Full Report

ORGANIZATION CHART

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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

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

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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

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1.6 Project Planning

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Concept Generation Brainstorming Ishikawa

DiagramConcept Evaluation Matrix

EvaluationMethodologyDesign Review

Primary Goal Product Design Specifications background of

the problems objective scope project planning

Gathering information about material and methods

Ergonomic

CHAPTER 1Identification Of Need

CHAPTER 2Background Research

CHAPTER 3Conceptual Design

CHAPTER 4Embodiment Design

CHAPTER 5Final Design

Dimensional Modeling

Material Selection Analysis/ Calculation Design Review

Detail Drawings Manufacturing

Process Evaluate Cost Design Review

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 :

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TARGET FORECAST

REAL FORECAST

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

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.

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2.1.1 Five Aspects Of Ergonomics

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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5 aspects

Comfort Easy to use

Productivity Safety Aesthetics

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.

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

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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 :-

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.

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

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Adjustable rostrum

Casing Table Body

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.

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.

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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

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ELECTRICAL PROPERTIES

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

Dielectric Constant 2.8-4

Dielectric Constant, Low Frequency 3-4

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%

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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.

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.

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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

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

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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.

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

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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.

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

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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:

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

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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

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

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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

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.

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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

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

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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.

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TYPES OF JACK

Bottle jack

Floor jack Scissor jack Transmission jack Screw jack

Mechanical jackFarm jackJack standHydraulic cylinder jack

Long ram jack

Hydraulic air jack

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

2.3.1.2  Floor Jack

Figure 2 :  Floor Jack

Features

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.

Usage

Mainly used in the shops, repair work or storage. 

Specification

Table 2 : Specification Of Floor Jack 

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Model Capacity Min.heightLiftingheight

Adjustingheight

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

CN2001 20T 235mm 145mm 60mm

CN3001 32T 255mm 150mm -

CN5001 50T 285mm 180mm -

CN10002 100T 330mm 180mm -

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

CNF1021 2T 135mm 320mm 7.5

CNF1022 2T 135mm 355mm 8.5

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.

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

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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.

Usage Rugged steel construction, ideal for auto and truck repairs

Figure 4 : Transmission Jack

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Table 4 : Specification Of Transmission Jack

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.

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MODEL: CNI05

CAPACITY 0.2TON

Saddle  Degree 60-10 degree

G.W. 14.5KGS

MODEL: CNI01

CAPACITY 0.6TON

MIN.HEIGHT 1260MM

MAX.HEIGHT 1970MM

G.W. 51KGS

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

Table 5 : Specification Of Screw Jack

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

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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 16 180 320

CNL020 20 180 325

CNL025 25 130 275

CNL032 32 200 395

CNL032 32 180 320

TYPE CNR015 CNR030 CNR050 CMR100

CAPACITY (KG) 1.5T 3T 5T 10T

TEST LOAD (KN) 22 44.1 73.5 147

EFFORT REQUIRED  TO LIFT MAX. LOAD (N)

300 350 400 580

NET WIGHT (KG) 16 20 28 46

Table 6 : Specification Of Mechanical Jack

Figure 7 : Mechaincal Jack For Railway  

Table 7 : Specification of Mechaincal Jack For Railway

2.3.1.7 Farm Jack

Features

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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

The farm jack (also known as the handyman jack or high lift jack) 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.

Figure 8 : Farm Jack

Table 8 : Specification Of Farm Jack

2.3.1.8 Jack Stand

Features With robust frame, alloy steel holding. Kind: ratchet types, pin luck type.

Usage Mainly used in the holding of most cars and trucks, safely over 2 feet off the ground. Perfect for repair work or storage.

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MODEL SIZE MIN.H.(MM)

MAX.H.(MM)

MEAS(MM)

N.W.(KG)

G.W.(KG)

CNJ1020 20" 130 680 540*245*140 11 12

CNJ1033 33" 130 700 892*245*140 12 13

CNJ1048 48" 130 1070 1235*245*140 13 14

CNJ1060 60" 155 1350 1515*245*140 14 15

Figure 9 : Ratchet Type Jack Stand

Table 9 : specification of Ratchet Type Jack Stand

Figure 10 : Jack Stand With Hitch Pin

Table 10 : Specification Of Jack Stand With Hitch Pin

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MODEL CAPACITY MIN.HEIGHT LIFTINGHEIGHT

N.W(KG)

CNST02 2T 260mm 390mm 5.2

CNST03 3T 300mm 430mm 7

CNST06 6T 405mm 610mm 13

CNST12 12T 485mm 760mm 28

MODEL CAPACITY MIN.HEIGHT LIFTINGHEIGHT

N.W(KG)

CNST05 5T 310mm 410mm 16

CNST22 22T 365mm 510mm 31.5

2.3.1.10 Hydraulic Cylinder

Features Including swivel cylinder, Lifting cylinder&Pushing cylinder. Easy to replace. Special size can be customized

Usage Component of material handing truck and other equipment.

