a Germanic
word for a transparent, lustrous substance.

2.2.3 Wood

Wood is an organic material produced as secondary xylem in the stems of woody plants,
notably trees and other woody plants. In a living tree it conducts water and nutrients to the leaves
and other growing tissues, and has a support function, enabling plants to reach large sizes. Wood
may also refer to other plant materials and tissues with comparable properties, and to material
engineered from wood, or wood chips or fiber.

People have used wood for millennia for many purposes, primarily as a fuel or as a
construction material for making houses, tools, weapons, furniture, packaging, artworks, and
paper. Wood can be dated by carbon dating and in some species by dendrochronology to make

14
inferences about when a wooden object was created. The year-to-year variation in tree-ring
widths and isotopic abundances gives clues to the prevailing climate at that time.

2.2.4 Plastic

Plastic is the general common term for a wide range of synthetic or semisynthetic organic
solid materials suitable for the manufacture of industrial products. Plastics are typically polymers
of high molecular weight, and may contain other substances to improve performance and/or
reduce costs.

The word derives from the Greek πλαστικός (plastikos), "fit for molding", from πλαστός
(plastos) "molded". It refers to their malleability, or plasticity during manufacture, that allows
them to be cast, pressed, or extruded into an enormous variety of shapes—such as films, fibers,
plates, tubes, bottles, boxes, and much more.

The common word "plastic" should not be confused with the technical adjective "plastic",
which is applied to any material which undergoes a permanent change of shape (a "plastic
deformation") when strained beyond a certain point. Aluminum, for instance, is "plastic" in this
sense, but not "a plastic" in the common sense; while some plastics, in their finished forms, will
break before deforming — and therefore are not "plastic" in the technical sense.

There are two main types of plastics, thermoplastic and thermoset. Thermoplastics, if
exposed to heat, will melt in two to seven minutes. Thermosets will keep their shape until they
are a charred, smoking mess. Some examples of thermoplastics are grocery bags, piano keys and
some automobile parts. Examples of thermosets are kid's dinner sets and jet skis.

2.2.5 Aluminium

Aluminium or aluminum is a silvery white and ductile member of the boron group of
chemical elements. It has the symbol Al; its atomic number is 13. It is not soluble in water under
normal circumstances. Aluminium is the most abundant metal in the Earth's crust, and the third
most abundant element therein, after oxygen and silicon. It makes up about 8% by weight of the
Earth’s solid surface. Aluminium is too reactive chemically to occur in nature as the free metal.

15
Instead, it is found combined in over 270 different minerals. The chief source of aluminium is
bauxite ore.

Aluminium is remarkable for its ability to resist corrosion (due to the phenomenon of
passivation) and its low density. Structural components made from aluminium and its alloys are
vital to the aerospace industry and very important in other areas of transportation and building.
Its reactive nature makes it useful as a catalyst or additive in chemical mixtures, including being
used in ammonium nitrate explosives to enhance blast power.

Aluminium is a soft, durable, lightweight, malleable metal with appearance ranging from
silvery to dull grey, depending on the surface roughness. Aluminium is nonmagnetic and non
sparking. It is also insoluble in alcohol, though it can be soluble in water in certain forms. The
yield strength of pure aluminium is 7–11 MPa, while aluminium alloys have yield strengths
ranging from 200 MPa to 600 MPa. Aluminium has about one-third the density and stiffness of
steel. It is ductile, and easily machined, cast, and extruded.

Corrosion resistance can be excellent due to a thin surface layer of aluminium oxide that
forms when the metal is exposed to air, effectively preventing further oxidation. The strongest
aluminium alloys are less corrosion resistant due to galvanic reactions with alloyed copper. This
corrosion resistance is also often greatly reduced when many aqueous salts are present however,
particularly in the presence of dissimilar metals.

Aluminium atoms are arranged in a face-centered cubic (FCC) structure, which may
explain its high melting point. Aluminium has a high stacking-fault energy of approximately 200
mJ/m².

Aluminium is one of the few metals that retain full silvery reflectance in finely powdered
form, making it an important component of silver paints. Aluminium mirror finish has the
highest reflectance of any metal in the 200–400 nm (UV) and the 3000–10000 nm (far IR)
regions, while in the 400–700 nm visible range it is slightly outdone by tin and silver and in the
700–3000 (near IR) by silver, gold, and copper.

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 Aluminium is a good thermal and electrical conductor, by weight better than copper.
Aluminium is capable of being a superconductor, with a superconducting critical temperature of
1.2 kelvin and a critical magnetic field of about 100 gauss.

Aluminium has nine isotopes, whose mass numbers range from 23 to 30. Only Al (stable
isotope) and Al (radioactive isotope, t1/2 = 7.2 × 105 y) occur naturally; however, Al has a natural
abundance of 99.9+ %. Al is produced from argon in the atmosphere by spallation caused by
cosmic-ray protons. Aluminium isotopes have found practical application in dating marine
sediments, manganese nodules, glacial ice, quartz in rock exposures, and meteorites. The ratio of
Al to Be has been used to study the role of transport, deposition, sediment storage, burial times,
and erosion on 105 to 106 year time scales Cosmogenic Al was first applied in studies of the
Moon and meteorites. Meteoroid fragments, after departure from their parent bodies, are exposed
to intense cosmic-ray bombardment during their travel through space, causing substantial Al
production. After falling to Earth, atmospheric shielding protects the meteorite fragments from
further Al production, and its decay can then be used to determine the meteorite's terrestrial age.
Meteorite research has also shown that Al was relatively abundant at the time of formation of our
planetary system. Most meteoriticists believe that the energy released by the decay of Al was
responsible for the melting and differentiation of some asteroids after their formation 4.55 billion
years ago.

