Post on 04-Nov-2015
description
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FIGURE LIST ` pg
Figure 2.1.1: Show the Boat Land after Netting Fish
Figure 2.1.3: Base example
Figure 4.1.1: Belting system
Figure 4.2.1: Structure of gear
Figure 4.3.1: Structure of polymer
Figure 4.4.1: Machine 1
Figure 4.4.1: Machine 2
Figure 4.4.3: Machine 3
Figure 6.1.1: Electrical Motor
Figure 6.2.1.1: Female Gear
Figure 6.2.2.2: Male Gear
Figure 6.3.1: Winch
Figure 6.4.1: Bearing
Figure 6.5.1: Shaft Holder
Figure 6.6.1: Worm gear holder
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Figure 6.7.1: Coupling
Figure 6.12.1: Basement
Figure 7.1.1: How to tight the base
Figure 7.4.1: How to hanging by cable
Figure 7.5.1: Process Drag the load
Figure 8.3.1: Product design (by using solid work)
Figure 8.3.2: Detail drawing
Figure 8.3.3: Part drawing
Figure 12.1.1: Assembly Drawing (Female Gear)
Figure 12.1.2: Assembly Drawing (Male Gear)
Figure 12.1.3: Assembly Drawing (Winch)
Figure 12.1.4: Assembly Drawing (Bearing)
Figure 12.1.5: Assembly Drawing (Shaft Holder)
Figure 12.1.6: Assembly Drawing (Worm gear holder)
Figure 12.1.7: Assembly Drawing (Coupling)
Figure 12.1.8: Assembly Drawing (Shaft)
Figure 12.1.9: Assembly Drawing (Bush)
Figure 12.1.10: Assembly Drawing (Basement)
TABLE LIST
Jadual 6.2.1 : Spesifikasi Am Enjin Proton Satria 1.3 (M) 19
Jadual 8.0.1: Senarai komponen yang digunakan 30
Jadual 8.2.1: Anggaran kos bahan 35
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LIST OF CONTENT
1.0 ABSRACT 7
2.0 INTRODUCTION 8
2.1 Problem Statement 8
2.2 Design Concept 10
3.0 OBJECTIVE 11
3.1 Overal Objective 11
3.2 Main Objective 11
4.0 LITERATURE REVIEW 12
4.1 Belt and Chain System 12
4.2 Gear System 13
4.3 Type of Material 16
4.4 Available Boat Winch at Pantai kundur and Pantai Puteri 18
5.0 IMPLEMENTATION METHOD 21
6.0 COMPONENT 22
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7.0 OPERATION METHOD 30
7.1 Basement 30
7.2 Position 30
7.3 Cable 31
7.4 Hanging Process 31
7.5 Drag 32
8.0 TECHNICAL SPECIFICATION 33
8.1 Product Cost 33
8.2 Product Specification 34
8.3 Product Design 35
9.0 DISCUSSION 37
10.0 CONCLUSION AND SUGGESTION 38
11.0 REFERENCES 39
12.0 APPENDIXES 40
1.0 ABSTRACT
First of all, this final project used to train us to become a knowledgeable and
matured in any field we attend, especially when we entered job environment after this.
Our design concept is according our problem statement. One of it, is to reduce the
machine cost at market but still effective. Then, the size of the machine must be smaller
than the product sold at market. From our literature review, we had recognized a few
types of gear that can transmit power from motor to a heavy load that not more than 1
tone. We add a few components like different gearbox from the available machine at
market. Our gearbox did not use oil, but only use grease to make it smooth. We also need
to draw the design using software to recognize the actual dimension before do the
machining process. The sketch for our design is our first idea before we find the really
effective design after our research from literature review and survey. After completing
our project at week 14, we still need more improvement for our product. What we mean
from the improvement phase is the aesthetic dimensional.
Pertama sekal tujuan projek ini adalah untuk merendahkan kos dan mengecilkan
saiz mesin. Berdasarkan kajian yang dijalankan terhadap produk yang sedia ada, terdapat
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pelbagai jenis gear yang digunakan. Namun keupayaannya berbeza-beza yang
membuatkan kumpulan kami terpaksa mendapat khidmat pakar dalam pemilihan gear.
