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ME3901 Project-Design Realization_

Department of Mechanical engineering

ME3901 Project Design Realization

Design Improvement of Goods Trolley

Final Report

Group No. Group Name Student ID 10945826T 10947936T 10951673T 10953120T

Group Members

5 KTB Name Li Ka Kin Chow Chi Hin Yu Sin Him Wong Tsz Yu

Project Role Project Manager Design Manager Design Manager Marketing Manager

Abstract
Our group found that when we were using trolley to deliver the goods, the whole trolley was oscillated during move and it made the goods move on the platform even dropping down. Thus, this report shows how to build a product to minimizing the vibration problem of a goods trolley in our project. In our consideration, vibration is also the parameter of producing other badly mechanical issues such as excessive wear, fatigue failure, damage to structure, etc. Therefore, we design anti-vibrators not only reduce vibration level but slow the mechanical issues occur. For supporting our design can improve the vibration problem, two vibration tests are held, one is for prototype and other one is for design product, and those are conducted under the same conditions. After the comparisons of the data which collect from the two tests, we find that the anti-vibrators have actually absorbed the part of vibration force during the movement of the goods trolley. Especially, it obviously has a better performance during moving in on-load condition. In addition, the practical experiment tests the durability of anti-vibrators which withstood the vibration force and ensure no components loosening during move.

Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu

Acknowledgement Dr. Udaya Kahangamage (The Lecturer of Project Design Realization) Chan Yu-Ming (TA) Dr. X J Jing (The Lecturer of Dynamics and Vibration)

Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu

Table of Content
Chapter 1 Introduction Chapter 2 Methodology Chapter 3 Initial product analysis Chapter 4 Building & improvements the conceptual design 4.1 Components 4.2 Production Process 4.3 Modifying the design product Chapter 5 Detail description of the vibration test 5.1 Instruments 5.2 Test 5.3 Data 5.4 Factor affecting the result Chapter 6 Data analysis & Findings Chapter 7 Conclusion Chapter 8 Reflection on the learning experience Reference Appendix: (a) Project Management (b) Manpower Management (c) Financial Management

Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu

Chapter 1 Introduction
The aim of this final report is to describe and illustrate in detail about the design problems, the data analysis, test and improvement which were the experiments in our project. First, our Group KTB is to design the anti-vibrator for minimizing the vibration level between the wheels and the rough road during the movement of a goods trolley. Before we decided to use now design to become true, we had to consider and analyze which designs were satisfied with easy for assembly and disassembly four anti-vibrators, material requirements, replaceable or easy maintenance and also did not over the budget, etc. Second, after carried out the material selection, we started to purchase the required components and applicable tools for making the anti-vibrators (IBI manufacture) and installation. Third, we started to measure and mark out the location for the installation of anti-vibrators. Because the anti- vibrators needed to compress for vibration isolation, we must remove the bracket which was bonded with wheels axles and the platform for allow mounting anti vibrators between them. Then, we drilled the holes on the wheels axles and the platform and mounted thread bolts on the platform which was used to increase the intervals for putting the anti vibrators on it. Finally, we installed the wheels axles and wheels and were locked by fasteners. (The details of assembly are illustrated in Chapter 4) Forth, we were conducting the second vibration tests as same as the first test for prototype with on-load and no load separately. Next, we compared the data between the design product and prototype and checked whether it was better than before and also the magnitude of the improvement (reduced vibration level).
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In addition, during the installation of anti-vibrators, we found that two problems were existed in our design and listed below: 1) The friction blocked the movement between thread bolts and the holes. It caused the anti vibrator could not move so lost its function. So we had to enclose part of the threads which may be contacting with the holes by plastic tube and enlarge the holes for allowing the thread bolts to pass through smoothly. 2) The four wheels were swaying during move as the thread bolts could not be locked securely. We had to lock the each thread bolts in the platform by two nuts to prohibit from sway. During the vibration test, two problems were occurred in our design and listed below: 1) The bottom nut which was mounting the anti-vibrator and the wheels axle loosed during move on the rough floor. For prevent the whole assembly to loose, we had dropped some screw glue between thread bolts and nuts. 2) The wheels level was not aligned that only three or two wheels could touch the ground during move or rest. We had to readjust the height (stiffness) of anti vibrators to align the level. Finally, we did a practical experiment about conveyance of goods on a general pedestrian road. The purpose of the experiment was testing its durability and ensuring no iteration or other problems would be occurred for affecting the safety. The aspect of design product was almost completed. The detail of test results, finding and conclusion are showed on the following chapter.

Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu

Chapter 2: Methodology
Prototype finding (After the vibration test) Excessive vibration during moving on the rough road The level of trolley wheels are not align Analysis Problem Identification Vibration affect the stability of the trolley Balance affect the controllability of the trolley
Conceptualization

Implementation: 1. Research and design a product to improve the problems 2. Use software to simulate our design product in the visual situation
Design Feasibility

Implementation: 3. Material selection 4. Follow the layout to build the product 5. Conduct a vibration test for the design product 6. Collect and compare the data
Finding

Modification Problems & Solutions: a) Problem: Stability of the trolley Solution: Adjust the same height (stiffness) of anti vibrators b) Problem: Friction between holes and thread bolt Solution: Put the plastic tubes outside the thread bolts and file the burrs on the holes. b) Problem: Nuts loosen during operation Solution: Use the thread locker glue or thread adhesive tape

Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu

Testing: Vibration test


1. 2.

First Vibration test for design product Take data of loading & unloading

3.Key issues & Problems 3.1 Nuts loosen during movement 3.2 4-wheels unbalance 3.3 Friction produced between holes and thread bolt

4. Second Vibration test for modified product 5. Take data of loading & unloading 6. Compare the vibration level with whether add loading or not after modification 7. Compare the vibration level difference between original and modifiable one

8. Practical experiment for modified product 9. Comment by the customer 10. Summary : comments, data and problems & solutions

Calculation: 1. Vibration level 2. Average vibration level 3. Accuracy

Documentation: Prepare the final report for the design product


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Chapter 3: Initial product analysis:


Problem Identification Vibration level affect the stability of trolley The relationship between vibration and loading weight The relationship between vibration and operation speed Balance of trolley The friction of between rotating components (shaft and wheels) Environmental condition and stationary machine

Vibration can be defined as the cyclic or oscillating motion of a product or component from its position of rest. It can cause damage to structures and machine assemblies, resulting in operation, excessive wear, or even fatigue failure For initial trolley, we found that many parameters (above table) affect the vibration level of it. In this project, we concerned and identified four main parameters which affect the vibration level obviously. On load / unload

Balancing

Parameters

Operation speed

Environmental condition
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Balancing: Unbalance is defined as an exciting force. The exciting force is trying to cause vibration. In this case, we found that the wheels level was not aligned that only three or two wheels could touch the ground. We need to minimize the vibration by readjusting the height after modification.

Mass of the vibrating system: We knew that mass (loading) is trying to oppose the exciting force and control or minimize the vibration. So, our prediction is that the oscillation in on-load test must be lower than the unload one. After the test, we want to compare the vibration different against the unload one and prove our assumption right through the result.

Operation speed: When the operation speed is high than the critical speed, the vibration level will be lower at the same time (refer to F.g3.1 chart). Obviously, operation speed is the important part in vibration. In following part, we will process the vibration test in several speeds and analyze the data different.

(F.g3.1) Environmental condition: Ground situation is also a main environmental condition in this project. We decided to test the trolley on different ground condition and thereby proved that ground condition had a great effect of vibration.
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Chapter 4: Building & improvements the conceptual design


In this chapter, we would like to illustrate how to develop our conceptual design and how to solve the design problems which is found in the vibration test. Initially, we would like to introduce the components which we had used.

4 Thread bolts

4 Springs

Fasteners

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Production Process:
Step 1: Dismantling the 4 wheels and 2 wheels axles

(a) Disassembling the wheels Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu

(b) The wheels axles with brackets


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Dismantled

(c) Using a hand bow saw to disassemble the wheels axles with brackets

Step 2: Drilling the holes on the wheels axles and platform. Those diameters of holes are 10 mm bigger than the diameters of thread bolts.

Mark out the drilling location

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(d) Drilling the holes on the wheels axles by the portable electric drill

(e) Drilling the holes on the platform Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu
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Step 3: Assemble all the components on the trolley.

(f) Using the fasteners to lock the thread bolts on the platform

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Modifying the design product:

(a) Put the plastic tube outside the thread bolts to minimize the friction produced between the holes of wheel axles, and also prevent the components for wearing.

(b) Using the fasteners to lock the assembly on the wheels axles Li Ka Kin, Chow Chi Hin, Yu Siu Him, Wong Tsz Yu
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After the vibration test, we found that the fasteners would be loosened during moving on a rough road.

(c) P.T.F.E thread seal tape wrap was used to prohibit the fasteners loosening.