2.2.5.1 Some Common Uses Of Aluminium-

2.2.5.1.1 Building & Construction Industry:

• door and window frames

• wall cladding, roofing, awnings

2.2.5.1.2 Manufacture of Electrical Products:

• high tension power lines, wires, cables, busbars

• components for television, radios, refrigerators and air-conditioners

2.2.5.1.3 Packaging & Containers:

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 • beverage cans, bottle tops
• foil wrap, foil semi-rigid containers

2.2.5.1.4 Cooking Utensils:

• kettles and saucepans

2.2.5.1.5 Aeronautical, Aviation & Automotive Industries:

• propellers
• airplane and vehicle body sheet
• gearboxes, motor parts
•

2.2.5.1.6 Leisure Goods:

• tennis racquets, softball bats

• indoor and outdoor furniture

2.2.5.2 Properties -

• Very lightweight (about 1/3 the mass of an equivalent volume of steel or copper)
but with alloying can become very strong.
• Excellent thermal conductor
• Excellent electrical conductor (on a weight-for-mass basis, aluminium will
conduct more than twice as much electricity as copper)
• Highly reflective to radiant energy in the electromagnetic spectrum
• Highly corrosion resistant in air and water (including sea water)
• Highly workable and can be formed into almost any structural shape
• Non-magnetic
• Non-toxic

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 2.2.6 Mild steel

Mild steel is the most common form of steel as its price is relatively low while it provides
material properties that are acceptable for many applications. Low carbon steel contains
approximately 0.05–0.15% carbon and mild steel contains 0.16–0.29% carbon, therefore it is
neither brittle nor ductile. Mild steel has a relatively low tensile strength, but it is cheap and
malleable; surface hardness can be increased through carburizing.

Type of steel
Percentage of
carbon
Mild steel Up to 0.25%

Medium carbon steel 0.25% to 0.45%

High carbon steel 0.45% to 1.50%

Table 2.1 : Carbon steels

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 2.2.7 Zinc

Zinc is a metallic chemical element with the symbol Zn and atomic number 30. It is a
first-row transition metal of the group 12 of the periodic table. Although zinc has been used in
the copper-zinc alloy brass since Roman times, and the metal was produced in large scale in
India around 1200 AD, the pure metal was unknown to Europe until the end of the 16th century.
Industrial-scale production in Europe had not started until the late 18th century. Corrosion-
resistant zinc plating of steel is the major application for zinc. Other applications are in batteries
and alloys, such as brass. Sphalerite, a zinc sulfide, is the most important zinc ore. Zinc
production includes roasting, leaching and, at the end, pyrometallurgic winning or
electrowinning.

Zinc is an essential mineral, necessary for sustaining all life. Enzymes with a zinc atom in
the reactive center are widespread in biochemistry, such as the alcohol dehydrogenase in
humans. Consumption of higher concentrations of zinc can cause ataxia, lethargy and copper
deficiency.

A variety of zinc compounds find use industrially, such as zinc chloride (in deodorants),
zinc pyrithione (anti-dandruff shampoos), zinc sulfide (in luminescent paints), and zinc methyl or
zinc diethyl in the organic laboratory. Roughly one quarter of all zinc output is consumed in the
form of zinc compounds.

Zinc, also referred to in nonscientific contexts as spelter, is a bluish-white, lustrous,

diamagnetic metal, though most common commercial grades of the metal have a dull finish. It is
somewhat less dense than iron and has a hexagonal crystal structure.

The metal is hard and brittle at most temperatures but becomes malleable between 100
and 150 °C. Above 210 °C, the metal becomes brittle again and can be pulverized by
beating.]Zinc is a fair conductor of electricity.For a metal, zinc has relatively low melting
(420 °C) and boiling points (900 °C).Its melting point is the lowest of all the transition metals
aside from mercury and cadmium.Many alloys contain zinc, including brass, an alloy of zinc and
copper. Other metals long known to form binary alloys with zinc are aluminium, antimony,
bismuth, gold, iron, lead, mercury, silver, tin, magnesium, cobalt, nickel, tellurium and

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sodium.While neither zinc nor zirconium are ferromagnetic, the alloy ZrZn2 exhibits
ferromagnetism below 35 K.

2.3 Component

Components in AHR are mechanical components requiring extra mechanical needs that
are needed to support other parts to completely function. In this design, we divided the system
into 2 category which is mechanical components, electrical components. For mechanical
components its consist the parts that’s make the system going smoothly in application.

The mechanical parts must able to sustain the mechanical properties such as load, force,
bends, deflection, etc. in AHR project, the mechanical parts involve is jack. The jack selected is
usually use in automotive sector. Below is the type of jack that can be use in this project.

21
22
 TYPES
OF JACK

Bottle Floor jack Scissor jack Transmission jack Screw jack

jack

Long ram jack Hydraulic Jack stand Farm jack Mechanical jack
cylinder jack

Hydraulic air
jack

23
2.3.1 TYPES OF JACK

2.3.1.1 Bottle Jack

Figure 1 : Bottle Jack

Features
• Hydraulic bottle jack is an excellent jack that has outstanding durability, anticorrosion
under any circumstances, ergonomic designs, pressure-persistent and excellence in air-
tightness with a safe design structure.

• Capacity from 2T to 100T.

• Kind: oddbal, heavy duty, long nose types with 1 step and 2 steps.

Usage
• Rugged steel construction, ideal for auto and truck repairs.

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Hydraulic Bottle Jack In U.S. standard

Table 1 : Hydraulic Bottle Jack In U.S. standard

Model Capacity Min.height Lifting Adjusting

height height
2.3.1.2 Floor Jack CN0201 2T 148mm 80mm 50mm
CN0401 4T 180mm 110mm 60mm
CN0601 6T 200mm 125mm 80mm
CN0801 8T 200mm 125mm 80mm
CN1001 10T 200mm 125mm 80mm
CN1201 12T 210mm 135mm 80mm
CN1601 16T 225mm 140mm 60mm
Figure 2 : Floor CN2001 20T 235mm 145mm 60mm
Jack
CN3001 32T 255mm 150mm -
Features CN5001 50T 285mm 180mm -
• CN10002 100T 330mm 180mm -

Professionally designed with thick welded steel plate construction and an oversized saddle

• Specially designed several sizes wide, low

profile, durable roller wheel for quick and accurate placement where you need it.

