Group No: 37 37

Project Report ME3052

Automated String Hopper Making Machine

By Index No. 080456A 080515F Name K.Sanjeevan Ushan G.A.C

Department of Mechanical Engineering University of Moratuwa Sri Lanka 01stApril 2012

Abstract Goal of this project is propose the detail design and drawings of automated string hopper making machine for large food industry applications. String hopper making machine is a device that squeezing the string hopper with following categorized efficiency such as time, human effort, safety, cleaning and quality during string hopper making. In this design, it is mainly notified about cost of the machine as well as time efficiency. This designed machine can squeeze string hopper using screw extruder with electric power, and extruded out using rotating conveyer from machine die to away as near to operator. Therefore, production rate of the string hopper making machine is high compared with other manual and commercially available machines.

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Table of Contents 1 Background ........................................................................................................................................... 1 1.1 1.2 2 Introduction .................................................................................................................................. 1 Problem definition ........................................................................................................................ 1

Literature Review .................................................................................................................................. 2 2.1 Available machines and their disadvantages ................................................................................ 2 Disadvantages of machines................................................................................................... 3

2.1.1 2.2 2.3 3

User needs analysis ....................................................................................................................... 3 Engineers perspective of the design ............................................................................................ 4

System design and methodology .......................................................................................................... 4 3.1 3.2 Methodology................................................................................................................................. 4 Concept Generation ...................................................................................................................... 5 Methods of string hoper making .......................................................................................... 5 Functional Analysis................................................................................................................ 5 Morphological chart .............................................................................................................. 6 Details chart of concept morphological ................................................................................ 7

3.2.1 3.2.2 1.1.1 3.2.3 3.3 3.4 4

Concept screening......................................................................................................................... 8 Final selection ............................................................................................................................... 9

Summary of Calculations .................................................................................................................... 10 4.1 4.2 4.3 4.4 Power calculation........................................................................................................................ 10 Barrel design ............................................................................................................................... 10 Motor selection ........................................................................................................................... 10 Coupling design ........................................................................................................................... 10 Design for key...................................................................................................................... 10 Design for flange ................................................................................................................. 10 Design for bolts ................................................................................................................... 10

4.4.1 4.4.2 4.4.3 4.5

Worm gear design ....................................................................................................................... 11 Strength calculation and material selection for worm and gear ........................................ 11 Design of worm gear ........................................................................................................... 11

4.5.1 4.5.2

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4.5.3 4.5.4 4.6 4.7

Design of worm shaft .......................................................................................................... 12 Design of worm gear shaft .................................................................................................. 12

Main Shaft design ....................................................................................................................... 12 Selection of bearing .................................................................................................................... 13 Bearing of main shaft calculation ....................................................................................... 13 Bearing of worm shaft calculation ...................................................................................... 13

4.7.1 4.7.2 5

Final Design ......................................................................................................................................... 13 5.1 Machine Specification ................................................................................................................. 13

6 7

CAD Model of the machine ................................................................................................................. 14 Advantages & Limitations of The machine ......................................................................................... 16 7.1 7.2 Advantages.................................................................................................................................. 16 Limitations................................................................................................................................... 16

8 9

Suggested Improvements ................................................................................................................... 16 References .......................................................................................................................................... 17

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List of Figures

Figure 1 Full automated machine and their important parts ....................................................................... 2 Figure 2 Lalit idiappam machine ................................................................................................................... 2 Figure 3 Typical available machine ............................................................................................................... 2 Figure 4 Functional analysis for string hopper making machine .................................................................. 5 Figure 5 Flange coupling ............................................................................................................................. 10 Figure 6 Details of worm and gear .............................................................................................................. 11 Figure 7 Forces acting on the worm and gear ............................................................................................ 11 Figure 8 Free body diagram of main shaft .................................................................................................. 12 Figure 9 Cad models of machine elements ................................................................................................ 14

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List of Tables

Table 1 Morphological chart ......................................................................................................................... 6 Table 2 details of morphological chart ......................................................................................................... 7 Table 3 Concept screening chart................................................................................................................... 8 Table 4 Final selection................................................................................................................................... 9 Table 5 Design parts .................................................................................................................................... 15