Mesin kami dijangka boleh menarik beban tidak lebih dari satu tan. Kami juga ter paksa
membuat lukisan menggunakan solid work bagi mendapatkan dimensi sebenar dalam
memastikan tiada masalah semasa proses pemasangan. Setelah selesai projek mesin ini,
masih terdapat kelemahan yang perlu diperbaiki iaitu dari segi fizikal dan bentuk produk
tersebut.
The purposes to develop a new design for a boat wicnh are to reduce machine cost
with machine easy to maintenance, easy to be used and can pull a heavy load. The
machine is design to improve the boat movement form the sea to the seashore at Pantai
Kundur. Survey conducted shows the existing machine consume high cost and limited
use where that machine cannot be shared with other fishermen
mesin tarik bot direkacipta untuk menarik bot di kawasan sekitart pantai kundur.
mesin yg telah sedia ada lebih tinggi kos dan tidak user friendly. ia juga terhad untuk
kemudian nelaya tertentu sahaja dan tidak dapat dikongsi dengna nelayan2 yg lain.
beberpa kajian telAH DILAKUKAN UNTUK MENCIPTA MESIN YG PALING
EFEKTIF DARI SEGI KPOS, PENYELEMNGGARAAN PEMASANSANGAN DAN
JUAG KEUPOYAAN. ANATAR YG TELAH DILAKUKAN ADALAH SURVEY
TERHADAP MOTOR, PENGGUNANN GEAR PEMASANGAN YANG RINGKAS
DAN JUAG KESELAMATN. MESIN YUG TELH BERJAYA DICIPTA DAPAT
MENARIK SEHIN NGA 500KG DENGAN KOS PEMBUATAN SEBANAYK
RM1663. BERBanding debgfab mesin yg sedia ada penjimatan jkos hampir 40 % daripad
harga di pasaran. mesin yg telah dicipta menaplikasikan gabungan motor dan gear utk
berfiungsi.
2.0 INTRODUCTION
2.1 Problem statement
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2.1.1 Most of fisherman at Pantai Kundur has problem while dragging their boat to
the land after netting fish. As we know boat is so heavy and beach sand give
only a bit help to pull it.
Figure 2.1.1: Show the Boat Land after Netting Fish
2.1.2 Only a few fishermen can afford to buy the previous machine because the
price is too high. It cost not less than RM 3000 per machine. The cost is
including motor, winch and gearbox, not with the cable cost. The cost for
3 phase wiring needs another RM 300.
2.1.3 The available machine can only can pull or drag one or two of boats that
really situated opposite of the machine because the available pole or
basement is fixed and cannot shift.
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Figure 2.1.3: Base example
2.1.4 The basement and the machine available at Pantai Kundur is too big which it
needs high cost and more space.
2.2 Design concept
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2.2.1 From the problem statement, the main focus of our product is to reduce cost
by design a product that used another application machine without giving
problems to the fisherman at Pantai Kundur.
2.2.2 The design concept will only need the fisherman to spend only half of the
cost of available machine. The estimation cost is around RM 1500
including motor, gearbox and winch. Our design concept might use
another type of gearbox. The gearbox named worm gear which transmit
more power, need small space, simple, more efficient and low of cost.
2.2.3 Our product would drag or pull the load or boat not only in front of the
machine but it can shift about 30 degree from the left or right of the
basement. This concept will help another fisherman boat which still
cannot afford to have the machine. This because our product need to
tightened to a pole using sling which it can shift according to the load
position.
2.2.4 A pole or basement of our machine only need half feet shaft and deeply
fixed in a surface to make it stronger.
3.0 OBJECTIVE
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3.1 Overall objective
3.1.1 To train and improve students creativity in producing a product which can
generate students idea.
3.1.2 Train the students how to do presentation and force their project design
while seminar session.
3.1.3 Apply how to write a technical report and how to take part in an exhibition.
3.1.4 Train the students how to handle any project with a minimum supervise.
3.1.5 Teach the students to become more innovative and competitive
3.2 Main objectives
In this project, we have our own objective where to get A in our final project and
also to support our mission to solve the fisher problem. The objective is:
To reduce machine cost
Design a machine easy to maintenance
Design a machine easy to use
Design a machine can pull heavy load
Design a machine more flexible
4.0 LITERATURE REVIEW
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Along this project, to design a good project, we had study many things from book,
internet and also from our analysis from customer comment, it like;
I. how to transfer the power from motor to winch
II. what is the efficient system for us to apply to our design
III. what the material we should be used
IV. how to reduce project cost
Every data collection we do analysis and discuss in group to make sure it really efficient
to apply or not. The data we collect is referring to the system what we want to used and is
it inside our mission where to reduce cost machine. The data is:
belt and chain system
gear system
type of material
4.1 Belt and Chain System
Belt and chain tensioners reduce belt or chain slack and transmit drive torque uniformly.