• Each floor jack paired with one handle for

easy operate.

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Usage
• Mainly used in the shops, repair work or
storage.

Specification

MODEL CAPACITY MIN.HEIGHT MAX.HEIGHT N.W(KG).

CNF1021 2T 135mm 320mm 7.5
CNF1022 2T 135mm 355mm 8.5

Table 2 : Specification Of Floor Jack

2.3.1.3 Scissor Jack

Figure 3 : Scissor Jack

Features
• Scissor jacks are mechanism defined by a connected series of levels, with screw bar to
adjust the height.

• Kind: light X, heavy duty X, light Y, heavy duty Y.

Usage
• The purpose of most scissor jacks is to raise and lower things. The reference to scissors is
due to the fact that the lever arms open and close like a pair of scissors.

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Specification

MODEL: CNS010
CAPACITY 1TON
MIN.HEIGHT 90MM
MAX.HEIGHT 3250MM
G.W. 2.3KGS

Table 3 : Specification of scissor jack

2.3.1.4 Transmission Jack

Features
• Transmission jack mainly used in the
assembly line of plant and also helpful in the garage, shop, and farm.

• Full range adjusting head assembly.

• Wide stable stance.

• Full swivel ball bearing casters.

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Usage
• Rugged steel construction, ideal for auto and truck repairs

Figure 4 : Transmission Jack

MODEL: CNI01
MODEL: CNI05 CAPACITY 0.6TON
CAPACITY 0.2TON MIN.HEIGHT 1260MM
Saddle Degree 60-10 degree MAX.HEIGHT 1970MM
G.W. 14.5KGS G.W. 51KGS

Table 4 : Specification Of Transmission Jack

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 2.3.1.5 Screw Jack

Figure 5 : Screw Jack

Features
• Compact screw jack, easy to maintain.

• Mechanical gears are safer for heavy duty usage.

• Screw jack with forged alloy steel Jaw, can use for inside and outside pulls.

Usage
• They are good for repairing vehicles, lifting tracks and Railway maintenance. And bearing
pull.

Specification
Type Capacity(ton) Lift height(mm) Min.h(mm)
CNL003 3.2 110 220
CNL005 5 130 250
CNL008 8 140 260
CNLA10 10 150 280
CNL016 16 Of 180 320
Table 5 : Specification Screw Jack
CNL020 20 180 325
CNL025 25 130 275
CNL032 32 200 395
CNL032 32 180 320

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 2.3.1.6 Mechanical Jack

Features
• Lifts with either fixed toe or on clawed head

• Versatile mechanical jack in all blue paint.

Usage
• They are good for repairing vehicles, lifting tracks and Railway mantainance.

Figure 6 : Mechanical Jack

TYPE CNR015 CNR030 CNR050 CMR100

CAPACITY (KG) 1.5T 3T 5T 10T
TEST LOAD (KN) 22 44.1 73.5 147
EFFORT 350 400 580
REQUIRED TO
300
LIFT MAX. LOAD
(N)
NET WIGHT (KG) 16 20 28 46

30
 Table 6 : Specification Of Mechanical Jack

Figure 7 : Mechaincal Jack For Railway

Model MAX.TOP MAX.TOE LIFT.H. TOP.H. TOE.H.

CNQD05 5T 2.5T 160mm 345mm 43mm
CNQD10 10T 5T 180mm 410mm 45mm
CNQD15 15T 7.5T 280mm 580mm 60mm

Table 7 : Specification of Mechaincal Jack For Railway

2.3.1.7 Farm Jack

Features

• The farm jack (also known as the handyman jack or high

is a versatile mechanical jack with auto lock pin.

Usage

• Ideal for lifting, pulling, clamping and spreading on tractors and

4-wheel drives vehicles.

• Adjustable top clamp clevis can be moved to any position on the

upright steel standard for clamping purposes.

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 2.3.2 TYPE OF MOTOR

Meanwhile, in order to make the rostrum more added value than other rostrum, the
mechanism that use must be in semi automatic or fully automatic. This rostrum is a semi
automatic system using a motor to adjust the height. Mostly jack in market use manual
mechanical method. By using the motor, the application can be converted into semi auto system.
Below are the selected motor that suitable to use in this project.

2.3.2.1 Pole motor

A shaded-pole motor is a type of AC single-phase induction motor. As in other induction

motors the rotating part is a squirrel-cage rotor. All single-phase motors require a means of
producing a rotating magnetic field for starting. In the shaded-pole type, a part of the face of
each field pole carries a copper ring called a shading coil. Currents in this coil delay the phase of

32
magnetic flux in that part of the pole enough to provide a rotating field. The effect produces only
a low starting torque compared to other classes of single-phase motors.

These motors have only one winding, no capacitor nor starting switch, making them
economical and reliable. Because their starting torque is low they are best suited to driving fans
or other loads that are easily started. Moreover, they are compatible with triac-based variable-
speed controls, which often are used with fans. They are built in power sizes up to about 1/6 hp
or 125 watts output. For larger motors, other designs offer better characteristics.

The first photo is of a common C-frame motor. With the shading coils positioned as shown,
this motor will start in a clockwise direction as viewed from the long shaft end. The second
photo shows detail of the shading coils.

Figure 13 : Pole Motor

33
 2.3.2.2 Stepper motor

Stepper motor (or step motor) is a brushless, synchronous electric motor that can divide a
full rotation into a large number of steps. The motor's position can be controlled precisely,
without any feedback mechanism (see open loop control). Stepper motors are similar to switched
reluctance motors (which are very large stepping motors with a reduced pole count, and
generally are closed-loop commutated).

Stepper motors operate differently from normal DC motors, which rotate when voltage is
applied to their terminals. Stepper motors, on the other hand, effectively have multiple "toothed"
electromagnets arranged around a central gear-shaped piece of iron. The electromagnets are
energized by an external control circuit, such as a microcontroller.