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Background

1.1 Introduction Food behaviours of developing countries like Sri Lanka are gradually getting changing in case of consuming fast foods. They have used to take instant food such as ready to eats. Most of them take simple food like bread, hoppers and string hoppers for their breakfast & dinner.As a matter of the fact these foods has a great selling market. So it clearly says there need to be an improvement in these food industries. From that we would like to pay attention to the string hoppers making industry. String Hoppers is a Sri Lankans traditional food made by steaming process. This is made with rice flour after passing much process. It is served for the breakfast or dinner as main food with hot chilli coconut sambol, hot chilli powder gravy or sweet tasting white gravy made with coconut milk. Mainly string hoppers are eaten only in Sri Lanka, but its not like that main food. In India, Singapore, Malaysia & most of Asian countries eat string hoppers but with different names. In South India PittuMayam is Indiappa in Sri Lanka *1+. Its a piece of evidence that we mainly eat string hoppers, for our breakfast or dinner and its a very famous dish in every part of the island, no matter you are rich or poor all Sri Lankans love to eat string hoppers. 1.2 Problem definition String hopper is more favourable food in Sri Lankan context of food consuming. Therefore making string hopper is important as well as having significance difficulties. This string hopper making device is commonly made with a handheld hand-made wooden device consist of a small cup have a cylindrical through bore extend from its top to bottom. A metal plate with a large number of pores formed therein is mounted with screws at the bottom of the cup so that the bore forms a cylindrical tube therein for holding the rice dough. The cup has two grips extending outwards from its two opposite sides. A wooden cylindrical plunger having the corresponding size as the cylindrical tube is mounted on a carrier which also has two opposite side grip similar to the cup. The device is operated by placing the rice dough into the cylindrical tube of the cup and then inserting the plunger into the cylindrical tube and squeezing the grips of the plunger and the cup tightly towards another by hands so as to extrude the dough through the plate with the plunger to form the string hopper. While extruding the string hopper, the operator must also move the device in a circular motion so as to deposit the string hopper onto a steam tray for its subsequent cooking [2]. Following criteria describes the dominant problem in making string hopper. o Health issue as lead to hand pain in traditional method. o Repetitive work it cause dullness to operator. o Low efficiency o Low productivity i.e. it can make bulk amount of string as need in once. o Cost factors traditional method is more cost full to hire a person to squeeze string hopper in case of food trader making with string hopper.

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LITERATURE REVIEW In literature survey it has been seen that many types machines are developed to make string

hopper. Especially, in India the different types of machines are introduced in food industry such as Lalit Food Machines, engineer mokans string hopper machine, Aarbee Engineering Industrys Idiappam Making Machine, etc. Most of the available machines are not adequate all the features that actually needed by user. Further the available machines are not environment friendly as well as in economical friendly. However the exiting devices have more powerful and making high production rate. Furthermore the industrial machines are more bulky and expensive those are not coping with our economy. 2.1 Available machines and their disadvantages

A. Aarbee Engineering Industrys Idiappam Making Machine Features production capacity: 2,000 2,500 / hour Idiappam die diameter: 100 110 mm Idiappam thickness: adjustable Machine construction: 100 % stainless steel Power: 5000watts. Operation: pneumatic with PLC controls. Appearance: elegant Size: 10 ft. (h) x 3 ft. (w) x 10 ft. (l) Man power: one B. Abc Agro & Food Machine India Private Limited Idiyappam Machines Capacity 250 pcs / hour onwards Power requirement 3 hp, single phase Floor space - 2m x 2m x 2m Figure 1 Full automated machine and their important parts

Figure 2 Lalit idiappam machine

Figure 3 Typical available machine

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2.1.1

Disadvantages of machines

Health issues:

Relatively large pressure must be exerted between the plunger and the cup in the operation, which requires a high degree of skill and effort to carry out the string hoppers. Furthermore, the device is unhealthy since it is difficult to clean any dough remains from the wooden cylindrical tube and between the cup and the metal plate. Those problems will cause to operators by hand pain, Arthralgia, hand spasms. Repetitive work: In traditional method, the movement of two hands squeeze and in circular motion in the same directions by several times is very dullness, awkward to carry out the process. Low productivity: Furthermore the overall production rate and efficiency are very low in traditional method and exiting machines. The problem arises in making string hopper in home and as in edible industries is more difficult. If squeezing the plunger through the cup is difficult, it is possibly due to following reasons.