Figure 11 : Hydraulic Cylinder For Material Handing

Table 11 : Specification of Hydraulic Cylinder For Material Handing

2.3.1.11 Long ram jack

Features Hydraulic jack with special long ram. Lever handle easy to use.

33

W.L.L（Mpa） 16

Proof Press（Mpa） 24

Min. Start Press ＜0.3

Min. Spee（mm/s） 30-200

Media Oil

Working Temp（℃） -40-+90

Usage Can be used to perform a variety of repair work.

Figure 12 : Long Ram Hydraulic Jack

Table 12 : Specification of Long Ram Hydraulic Jack

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

34

MODEL CAPACITY MIN.HEIGHT LIFTINGHEIGHT

N.W(KG)

CNSL03 3T 620mm 1100mm 9

CNSL05 5T 620mm 1100mm 10

CNSL08 8T 620mm 1100mm 11.5

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

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.

35

Figure 13 : Pole Motor

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.

36

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

37

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.

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.

38

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

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

39

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

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.

40

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

41

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

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

42

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

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

43

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:

44

Appearance Competition Customer

Documentation Ergonomics Environment

Installation Product disposal Lead times

Legal and safety implicationsLegislation, patents and

copyrightMaintenance

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.

45

d. Life in Service

The product should withstand normal daily use for many years.

e. Operating Environment

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.

46

b. Customer

The customer would be firms, schools, universities and etc. The AHR would be most

useful also new invention in rostrum area.

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

47

Figure 3.1 : Brainstorming Method

3.2.3.2 Morphological Chart

48

Chart 3.1 : Morphological Chart

3.2.3.3 Function Structure

49

FeaturesMeans

1 2 3 4

1 Support Bottom Base

Tracks Air Cushion Slides

2 Power

Electric

Battery Hydraulic Pneumatic

3 structure mild steel woods stainless steel

aluminum

6 Lifting Hydraulic Ram

Rack and Pinion

Screw Scissor Jack

AHR

Input Output

Chart 3.2 : Function Structure

50

Force

Battery

Energy

Vertical Movemen

t

Scissor Jack

Jack Mechanism

Power Window Motor

3.3 Component Selection

FUNCTION CONCEPT 1 CONCEPT 2 CONCEPT 3 CONCEPT 4

Type of jack

ScissorBottle

StandHydraulic Air

Type of motor

Pole StepperPower Window

DC

Type of switch

Multi-switch Power window

switch

Push button One way switch

Table 3.2 : Component Selection

51

3.3.1 Material Selection (Final Decision)

Sub-function

Part1 2 3 4 Selection Factor

BOTTOM BASE

AluminumSta

inless Steel

Mil

d SteelPlas

tic

-strong

-easy to join

-high stiffness

-sustainable

-flat surface

BODYAcr

ylic

Ply

wood

Glass

Ho

llow Iron

-esthetic look

-tough

-smooth and flat

surface

-transparent

-no fragile

TOP BASE

Acr

ylic

Wo

od

Glass

Sta

inless steel

-light

-smooth and flat

surface

- transparent

- no fragile

-tough

Table 3.3 : Material Selection

52

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

53

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.

54

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

Body

Bottom base

310mm x 310mm

920mm x 320mm

720mm x 210mm

455mm x 310mm

910mm x 305mm

720mm x 200mm

310mm x 455mm

930mm x 330mm

720mm x 220mm

455mm x 455mm

940mm x 340mm

720mm x 230mm

Final Design

Table 3.4 : Developing Drawing Concept

55

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

56

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

57

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 Items

Ergonomic Cost Space Operation Multi purpose-use Total

Weighting factor

0.30 0.20 0.20 0.20 0.30 1.00

Concept 25

0.30

3

0.2

3

0.20

2

0.20

5

0.301.00

Table 3.5 : Rating Of Matrix Evaluation

58

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)

(460mm x 305mm x 5mm)

1

1

RM 50.00

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

59

CHAPTER IV

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.

.

60

Figure 4.1 : MIG welding machine

Safety rules

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.

61

• 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

62

• 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

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.

63

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

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.

64

Figure 4.6 : Bottom Base Frame

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

65

Figure 4.8 : The Welding Process2) 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

66

Figure 4.11: Cutting acrylic with angle

Figure 4.12 : New Angle View

Figure 4.13 : High speed cutter

67

15°

Figure 4.14 : Cutting Using Hydraulic Swing Beam Shear Machine

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.

68

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,

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.

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Figure 4.17 : Bending Process

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.

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Figure 4.19 : Riveting Process

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

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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

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Power window motor

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.

+ - + - -

+

+ - -

Figure 4.24 : Schematic Circuit

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Power window switch

battery

Figure 4.25 : Assemble Wire To The Switch

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

1.

2.

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3.

4.

5.

0.01m

6. Shaft mass

7. Gear ratio

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8.

9. Motor torque

10. Force transferred from motor

Motor can generate power to the system.

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5.1.2 Ansys (Total deformation)

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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