To make the motor shaft turn, first one electromagnet is given power, which makes the
gear's teeth magnetically attracted to the electromagnet's teeth. When the gear's teeth are thus
aligned to the first electromagnet, they are slightly offset from the next electromagnet. So when
the next electromagnet is turned on and the first is turned off, the gear rotates slightly to align
with the next one, and from there the process is repeated. Each of those slight rotations is called a
"step," with an integral number of steps making a full rotation. In that way, the motor can be
turned by a precise angle.

34
 Figure 14 : Stepper motor

2.3.2.3 Power window

Power windows or electric windows are automobile windows which can be raised and
lowered by depressing a button or switch, as opposed to using a hand-turned crank handle.

Power windows are usually inoperable when the car is not running as the electrical
system is not 'live' once the ignition has been turned off. The Hydro-Lectric system; however,
could lower the windows at rest, since pressure from the hydraulic system was merely released to
lower the window. Raising the windows required the pump to operate (at a fairly high noise
level) and introduce pressure at each cylinder. These hydraulic systems also required pressure
lines to each cylinder (door, seat and top) and tended to leak.

Power windows have become so common that by 2008, some automakers eliminated
hand cranks from all models. Some many vehicles have power windows that some people no
longer understand the (formerly) common sign from another driver of using their hand to
simulate moving a window crank to indicate that they wish to speak with someone (stopped at a
light or in a parking lot).

Power windows have come under some scrutiny after several fatal accidents in which
children's necks have become trapped, leading to suffocation. Some designs place the switch in a
location on a hand rest where it can be accidentally triggered by a child climbing to place his or
her head out of the window. To prevent this, many vehicles feature a driver-controlled lockout
switch, preventing rear-seat passengers (usually smaller children) from accidentally triggering
the switches. This also prevents children from using them as toys and pets riding with their heads
out windows from activating the power window switch.

35
 Figure 15 : Power windows

2.3.2.4 DC Motor

A DC motor works by converting electric power into mechanical work. This is

accomplished by forcing current through a coil and producing a magnetic field that spins the
motor. The simplest DC motor is a single coil apparatus, used here to discuss the DC motor
theory.

The voltage source forces voltage through the coil via sliding contacts or brushes that are
connected to the DC source. These brushes are found on the end of the coil wires and make a
temporary electrical connection with the voltage source. In this motor, the brushes will make a
connection every 180 degrees and current will then flow through the coil wires. At 0 degrees, the
brushes are in contact with the voltage source and current is flowing. The current that flows
through wire segment C-D interacts with the magnetic field that is present and the result is an
upward force on the segment. The current that flows through segment A-B has the same
interaction, but the force is in the downward direction. Both forces are of equal magnitude, but in
opposing directions since the direction of current flow in the segments is reversed with respect to
the magnetic field. At 180 degrees, the same phenomenon occurs, but segment A-B is forced up
and C-D is forced down. At 90 and 270-degrees, the brushes are not in contact with the voltage
source and no force is produced. In these two positions, the rotational kinetic energy of the motor
keeps it spinning until the brushes regain contact.

One drawback to the motor is the large amount of torque ripple that it has. The reason
for this excessive ripple is because of the fact that the coil has a force pushing on it only at the 90
and 270 degree positions. The rest of the time the coil spins on its own and the torque drops to

36
zero. The torque curve produced by this single coil, as more coils are added to the motor, the
torque curve is smoothed out.

The resulting torque curve never reaches the zero point and the average torque for the
motor is greatly increased. As more and more coils are added, the torque curve approaches a
straight line and has very little torque ripple and the motor runs much more smoothly. Another
method of increasing the torque and rotational speed of the motor is to increase the current
supplied to the coils. This is accomplished by increasing the voltage that is sent to the motor,
thus increasing the current at the same time.

Figure 16 : DC Motor

2.3.3 TYPE OF SWITCH

2.3.3.1 Push Button

A push-button (also spelled pushbutton) or simply "button is a simple switch mechanism

for controlling some aspect of a machine or a process. Buttons are typically made out of hard
material, usually plastic or metal. The surface is usually flat or shaped to accommodate the
human finger or hand, so as to be easily depressed or pushed. Buttons are most often biased
switches, though even many un-biased buttons (due to their physical nature) require a spring to

37
return to their un-pushed state. Different people use different terms for the "pushing" of the
button, such as press, depress, mash, and punch.

In industrial and commercial applications push buttons can be linked together by a

mechanical linkage so that the act of pushing one button causes the other button to be released.
In this way, a stop button can "force" a start button to be released. This method of linkage is used
in simple manual operations in which the machine or process have no electrical circuits for
control.

Pushbuttons are often color-coded to associate them with their function so that the
operator will not push the wrong button in error. Commonly used colors are red for stopping the
machine or process and green for starting the machine or process.

Red pushbuttons can also have large heads (called mushroom heads) to for easy operation
and to facilitate the stopping of a machine. These pushbuttons are called emergency stop buttons
and are mandated by the electrical code in many jurisdictions for increased safety. This large
mushroom shape can also be found in buttons for use with operators who need to wear gloves for
their work and could not actuate a regular flush-mounted push button. As an aid for operators
and users in industrial or commercial applications, a pilot light is commonly added to draw the
attention of the user and to provide feedback if the button is pushed. Typically this light is
included into the center of the pushbutton and a lens replaces the pushbutton hard center disk.
The source of the energy to illuminate the light is not directly tied to the contacts on the back of
the pushbutton but to the action the pushbutton controls. In this way a start button when pushed
will cause the process or machine operation to be started and a secondary contact designed into
the operation or process will close to turn on the pilot light and signify the action of pushing the
button caused the resultant process or action to start.

38
 Figure 16 : Pushbutton

2.3.3.2 Rotary Switch

A rotary switch is a type of switch that is used on devices which have two or more
different "states" or modes of operation, such as a three-speed fan or a CB radio with multiple
frequencies of reception or "channels".