2.2 Cheap

User needs analysis

Most of the available machines are more expensive. So Machine Initial cost and maintenance cost should be low Quality Machines product should be taste and quality like traditional one. And Machine permanence should be high and functional and controlling also should be best Safe Machine parts and operation should not be harmful for the user Less Power Machine should have an efficient power controlling Quickly Machine able to extrude the string hopper quickly as well as conveyed out. Portable Machine should be easily moved by the user

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2.3

Engineers perspective of the design Appropriate for Sri Lankan food industry Reduce the time for making string hopper by making 10 string hoppers per minutes Size of the machine within the 1X1 m2 area and height as 1.5m Power supply to the machine is less than 5kW To transfer the power from power source to the machine with Workability of the machine for large industries in urban area Materials for the machine should be acceptable to food organization code and conduct Capacity of the machine around 5 kg of dough at the instant Efficiency of the machine considered as more than 90%

SYSTEM DESIGN AND METHODOLOGY Following units define the methodology of the project and system design with idea generation.

Further the concept generation and final selection of concept gives machine function and design elements. 3.1 Methodology Problem identification and define the scope of the project Identify the user needs and define required specification Conceptual design(Function analysis, Morphological chart and concept generation, analysis and concept selection) Draw the free body diagram and the velocity diagram and find requirements Select proper material and make the design calculation of machine element Design a 2D and 3D CAD model of the machine using solid works Carry out through computer simulation of motion generation Optimization and improvement of the overall design

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3.2 3.2.1

Concept Generation Methods of string hoper making

As discussed above in literature survey there are various machines are available in the market. Hence each machine has their own method to extrude the string hopper according to their construction. So there is no proper method in making string hopper. The following section describe the major stages in string hopper making as well as functions. 3.2.2 Functional Analysis

The following figure shows the functions of string hopper squeezing device which can automatically getting the string hopper after feeding the dough to machine. These functions can be performed different ways which are showed in following morphological chart.

Figure 4 Functional analysis for string hopper making machine

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1.1.1

Morphological chart

This chart describe the possible method to select concept which are mostly satisfying with above function Table 1 Morphological chart

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3.2.3

Details chart of concept morphological Table 2 details of morphological chart

Functions

Concept 1

Concept 2

Concept3

Concept 4

Concept 5

Storing

Within the cylinder for batch process

Hopper with screw feeder

Hopper

Within the cylinder for batch process

Hopper

Squeezing

Power screw mechanism

Screw extruding

Sliding crank mechanism

Hydraulic system

2 Lever mechanism

nd

Extruding

Screw cup with holes

Screw cup with holes

Circular plate with holes

rectangle plate with holes

Circular plate with holes

Shaping

Rotating mates

Rotating mates

Manual

Rotating mold

Manual

Conveying

Belt conveyer

Rotating disk

Manual

Belt conveyer Hydraulic power (Electric power)

Manual

Power Source

Manual

Electric power

Hand driven

Hand driven

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3.3

Concept screening

Table 3 Concept screening chart

Concept Selection Criteria

Concept 1

Concept 2

Concept 3

Concept 4

Concept 5

Can be operated by one person High Storage Capacity Capable of making several type simultaneously Can be used by disability Easy to cleaning Portability Can be make various type foods Redundant elements Environmental safety Easy to operate Maintain free Life time Time consumption Wastage Power consumption Total point