(d) Readjusting the height of anti-vibrators to align the wheels level

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Chapter 5: Detail description of the vibration test


We decide an experiment to test the vibration level of the trolley. In our experiment, we measure the damping ratio by the signal analyzer to isolate a single mode from the frequency response function. We test the trolley on the rough path (Fig.5.4) with different load add on it (Fig 5.5 & Fig 5.6). (a)Instrument
The Dual-Channel Signal Analyzers type 2032(Fig.5.1) is the instrument to determine the modal parameters of simple structures. The model frequencies are determined from the frequency response function. The model damping is found from the decay rate, measured from the magnitude of the impulse response function, which is produced by isolating a single mode from the frequency weighting function. The charge amplifier (Fig.5.2) use to transfers the input charge to another reference capacitor and produces an output voltage equal to the voltage across the reference capacitor. The accelerometer (Fig.5.3) is a device that measures proper acceleration.

Fig.5.1

Dual channel signal analyzer type 2032

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Fig.5.2

Charge amplifier

Fig.5.3

Accelerometer

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(b)Testing We divide the experiment into two parts, no-load test & on-load test. We use same instrument and load to test the trolley before and after modification.

1.

First test (before modification) Put the trolley on the rough path and pull it in a constant acceleration

Fig.5.4

10 kg add on the trolley for the test

Fig.5.5

Fig.5.6

20 kg add on the trolley for the test

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Fig.5.7

Record the Y (-19.5dB)with fixed frequency bandwidth X in different test

Fig.5.8

The value of Y is more negative, the less oscillation of the trolley is presented.

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2.

Second test (after modification) Trolley after modification

Fig.5.9

Test without loading Fig.5.10

10kg load add on the trolley

Fig.5.11

Fig.5.12

20kg load add on the trolley

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Data X is the frequency bandwidth = 117.0Hz 1. Before modification, 1st test Loading(kg) 0 10 20 -19.5 -22.5 -30.9 2nd test 3rd test 4th test

Vibration level Y (db) -17.9 -21.8 -29.0 -19.3 -22.1 -32.2 -20.1 -24.0 -30.9

2. After modification,
1st test

2nd test

3rd test

4th test

Loading(kg) 0 10 20 -27.6 -33.2 -41.3

Vibration level Y (db) -22.6 -33.3 -43.2 -24.3 -31.8 -39.7 -25.4 -32.5 -41.1
Li 10

1 To calculation the mean value L p 10 log[ N


Before Loading(kg) 0 10 20 Mean (db) -19.1 -22.5 -30.6

10
i 1

] where Li = average of the dB

After Loading(kg) 0 10 20 Mean (db) -24.6 -32.7 -41.2

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(d)Factors affecting the result Factor:

1. Uneven velocity of the trolley during the test 2. level of 4-wheels unbalances

3. Friction produced between holes and thread bolt Remedial actions taken:

1. To get the accuracy data, we try to pull the trolley with a constant acceleration. We also do the test 4 times to reduce the error. 2. To keep to the trolley in a balance level, we adjust the nut to balancing the trolley. We use the level bar to balance the 4wheels. The friction produce between the holes and the thread bolt will affect the vibration level. To improve this, we try to use the plastic tube to cover it, as the result to reduce the friction between them.

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Practical experiment: The main objective of our project is decreasing the vibration and no risk for human use. So, we need to provide a final practical experiment to test the trolley is functional and safety. In experiment process, we decided to test the structure of subassemblies whether firm or not first. Base on previous experience, the sub- assemblies will be possible to loosen during operation. We expected the sub- assemblies will not be loosen and raise the reliability of product. During experiment process, we trial use to keep the trolley in motion in 30 minutes continuously. After 30 minutes movement, the trolley can still function normally and all parts are firmly.

Rough condition

Smooth condition

In second part of practical experiment, each group-mate will try to pull the trolley individually on several ground condition and make a comment.
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Chapter 6: Data analysis & findings


Vibration may be characterized by: (i) The frequency in Hz; (ii) The amplitude of the measured parameter, which may be displacement, velocity, or acceleration. This is normally referred to as the vibration amplitude when expressed in units, but vibration level when expressed in decibels. Thus if the measured amplitude is A1 and the reference amplitude is A0, the vibration level expressed in decibels is:

1. From the data of first test, Before 1st 2nd modify test test Loading(kg) 0 10 20 -19.5 -22.5 -30.9

3rd test

4th test

Vibration level Y (db) -17.9 -21.8 -29.0 -19.3 -22.1 -32.2 -20.1 -24.0 -30.9
Table 6.1

In the first experiment before modify, after 4 trials, we find that the vibration level of the trolley will decrease when loading is add on it. In this analysis, we prove that mass, reduce frequency. increasing the

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2. From the data in both test,

Before Modify Loading (Mean (kg) (db) 0 -19.1 10 -22.5 20 -30.6

After Modify Loading (Mean (kg) (db) 0 -24.6 10 -32.7 20 -41.2

Compare the mean vibration level before and after modification, it shows that our design can reduce the vibration level as below chart:

Fig. 6.1

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Chapter 7: Conclusion
Since vibration is characterized by the frequency and the amplitude, as has been shown in preceding chapter. We have to aim at the above parameters to design a product to solving the vibration problem. We arranged two vibration tests, one for the prototype and other for the design product. We recorded the data from the above tests and compared these data. We made a vibration chart to represent our finding, and it showed that the product which installed the anti vibrators have lower decibel than not installed. The reasons of phenomenon are the amplitude of oscillation is minimized by damping effect and also the frequency is reduced by increasing the weight of the mass on the trolley. It means two parameters are changed to cause the decease of decibel. This finding proves that our design product (anti vibrators) can achieve our target that minimizing the vibration level of the goods trolley during move on a rough road. Although the design successfully reduces the vibration level, some problems are existed in our design. Since we did not have the drilling machine and the holes may not be drilled accurately on the marked location by electric hand drill, we need to enlarge the holes for fitting the anti vibrator installation. During the test, we just push the trolley by hand and no equipment monitors the speed of trolley so this is the main factor to affect the accurate of the testing result.

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Chapter 8 Reflection on the Learning Experience


Name: Li Ka Kin Student ID: 1094826t This project is a great experience and opportunity for me to learn how to build from zero to a whole product for solving the problem. I am so enjoyed the development process and satisfied the finished product. I really have learned so much in this project. While you are effort to find the information and sample to design your product, you will study lot of academic information and your knowledge also improve so much. It is an effective method for learning. Finally, this project can be finished smoothly, thanks my group mates for their good-cooperation and effort. I am so pound of them. Thanks. Name: Yu Sin Him Student ID: 10951673t

I got a valuable experience during this project. Initially, our group decided to design an automatic braking system for the good trolley. At the beginning of project, we had full of ideas about the automatic braking system. We found that our ideas all are not function after we communicated with ourselves and hear the recommendation of teacher. In above event, the experience enriched my learning and strengthened my communication skills. It will be a positive impact on my study even career path. After that, we changed the topic from braking system to anti-vibrator. During process of project, we met many design problems on the anti-vibrator such as friction blocked the movement, wheels sway In design process, we also appeared disagreement of opinions between group mates .At last, we also can choose the better method to solve the problem via a proper communication. So, I think that a proper communication was important to ensure smooth collaboration with each other Apart from learning vibration knowledge; I also learnt teamwork is an important parameter of a successful project.
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Name: Chow Chi Hin

Student ID: 10947936t

In this project, I am the design manager in our group. In the meetings, I try to bring out the ideas for the project. Through this process, I must have a clear concept of the design and do the presentation to my group mates. After the modification part, we face some problem which affecting our testing result. To solve those problems, we try to collect all suggested solution and find out the suitable one by using my knowledge of vibration. Besides, I also get the firsthand experience in doing a project from problem identification to idea implement. It can help my future continuality studying.

Name: Wong Tsz Yu

Student ID: 10953120t

First of all, I should thank all of my group mates. During the project, we face some barrier. There are many steps to connect the spring with the trolley. This is the most difficult part of the project, since the spring should be installed between the wheels and the base of the trolley. Second, I have learnt some technical knowledge form this design project. For the push trolley, a hard spring is more suitable for our situation. Due to the heavy loading of the trolley in real life, the spring system will be broken, if we use soft spring. Thats mean, we should choose the spring with larger spring constant.

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Reference
Reference website: Vibration parameter www.mech.gla.ac.uk/~sharpj/vibration.pdf

Vibration theory www.newagepublishers.com/samplechapter/001216.pdf

Logarithmic Frequency Scaling http://www.maintenanceworld.com/Articles/DLIEngineering/Whatis3.htm

Reference book: Theory& formula of vibration Vector Mechanics for Engineers Dynamics Author: FERDINAND P.BEER, E.RUSSELL JOHNSTON,JR. & PHILLIP J. CORNWELL

Process of vibration analysis The Vibration Analysis Handbook Author: JAMES I. TAYLOR

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Appendix (a)Project Management

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Project Work Schedule

(b)Manpower Management
Group member Li Ka Kin Project Role Project Manager Activities Carried out Design, Make the product, Test, Work distribution, Organize the activities, Control the progress and Quality of works Identify the problem of prototype, Design, Make the product and Test Identify the problem of prototype, Design, Make the product and Test Purchase, Financial management, Record the activities and Draw the design layout

Chow Chi Hin

Design Manager

Yu Sin Him

Design Manager

Wong Tsz Yu

Marketing Manager

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(c)Financial Management
No.1 1 2 3 Item Description Goods Trolley 1 no. Round File 1 no. Springs 4 nos. Receipt/invoice No. Not provided Not provided Not provided Price (HKD)

$170 $52 $200

Total: $422-

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