Figure 17 : A three-deck rotary switch allows controlling three different circuit

functions

A rotary switch consists of a spindle or "rotor" that has a contact arm or "spoke" which
projects from its surface like a cam. It has an array of terminals, arranged in a circle around the
rotor, each of which serves as a contact for the "spoke" through which any one of a number of
different electrical circuits can be connected to the rotor. The switch is layered to allow the use
of multiple poles, each layer is equivalent to one pole. Usually such a switch has a detent
mechanism so it "clicks" from one active position to another rather than stalls in an intermediate
position. Thus a rotary swich provides greater pole and throw capabilities than simpler switches
do.

Rotary switches were used as channel selectors on television receivers until the early
1970s, as range selectors on electrical metering equipment, as band selectors on multi-band
radios, etc.

2.3.3.3 Packet switching

Packet switching is a network communications method that groups all transmitted data,
irrespective of content, type, or structure into suitably-sized blocks, called packets. The network

39
over which packets are transmitted is a shared network which routes each packet independently
from all others and allocates transmission resources as needed. The principal goals of packet
switching are to optimize utilization of available link capacity and to increase the robustness of
communication. When traversing network adapters, switches and other network nodes, packets
are buffered and queued, resulting in variable delay and throughput, depending on the traffic load
in the network.

Network resources are managed by statistical multiplexing or dynamic bandwidth

allocation in which a physical communication channel is effectively divided into an arbitrary
number of logical variable-bit-rate channels or data streams. Each logical stream consists of a
sequence of packets, which normally are forwarded by a network node asynchronously using
first-in, first-out buffering. Alternatively, the packets may be forwarded according to some
scheduling discipline for fair queuing or for differentiated or guaranteed quality of service, such
as pipeline forwarding or time-driven priority (TDP). Any buffering introduces varying latency
and throughput in transmission. In case of a shared physical medium, the packets may be
delivered according to some packet-mode multiple access scheme.

Packet switching contrasts with another principal networking paradigm, circuit switching,
a method which sets up a specific circuit with a limited number dedicated connection of constant
bit rate and constant delay between nodes for exclusive use during the communication session.

Packet mode (or packet-oriented, packet-based) communication may be utilized with or

without intermediate forwarding nodes (packet switches).

2.3.3.4 Power Window Switch

A Power Window Switch is a electrical switch that controls the power window to open
the window or close it. The system of this power windows switch is using the 12V current direct
from the source such as battery. There are many types of power window switch in the market
comes with variety system and function. Usually new cars with special specs and old cars using
this switch to regulate the power window motor in order to make the window become semi

40
automatic than ordinary type by using handle. The system of this power windows switch comes
with many types of system. Some of the power window switch only functions when we push the
button. Some of the switch comes with the automatic system that because the system
automatically stops when the windows are fully open or fully closed.

Figure 18 : Power Window Switch

CHAPTER III

CONCEPTUAL DESIGN

41
3.1 Introduction

This chapter presents the conceptual design of the Adjustable Height Rostrum (AHR),
which includes product specification, concept generation and concept evaluation. In this stage of
design involves drawing up a number of difference viable concept designs which satisfy the
requirement of the product outline in the Product Design Specification (PDS) and then
evaluating them to decide on the most suitable to develop our product design.

3.2 Product Design Specification (PDS)

The product design specification (PDS) is a very important document in the design
process as it contains all the information necessary for a design team to successfully produce a
solution to the design problem. A PDS splits the problem up into smaller categories to make it
easier to consider the problem. The final document should fully document as unambiguously as
possible all the requirements that a product must fulfill together with any constraints that may
affect the product. The actual or intended customer should be consulted as fully as possible while
the PDS is being drawn up as their requirements are of paramount importance.

Any numeric properties in the PDS should be specified as exactly as possible together
with any tolerances allowed on their value.

3.2.1 Common categories

Various aspects relating to the product must be considered. The actual categories can
vary, but a typical PDS may consist of the following categories:

42
 Appearance Competition Customer
Documentation Ergonomics Environment
Installation Product disposal Lead times
Legislation, patents and
Legal and safety implications Maintenance
copyright
Materials Packaging and transport Performance
Processes Product cost Product dimensions
Product life Quality Quantity
Standards Testing

Table 3.1 : Product Design Specification

3.2.2 Design requirements

i. Physical and Operational Characteristics

a. Performance requirements

The device must be able to move smoothly either upwards or downwards. It must be
strong enough to withstand the forces that are applied from top base through the body.

b. Safety

The material of the device should be non-sharpen edge and anti-corrosion. Light-weight
material should be used in making the top base. The device must be durable enough to
stand firmly from collapse.

c. Accuracy and Reliability

The device should be manufactured with a high level of precision in order to ensure
proper clearances between the ranging of normal Asian height from 145cm to 170 cm.

d. Life in Service

The product should withstand normal daily use for many years.

e. Operating Environment

43
 The product could be operated in any environment.

f. Ergonomics

The AHR should be sized according the range of normal Asian height population. It
should be constructed in such a way that reduce uncomfortable situation that were happen
to the speeches when use the ordinary rostrum.

g. Size

The body of the AHR should be 910mm in length and 305mm in width. The size of the
bottom base should be large enough to support the whole body, 720mm x 200mm. The
top base should be suitable to place at least a laptop.

h. Weight

The device should not weigh less than 20kg.

i. Materials

The entire AHR should be composed of a rod iron, acrylic and zinc plate. The materials
should all be anti-corrosion.

ii. Production Characteristics

a. Target Product Cost

The cost should be no more than RM 250.

b. Customer

The customer would be firms, schools, universities and etc. The AHR would be most
useful also new invention in rostrum area.