10

10

10

10

10

7 7 3 7 7 9 5 8 5 5 6 7 8 8 102

9 7 9 5 5 9 4 8 9 5 8 9 8 7 112

8 5 3 5 5 9 7 8 5 5 6 7 8 8 99

7 9 9 7 5 9 3 3 9 3 4 9 8 5 100

8 3 3 8 7 9 8 8 5 8 8 3 8 8 104

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3.4

Final selection Table 4 Final selection

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SUMMARY OF CALCULATIONS

4.1 Power calculation Evaluated torque = 1.7kNm Evaluated speed of rotating speed of the main shaft = 20 rpm Hence required minimum power of the machine= torque X angular velocities = 1.7 X 2 X X 20/60 =3.56 kW Hence to overcome friction and other resistance power of the equipment 3.6kW 4.2 Barrel design Material - Stainless Steel S43100 with allowable stress in tensile 140MPa and Safety factor is 2 Defined parameters for barrel Operating pressure of the barrel is 8MPa diameter D = 90 mm or R = 45 mm; P = 8 N/mm 2; t = 70MPa = 70 N/mm2; Then t=6mm 4.3 Motor selection Motor selected as at speed 1000 rpm So required speed reduction is 50:1 Hence the worm and wheel is good for gear reduction and exerted torque will not affect motor 4.4 Coupling design Coupling selected type as flange coupling because high torque transmission. Transmitting torque 1.7kNm d=35mm Hence L=52.5mm, d1=? , D=70mm, D2=140mm, D1=105mm, No of bolts is 3 Assume safety factor as 2 and Material-carbon steel .55% with Allowable Shear stress for shaft, bolt and key material = 282 MPa Crushing stress for bolt and key = 150 MPa Permissible Shear stress for cast iron = 30 MPa s = b= k = 282 MPa = 282 N/mm2 ; cb = ck =150 MPa = 150N/mm2 ; c = 30 MPa =30 N/mm2 4.4.1 Design for key Figure 5 Flange coupling Width of key, w = 12 mm and thickness of key, t = w = 12 mm The length of key (l) is taken equal to the length of hub. l = L = 55 mm 4.4.2 Design for flange

T= Since =6.929mm Take as 7mm 4.4.3 Design for bolts Taken the number of bolts, n = 3 and pitch circle diameter of bolts, D1 = 3d = 3 35 = 105 mm Then calculated bolt size is M8 Other proportions of the flange are taken as follows: Outer diameter of the flange, D2 = 4 d = 4 35 = 140 mm Thickness of the protective circumferential flange, tp = 0.25 d = 0.25 35 = 8.75 say 10 mm

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4.5 Worm gear design No of starts is one Worm gear velocity ratio is 50:1 Ankle of pitch Pa=Pc =20mm Pressure angle = 14.5; = 0.05; Lead angle15.2 1. Lead l =20mm 2. Normal pitch PN = 19.3mm 3. Pitch circle diameter Dw=60mm 4. Module of teeth m=7mm 5. Gear diameter DG=350mm 6. Outside diameter (DOG) =370mm 7. Throat diameter (DT) =360mm 8. Face width (b)=54mm 9. Radius of gear face (Rf) =32mm 10. Radius of gear rim (Rr)= 58mm 11. Face length (LW) = 100mm 12. Depth of tooth (h)= 13.72mm 13. Addendum (a) =6.36mm 14. Centre distance 205mm 15. Efficiency of the worm gearing =82.84% 4.5.1

Figure 6 Details of worm and gear

Strength calculation and material selection for worm and gear

Forces acting on the worm teeth

Figure 7 Forces acting on the worm and gear

WT -tangential force
W A -axial force
4.5.2 Design of worm gear a. Check for the tangential load Let speed of the worm gear in rpm Tangential load adding on the gear =9.7142kN Peripheral velocity of the worm gear, V = 0.733 Lewis factor y = 0.124 for

Velocity factor

=0.8911

involute teeth = 0.11

Worm gear material is phosphor bronze with o= 84MPa

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Allowable Tangential load

= (

) b m y = 9.777kN

b. Check for dynamic load = 9.9653kN

c. Check for static load or endurance strength Assume - flexural endurance limit for phosphor bronze = 168 MPa Static load = = 21.945kN d. Check for wear Assuming the material for worm as hardened steel, therefore hardened steel and phosphor bronze stress factor can be got from table31.5 reference [1]. K = 0.55 N Limiting or maximum load for wear = bK=0.395kN 4.5.3 Tgear=1.7kNm Tworm = = Design of worm shaft =41.042Nm It known that tangential force on the worm, = 1440.07N = 9714.28N

WT = Axial force on the worm gear = WA = Axial load on the worm

WR = Radial or separating force on the worm gear= WA . Tan =2512.28N Material of worm shaft is carbon steel 0.55%carbon 4.5.4 Design of worm gear shaft

Material- Stainless Steel S43100 and with shear stress 200MPa Diameter of worm gear shaft= 35mm Axial force on worm gear = 1440.07N Tangential force on worm gear = 9714.28N Radial force on worm gear = 2512.28N 4.6 Main Shaft design

Torque exerted on the shaft is T= 1.7 kNm Safety factor as 3 Material - Stainless Steel S43100 with yield stress =0.6 tensile strength= 847MPa As safety factor allowable shear stress 847/3 =282MPa Since d=35mm