They also reduce noise and vibration; decrease sprocket, pulley, belt, and chain wear; and
increase the life of drive components. In drives, belts and chains are installed with
enough tension to create a level of friction that causes the belts or chains to grip the
pulleys and the pulleys to turn. Most belt drives consist of flat leather, rubber, or fabric
belts running on cylindrical pulleys, or belts with a V-shaped cross section running on
grooved pulleys. V-belts require less tension than flat belts because their greater surface
area creates more friction. Chain drives that use sprockets are reliable systems for long
running, continuous drive applications with limited shock and torque loads.
Belt and chain tensioners are available in a variety of sizes, styles, and materials. They
can handle different minimum and maximum loads as well as temperatures. With chain
drives, maximum chain pitch is an additional consideration. Belt and chain tensioners are
used in machinery and equipment, automobiles, bicycles, conveyor belts, and numerous
other applications
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Figure 4.1.1: Belting system
4.2 Gear System
In gear system, they have many aspects we have to see like there size, bill of tooth, the
material we used and more. The picture below show the basic structure of gear:
Figure 4.2.1: Structure of gear
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We also know, they have many type of gear in industry, where every type has their own
application and different function, but if we look it closely all of this gear has same
application where to transfer the rotation of movement. The main type of gear likes;
Table 4.2.2: Type of gear
No. Type of gear Picture
1. Helical
- In helical gear, the system if like spur
gear but the angle of tooth is not 90
degree.
- Basically used for transfer rotation in
heavy load; like car, bus and more
- Used the concept of gear ratio to
increase the power or system
- Used direct load from motor or supply
2. Hypoid
- this gear is used to change the angle of
rotation from vertical to horizontal
- Used direct load from motor or supply
- Not efficient at heavy load
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3. Spur
- In spur gear, the system if like helical
gear but the angle of tooth is 90 degree
straight
- Basically used for transfer rotation at
light load; like bicycle, clock and more
- Used the concept of gear ratio to
increase the power or system
- Used direct load from motor or supply
4. Worm
- the concept worm gear is like screw,
where it can reduce load and at the same
time can reduce speed of motor rotation
5. Bevels
- basically only to transfer the rotation
directly from motor or supply
- where if more speed we give the
rotation also increase like car coupling
and arm
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6. Rack and pinion
- basically used at conveyer system where
the gear cannot static when move
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4.3 Type of Material
For convenience most engineering are divided into 3 main classes; metallic, polymer
(plastic), and ceramic materials. All of this we have to know their important mechanical,
electrical and physical properties. Where must choose it correctly to make sure it have all
specs that we wanted such as; strength, durability, hardness, and more that able to apply
base on applications. The basic materials are;
I. Metallic
- These materials are inorganic substance that are composed of one or more
metallic elements and may contain some nonmetallic elements.
- Metal and alloy are commonly divide into 2 classes; ferrous metals and
alloy that contain a large percentage of iron such as the steel and cast ion
and nonferrous metals and alloys that do not contain iron or contain only a
relatively small amount of iron
II. Ceramic
- Ceramic material is inorganic material that consists of metallic and non-
metallic element chemically bonded together.
- Ceramic material can be crystalline, non-crystalline or mixtures of both.
Most ceramic material have high hardness and high-temperature strength
but tend to be brittle.
III. Polymer
- Most polymer materials consist of organic (carbon
molecule chains or network.
- Structurally, most polymer material is no crystalline but some consist of
mixtures of crystalline and no crystalline regions. The strength and
ductility of polymer vary greatly
IV. Composite
- Composite are mixtures of two or more
of a selected filler or reinforcing material and a compatible resin binder to
obtain the specific characteristic and properties desired
- Composite can be of many types. Some of the predominant types are
fibrous(composite of
particles in a matrix)
V. Electronic
- Are not a major of material by volume but are an extremely important type
of material for advanced engineering technology.
- The most important electronic material is pure sil
various ways to change its electrical characteristic.