44
3.2.3 Concept Generation

Concept generation produces a number of solutions which we write or draw every

idea on paper as it occurs to us. This will help us to remember and to describe the design
more effectively. Besides that, it also becomes easier to us when we discuss with others
group member. The more ideas we have, the more likely we will end up with good solutions.
There are a number of techniques available to the designer to aid the development of new
concept. To generate the ideas, we used three concept of creativity thinking method which is
brainstorming and morphology chart.

3.2.3.1 Brainstorming Method

45
 Figure 3.1 : Brainstorming Method

3.2.3.2 Morphological Chart

46
 Means
Features
1 2 3 4

1 Support Tracks Air Cushion Slides

Bottom
Base

2 Power Battery Hydraulic Pneumatic

Electric

stainless
3 structure woods aluminum
steel

mild steel

Hydraulic Rack and

6 Lifting Screw Scissor Jack
Ram Pinion

Chart 3.1 : Morphological Chart

3.2.3.3 Function Structure

47
 Input AHR Output

Battery Scissor
Jack Mechanism Jack
Energy

Vertical
Power Window
Force Movemen
Motor
t

Chart 3.2 : Function Structure

48
3.3 Component Selection

FUNCTION CONCEPT 1 CONCEPT 2 CONCEPT 3 CONCEPT 4

Type of jack

Bottle
Scissor
Stand
Hydraulic Air

Type of motor

Power Window
Pole Stepper DC

Type of switch

Multi-switch Power window Push button One way switch

switch

Table 3.2 : Component Selection

49
 3.3.1 Material Selection (Final Decision)

Sub-function
1 2 3 4 Selection Factor
Part

-strong
-easy to join
BOTTOM BASE -high stiffness
Mil Plas
Sta -sustainable
d Steel tic
inless Steel -flat surface
Aluminum

-esthetic look
-tough
Glass -smooth and flat
BODY
Ply Ho surface
Acr wood llow Iron -transparent
ylic -no fragile

-light
-smooth and flat
surface
TOP BASE Glass
Acr Wo - transparent
Sta
ylic od - no fragile
inless steel
-tough

Table 3.3 : Material Selection

50
3.4 Selected Component

i. Scissor jack

Figure 3.2 : Scissor jack

Features
• Scissor jacks are mechanism defined by a connected series of levels, with screw bar to adjust
the height.

• Kind: light X, heavy duty X, light Y, heavy duty Y.

Usage
• The purpose of most scissor jacks is to raise and lower things. The reference to scissors is
due to the fact that the lever arms open and close like a pair of scissors.

i. Power window motor

ii. Power window switch

51
 3.5 Selected material

i. Bottom base

Mild steel is the most common form of steel as its price is relatively low while it provides
material properties that are acceptable for many applications. Low carbon steel contains
approximately 0.05–0.15% carbon and mild steel contains 0.16–0.29% carbon, therefore it is
neither brittle nor ductile. Mild steel has a relatively low tensile strength, but it is cheap and
malleable; surface hardness can be increased through carburizing.

ii. Body and Top base

Acrylic is a useful, clear plastic that resembles glass, but has properties that make it
superior to glass in many ways. Common brands of high-grade acrylic include Polycast, Lucite
and Plexiglass.

There are two basic types of acrylic: extruded and cell cast. Extruded or "continuous cast"
acrylic is made by a less expensive process, is softer, can scratch easier and may contain
impurities. Cell cast acrylic is a higher quality acrylic and U.S. domestic cell cast is a good
choice for applications that require the best. Imported cell cast acrylic is often manufactured to
lesser standards.

Acrylic is used to make various products, such as shower doors, bath enclosures,
windows and skylights. It is chosen over glass for many reasons. It is many times stronger than
glass, making it much more impact resistant and therefore safer. Falling against an acrylic
shower door will not likely break it. Baseballs that crash through glass windows will, in most
cases, bounce off acrylic windows. Acrylic also insulates better than glass, potentially saving on
heating bills.

52
3.6 Developing Drawing Concept

Function Concept 1 Concept 2 Concept 3 Concept 4

Top base Pentagon Rectangular Parabolic Hexagon

Body Parabolic Coffin Diamond Rectangular

Bottom base Rectangle Rectangular Circle Cuboids

Size:

Top base 310mm x 310mm 455mm x 310mm 310mm x 455mm 455mm x 455mm

Body 920mm x 320mm 910mm x 305mm 930mm x 330mm 940mm x 340mm

Bottom base 720mm x 210mm 720mm x 200mm 720mm x 220mm 720mm x 230mm

Final Design

Table 3.4 : Developing Drawing Concept

53
3.7 Final Design Decision (Concept 2)

a) Ergonomic
• this product is easy to used and comfortable
• friendly user

b) Cost
• product cost are not expensive
• component can be obtained easily

c) Multi purpose use

• Can be used in any function

d) Space
• The AHR smaller than available rostrum.
• The AHR covered normal Asian height population compared to available rostrum
that needed more than one rostrum for different height of person, therefore big
storage space must be provided.

e) Operation
• User friendly
• Easy to handle

54
3.6 Matrix Evaluation

In matrix evaluation, firstly we chose a suitable number of concepts which have been
generated in the product design specification. The product design specification should be used as
the basis of any decision being made. One of the useful techniques for matrix evaluation is to
decide on which concepts is the best is by giving a rating. In the rating matrix evaluation, some
criteria have to consider:

i. Ergonomic
ii. Cost
iii. Space
iv. Multipurpose-use
v. Operation

55
3.7 Rating Of Matrix Evaluation

By using the rating of matrix evaluation, marks are given according to the criteria that
most been chosen by our group members. The procedure of this rating is:

Step 1:Determine the criteria.

E.g. ergonomic, operation, space, multi purpose use, cost

Step 2:Define the concept and fulfill the specification that needed for entire design.

Step 3:Giving the mark for each idea or concept by using the point rating (1 – 5)

Step 4: Calculate and analyze the rating

Criteria
Ergonomic Cost Space Operation Multi purpose-use Total
Items

Weighting 0.30 0.20 0.20 0.20 0.30 1.00

factor
5 3 3 2 5
Concept 2 1.00
0.30 0.2 0.20 0.20 0.30

Table 3.5 : Rating Of Matrix Evaluation

56
3.8 Cost Estimation

Every design involved big expense for each part. The aesthetic value for every design
depends on how much money spends on it.