125mm Self-weight and extruder FT

125mm

F
R

400mm
Figure 8 Free body diagram of main shaft

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Finally total bending movement affecting on the shaft also considered that were not affect with diameter of the shaft as above calculated. 4.7 4.7.1 Selection of bearing Bearing of main shaft calculation

Assumptions Average life = 10years at 8 hours per day 300 working days per year Radial load = 2512.28N

Axial Thrust force when extruder extrude in word FT = 26228N Axial load by worm = 1440.07N

Total axial forces =27668N Hence selected 3 bearings are No 308 with Indian stranded 4.7.2 Bearing of worm shaft calculation

Assumptions Average life = 10years at 8 hours per day 300 working days per year Operating speed N= 1000 rpm There are 2 bearing has been decided to put in shaft Radial force on worm = 2512.28N

Axial load on the worm 9714.28N Finally radial forces on the each bearing =1256.14N Axial forces on the each bearings = 4857.14N Hence selected 2 bearings No are 308 with Indian standard

5 FINAL DESIGN
The project final design is having following specifications.

5.1

Machine Specification
Power of the machine is 3.6kW Capacity of the machine at the instant is 5kg production capacity: 500 600 / hour Idiappam die diameter: 40-50 mm Idiappam thickness: adjustable by changing die holes Machine construction: stainless steel, other plastics material and aluminium alloys Size: 1.25m. (H) x 1m. (W) x 1m. (l) Man power: one

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6 CAD MODEL OF THE MACHINE

Figure 9 Cad models of machine elements

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Table 5 Design parts PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Aluminium Table Frame Teak wood table plate Electric Motor Worm Worm gear Extruder screw Barrel Gear Box Conveyer Pulley Rotating Conveyer Conveyer pulley mount Die Plate Clamp_60mm for die plate Clamp_130mm with adapter and barrel Adapter 130mm in front IS 6455 SR - 03-40-S groove ball bearing IS 6455 SR - 03-35-D sliding ball bearing no 308 Gear Shaft Barrel Holder Pulley38mm coupled with motor Pillar Block for barrel Flange coupling B18.2.3.2M - Formed hex screw, M8 x 1.25 x 50 --22CN AM-M8-N B18.2.3.1M - Hex cap screw, M10 x 1.5 x 70 --26N B18.2.2.4M - Hex flange nut, M10 x 1.5, with 15 WAF --N Pulley35mm main power transmission to worm Pulley 40mm for conveyer belt nut Not visible under rotating conveyer Not visible under rotating conveyer Not visible insight barrel DESCRIPTION QTY. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 5 1 1 1 1 2 3 3 6 6 1 1

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7 ADVANTAGES & LIMITATIONS OF THE MACHINE

7.1 Strength 1. Reliable 2. No need of high technical knowledge 3. Even a female labor can participate this event 4. Low time consumption 5. Low pollution 6. Can use to assemble with various machine Opportunities 1. Anyone can operate 2. Portable 3. Disability can use it 4. New concept for Sri Lankan market 5. Low noise pollution hence acceptable Advantages

7.2 Weakness

Limitations

1. High initial cost 2. Additional maintenance 3. Power source required Threats 1. Cheap man power in Sri Lanka 2. Limits in usable area

8 SUGGESTED IMPROVEMENTS
The following criteria describes the improvement that are used to enhance string hopper making machine design The full automation may be introduced by PLC control panel and pneumatic valve. The plastic material can be used in barrel to reduce the weight of the machine such as ARAMID fiber plastic which is used in helmet manufacturing It will introduce the sensor system such as limiting switch for safety improvement Pneumatic or magnetic clutch can be used to stop between two operations (i.e. extruding string hopper one after other should have interval to extrude dough). Cam system could be used to improve above problem

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9 REFERENCES
*1+ R.S. Khurmi, J.K.Gupta A Textbook of Machine Design *2+ A. W. Birley, B. Haworth and J. Batchelor, Single-Screw Extrusion the Extruder Characteristic Physics of Plastics: Processing, Properties and Materials Engineering, Hanser(1992) Chapter 4. *3+ Peter Fischer, Johannes Wortberg Single-Screw Extruders and Barrier Screws *4+ Chunguang Wang, Shaocong Dai and Roger I. Tanner On the compressibility of bread dough Received May 17, 2006, final revision received August 23, 2006 [5] Design basis and hydrodynamic performance analysis of single-screw extruders

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