Most polymer materials consist of organic (carbon-containing) long
molecule chains or network.
most polymer material is no crystalline but some consist of
mixtures of crystalline and no crystalline regions. The strength and
ductility of polymer vary greatly
Figure 4.3.1: Structure of polymer
Composite are mixtures of two or more material. Most composite consist
of a selected filler or reinforcing material and a compatible resin binder to
obtain the specific characteristic and properties desired
Composite can be of many types. Some of the predominant types are
fibrous(composite of fiber in a matrix) and particulate (composite of
particles in a matrix)
Are not a major of material by volume but are an extremely important type
of material for advanced engineering technology.
The most important electronic material is pure silicon that is modified in
various ways to change its electrical characteristic.
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containing) long
most polymer material is no crystalline but some consist of
mixtures of crystalline and no crystalline regions. The strength and
material. Most composite consist
of a selected filler or reinforcing material and a compatible resin binder to
Composite can be of many types. Some of the predominant types are
fiber in a matrix) and particulate (composite of
Are not a major of material by volume but are an extremely important type
icon that is modified in
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4.4 Available boat winch at Pantai Kundur and Pantai Puteri
This entire machine we get it from our survey at Pantai Kundur and Pantai Puteri.
There have 3 machines still function like figure below:
Figure 4.4.1: Machine 1
High cost of machine( more than RM 3000.00)
The cable not arrange correctly
Used motor 4 Hp
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Figure 4.4.2: Machine 2
High cost of machine( more than RM 3000.00)
Difficult to find the spare part
Difficult to maintenance (high cost)
Used motor 7 Hp
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Figure 4.4.3: Machine 3
High cost of machine( more than RM 3000.00)
Used bigger space to put the machine
Difficult to maintenance (high cost)
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5.0 IMPLEMENTATION METHOD
Table 5.0: Gantt chart for our scheduled project
NO. Activity W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14
1 Title selection #
2 Idea of design concept #
3 Sketching #
4 Searching information #
5 Motor survey #
6 Worm gear survey #
7 Book worm gear/bush/motor #
8 Buy parts #
9 Design winch #
10 Design shaft #
11 Design 4 pieces holder # #
12 Design base #
13 Product assemble #
14 Product testing #
15 Presentation and seminar #
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6.0 COMPONENTS
6.1 Motor (custom made)
Figure 6.1.1: Electrical Motor
2 horsepower
3 phase
1500rpm
20 ampere
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6.2 Worm gear (custom made)
The main system that used in our product is worm gear, where we have to order from
supplier because it difficult to make it, figure below show the worm gear we used:
6.2.1 Female
Figure 6.2.1.1: Female Gear
Hardened brass
Have 32 teeth
4 holes for screw
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6.2.2 Male
Figure 6.2.2.2: Male Gear
Hardened mild steel
Have 4 teeth
Has key way
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6.3 Winch
Figure 6.3.1: Winch
The material is from mild steel
Have 4 holes for screw
Tightened with cable
The with is about 5 times of cable diameter
Welding and grinding
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6.4 Bearing (custom made)
Figure 6.4.1: Bearing
High speed steel
3 pieces
Inner diameter is 1 inch
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6.5 Shaft holder
Figure 6.5.1: Shaft Holder
The material is from mild steel
Use milling process
2 pieces
6.6 Worm gear holder
Figure 6.6.1: Worm gear holder
The material is from mild steel
Use milling, chamfering, drilling and threading process
4 pieces
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6.7 Coupling
Figure 6.7.1: Coupling
The material is from mild steel
Has key way
2 Key jam holes
2 shaft jam holes
6.8 Key
The material is from mild steel
Milling process
1 pieces
6.9 Shaft
The material is from mild steel
Using lathe process
1 pieces
6.10 Hook (custom made)
The material is from mild steel
Adjustable
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6.11 Bush (custom made)
The material is from mild steel
6.12 Basement
Figure 6.12.1: Basement
The material is from mild steel
6.13 Key jam
The material is from mild steel
5mm screw
6.14 Bolls
The material is from mild steel
10mm screw
12 pieces
6.4.15 Cam starter (custom made)
Model QS5
AC.500V50-60Hz
6.4.16 Cable (custom made)
Alloy
Long - 10 meter
Maximum load 450 kg
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7.0 OPERATION METHOD
7.1 Basement
First of all, the machine need to join to any base or pole for holding the machine
while pulling the load such as boat. The joining process we done are using to test
our product or machine is using sling. The sling can used to hang a load not more
than 4 ton. But, for the real testing at Pantai Kundur we need to join our machine
basement with the basement that ready for the previous machine using bolls and
nuts. The fasteners for the sling and our machine must be tidy.