Bil. Item Quantity Price

1. Rod iron (5.85 meter) 1 RM 18.00
2. Power window motor 1 RM 38.00
3. Scissor jack 1 RM 38.00
4. Power window switch 1 RM 8.00
5. Acrylic

(915mm x 305mm x 25mm) 1 RM 50.00

(460mm x 305mm x 5mm) 1 RM 24.00

6. Wire 1 RM 4.00
7. Bolt and nut 1 set RM 4.00
8. Cloth 3.5 meter RM 8.70
9. Zinc plate (1000mm x 1000mm) 1 RM 12.00
10. Sticker 2 RM 8.00
Total RM 212.70

Table 3.6 : Cost Estimation

CHAPTER IV

57
 METHODOLOGY

1) Welding process

The type of welding that use is metal inert gas (MIG). The arc continuously melts the
wire as it is fed to the weld puddle. The weld metal is shielded from the atmosphere by a flow of
an inert gas, or gas mixture.

Continuing developments have made the mig process applicable to the welding of all
commercially important metals such as steel, aluminum, stainless steel, copper and several
others. Materials above .030 in. (.76 mm) thick can be welded in all positions, including flat,
vertical and overhead. It is simple to choose the equipment, wire electrode, shielding gas, and
welding conditions capable of producing high-quality welds at a low cost.

Figure 4.1 : MIG welding machine

Safety rules

58
 While doing the welding process, we need to wear the suitable cloth and equipment in
order to ensure the safety of the welder. Below is the figure that allow for the welding process.

i. Goggle

Helmets and welding goggles used for eye protection are made from a nonflammable
insulating material. They are fitted with a removable protective colored filter and a clear cover
lens. When welding in locations where other welders are working, the welder should wear flash
goggles beneath his helmet to provide protection from the flashes caused by the other welders’
arcs. The flash goggles will also serve as eye protection when chipping the slag from a previous
weld deposit.

Figure 4.2 : Types Of Goggle

• Flash goggle (picture A) is worn under the welder’s helmet and by persons working
around the area where welding operations are taking place. This spectacle type of goggles
has side shields and may have either an adjustable or nonadjustable nose bridge.

59
 • Eyecup or cover (picture B) is for use in fuel-gas welding or cutting operations. They are
contoured to fit the configuration of the face. These goggles must be fitted with a shade
of filter lens that is suitable for the type of work being done.

• The helmet shown in view C has an opening, called a window, for a flip-up filter lens 2
inches by 4 1/4 inches second is to eliminate the harmful infrared.

• The helmet shown in view D has a 4 1/2-inch by 5 1/4-inch window. The larger window
affords the welder a wider view and is especially useful when the welder is working in a
confined place where head and body movement is restricted.

ii. Cloth

Figure 4.3 : Types Of Cloth

• The cape and sleeves are particularly suited for overhead welding, because it protects the
back of the neck, top of the shoulders, and the upper part of the back and chest. Use of

60
 the bib, in combination with the cape and sleeves, gives added protection to the chest and
abdomen.

• The jacket should be worn when there is a need for complete all-around protection to the
upper part of the body. This is especially true when several welders are working in close
proximity to one another.

• Aprons and overalls provide protection to the legs and are suited for welding operations
on the floor.

iii. Glove

Figure 4.4 : Glove

• A variety of special welder’s clothing is used to protect parts of the body. The clothing
selected varies with the size, location, and nature of the work to be performed.

• During any welding or cutting operation, you should always wear flameproof gauntlets.
For gas welding and cutting, five-finger gloves like those shown in view A should be
used.

• For electric-arc welding, use the two-finger gloves (or mitts) shown in view B.

61
 Figure 4.5 : Proper Way Of Safety Wearing Cloth

Welding procedure :

i. Before started the welding process, we had cut the rod iron according to dimension that
decided.
ii. At the beginning process of making bottom base, we weld to each proportional joint
based on drawing specification which is rectangular shape. The figure is shown below.

Figure 4.6 : Bottom Base Frame

62
iii. The welding process was continued until the base completely builds.

iv. Scissor jack with power window assembled was located in the middle of the bottom base
as a main mechanism of the whole system.

Figure 4.7 : Assembly Of Power Window And Scissor Jack

Figure 4.8 : The Welding Process

63
2) Cutting process

Cutting is a collection of processes wherein material is brought to a specified geometry

by removing excess material using various kinds of tooling to leave a finished part that meets
specifications. The net result of cutting is two products, the waste or excess material, and the
finished part. If this were a discussion of woodworking, the waste would be sawdust and excess
wood. In cutting metals the waste is chips and excess metal. These processes can be divided into
chip producing cutting, generally known as machining.

Before doing the cutting process, the measurement of the dimension needs to be done.
The equipment that used for the measurement processes are L-elbow, protractor, ruler and liner.
Beside that, tool that used for cutting processes are jig saw and high speed cutter. While doing
the process, safety rules must be obey to prevent unexpected accident.

Figure 4.9 : Measuring Dimension

Figure 4.11: Cutting acrylic with angle

64
 15°

Figure 4.12 : New Angle View

Figure 4.13 : High speed cutter

Figure 4.14 : Cutting Using Hydraulic Swing Beam Shear Machine

65
3) Grinding process

Grinding is a type of machining using an abrasive wheel as the cutting tool. Grinding is
considered to be the most accurate of the existing machining processes. Grinding practice is a
large and diverse area of manufacturing and tool making. It can produce very fine finishes and
very accurate dimensions; yet in mass production contexts it can also rough out large volumes of
metal quite rapidly. Technically, grinding is a subset of cutting, as grinding is a true metal
cutting process. Each grain of abrasive functions as a microscopic single-point cutting edge and
shears a tiny chip that is analogous to what would conventionally be called a "cut" chip.

Figure 4.15 : The Grinding Process

4) Drilling process

Drilling is the cutting process of using a drill bit in a drill to cut or enlarge holes in solid
materials, such as wood or metal. Different tools and methods are used for drilling depending on
the type of material, the size of the hole, the number of holes, and the time to complete the
operation.

Drilling is a cutting process in which a hole is originated or enlarged by means of a

multipoint, fluted, end cutting tool. As the drill is rotated and advanced into the work piece,

66
material is removed in the form of chips that move along the fluted shank of the drill. One study
showed that drilling accounts for nearly 90% of all chips produced.

Risks should be taken into consideration when drilling. Quickly rotating tools, hot sharp
chips expelled from the work piece, and skin irritation from cutting fluids all create situations
that could pose a problem for the operator.

Figure 4.16 : The Drilling Process

5) Bending process

Bending characterizes the behavior of a structural element subjected to an external load

applied perpendicular to the axis of the element. Bending produces reactive forces inside a beam
as the beam attempts to accommodate the flexural load; the material at the top of the beam is
being compressed while the material at the bottom is being stretched.

Figure 4.17 : Bending Process

67
 Figure 4.18 : Folding And Bending Machine

6) Rivet process

Blind rivets that are used for this project which are tubular and are supplied with a
mandrel through the center. The rivet assembly is inserted into a hole drilled through the parts to
be joined and a specially designed tool used to draw the mandrel into the rivet. This expands the
blind end of the rivet and then the mandrel snaps off. These types of blind rivets have non-
locking mandrels and are avoided for critical structural joints because the mandrels may fall out,
due to vibration or other reasons, leaving a hollow rivet that will have a significantly lower load
carrying capability than solid rivets.

Figure 4.19 : Riveting Process

68
7) Filing process

Filing is a material removal process in manufacturing. Similar, depending on use, to both

sawing and grinding in effect, it is functionally versatile, but used mostly for finishing
operations, namely in deburring operations. Filing operations can be used on a wide range of
materials as a finishing operation. Filing helps achieve work piece function by removing some
excess material and deburring the surface.

Figure 4.21 : Filing Process

69
8) Tapping process

Procedure :

i. A hole drilled into a material from one side without penetrating the opposite side.
ii. This is the initial tap used to start the tapping process for a female thread. Also known as
'1st Tap'.
iii. The second tap used after the first tap to produce the full thread in blind holes where the
thread does not need to go close to the bottom of the hole.
iv. A tool for holding the tap during the hand tapping process using 'Tee Handle'.

Figure 4.22 : Hole Drilling Process

Figure 4.23 : Tapping Process

70
9) Wiring process

The wiring process that has been done is for switch to control the height movement
whether upward or downward. The power source that used to generate the system by using 12 V
motorcycle battery. The 12V battery is sufficient to give motion to power window motor that
used for the system.

Power window switch

+ - + - -

+ - -
Power window motor

battery

Figure 4.24 : Schematic Circuit

Figure 4.25 : Assemble Wire To The Switch

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Figure 4.26 : Power Window Switch

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 CHAPTER V

ANALYSIS AND DISCUSSION

5.1 Introduction

The important when doing the analysis of the product, we can obtain the critical
part value that influence the performance and efficiency of the product. In this project, we
analyze the maximum load can be applied to our AHR. Therefore, we can predict what
will happen if AHR having an overload condition. Its might be the mechanism can’t
move upward smoothly as we expected.
The significant of the analysis will shows that the AHR will collapse if the top
base can’t afford the overload. Hence, the analysis below guides us to get proper
specification in our design before started fabricate the AHR.

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5.1 Calculation

5.1.1 Maximum Load Analysis

Figure 5.1 : The System Schematic

v = 0.288 m / s
ρ = 7300 kg / m 2 (mulleable cast iron )
s = 0.19 m
Dshaft = 0.05 m

1. v 2 = u 2 + 2as
0.288 2 = 0 2 + 2( a )( 0.19 )
0.288 2
a= = 0.218 m / s 2
0.38

2.
a 0.218
µ= = = 0.02
g 0.38

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 3.
v = ωr
(
0.288 2 = ω + 2.5 ×10 −3 )
0.288 2
ω= = 115 .2rad / s
2.5 ×10 −3

4.
ω22 = ω12 + 2as
115 .2 2 = 0 2 + ( 2 ×α × 0.19 )
13271 .04 = 0.38α

13271 .04
α= = 34923 .78 rad / s
0.38

5.
d A = 0.025 m 2

0.01m

v = πj 2 
v = π( 0.025 ) ( 0.01 )
2

−5
v = 1.963 ×10

6. Shaft mass

m = ρv = 7300 (1.963 ×10 −5 ) = 0.14 kg

7. Gear ratio
αmotor
= =1
α jack

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 8. I motor = I shaft = MK 2

= 0.14 ( 0.0125 )2
= 2.1875 ×10 −5 kgm 2

( ) 21 
I setara = 2.1875 ×10 −5 + 2.1875 ×10 −5 (1)  
4

= 2.374 ×10 −5 kgm 2

9. Motor torque

Torque = Iα motor = ( 2.734 × 10 −5 )( 34923 .78 )

= 0.955 Nm

10. Force transferred from motor

P = TW
= 0.955 (115 .2 )
=110 N
110
= =11 .21 kg
9.81
∴11 .21 kg > 7 kg
Motor can generate power to the system.

5.1.2 Ansys (Total deformation)

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 The analysis to the structure has been done by using Ansys software. The analysis
undergone to investigate the structure which is the body of the AHR either deform when the
maximum allow load is applied. Refer to the result, the deformation value at the top base is
1.248 x 10-4 m and at the bottom base is 3.9263 x 10-9 m. The values are too small and we
can assume that value approximate to zero. Hence, we can say that the body can be afford
the maximum load which is 110N based on calculation analysis.

Figure 5.2 : Total Deformation

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