Figure 7.1.1: How to tight the base
7.2 Position
The position of the machine might in any position. The motor is either at the
upside or down side. As long as the winch of this machine is opposite of the load
that were pulled.
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7.3 Cable
Before any process started, the cable need to be release as far as the load from the
machine was tighten with the basement. To release the cable we need to connect
the socket to the power supply. Then, switch on the power supply switch. Next,
push on the cam starter forward and the motor part will move the shaft which
connected to the worm fear and the winch. All the parts will move backward to
release the cable. The distance for the cable to release is according to the boat or
load situated.
7.4 Hanging process
At the end of the cable, we had tightened the cable with a hook. The hook that
joins with the cable needs to entwine about two times at the boat head or the load.
For our test we entwine the hook two times around the load and for the last
entwine we put the hook back with the cable to make it firmly fixed.
Figure 7.4.1: How to hanging by cable
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7.5 Drag
After tighten the cable with the load we start to drag the load. To drag the load we
just push the cam starter backward which will move the motor and the parts
related backward together.
Figure 7.5.1: Process Drag the load
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8.0 TECHNICAL SPECIFICATION
Table 8.0.1 Product cost
Component Price/unit Quantity Price(RM)
3 phase 2 hp motor RM 300 1 250.00
Coupling RM 300 1 250.00
Key RM 5.00 2 10.00
Jam screw RM 0.50 4 2.00
Male worm gear RM300 1 250.00
Female worm gear RM300 1 280.00
Bearing RM 10 3 30.00
Female worm gear shaft and acc RM 80 1 80.00
Bush RM 50 1 50.00
Winch and acc RM 50 1 40.00
Worm gear holder RM 50 4 200.00
Cable RM 3 20 m 60.00
Hook and acc RM 5 1 5.00
Base RM 20 1 20.00
Bolls RM 0.50 12 6.00
Wiring acc RM130 1SET 130.00
TOTAL RM 1663.00
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8.2 Product specification
Table 8.2.1 product for production
Parameter Specification
Length 480 mm
Width 205 mm
Height 170 mm
Weight 30 kg
Type of gear box Worm gear
Material used:-
Holder/shaft/ winch/base/coupling
Male worm gear
Female worm gear
Mild steel
Hardened mild steel
Hardened brass
Motor type 3 phase
Motor speed 1500 rpm
Motor volt 450 V
Motor current 20 A
Motor torque 2 hp
Cable type Alloy
Color Black and green
Capacity load Below 1 tan
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8.3 Product Design
Figure 8.3.1: Product design (by using solid work)
Figure 8.3.2 Part drawing
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Figure 8.3.3: Detail Drawing
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9.0 DISCUSSION
For along 14 weeks designing this project, we faced many problems. At the first
week until third week we cannot find the type of gear should be used. Is it the bigger ratio
is more powerful or type of material will make it different from each other? At last we
find Mr. Saifuddin at Muar Johor to make decision because he is an expert for custom
made product. He said for pulling a load the most powerful gearbox is using worm gear.
The other problems are selection of 3-phase and single phase motor. The available
machines at Pantai Kundur are using 3-phase motor. But the phase motor need 420volt
power supply, not as usual at Malaysia. The power supply is 240volt. Using 3-phase
motor need special wiring that need an application from Tenaga Nasional Berhad (TNB)
for that type of wiring. For 420 watt, it usually used at factory field or lab as at KUTKM
fasa B laboratory. 3 phase motor socket or plug also different. The single phase motor
plug is same as our home accessories. It is 3 pin plugs.
This subject is the most difficult subject which needs full concentration and
calculation from start until end. At last, we solve those problems with Mr. Saifuddin, our
gearbox expert.
We also difficult to find the raw material according to the size we want. To solve
this problem, we use a second hand part and rubbish material from mild steel which find
by our expert Mr. Saifuddin.
Capabilities of machine.
Problem of mounting
Cable
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10.0 CONCLUSION & SUGGESTION
As a conclusion, our project was successfully done to reduce the available
machine cost. The cost we had reduced is more than half prize from the market price but
with same product efficient. The cost at market is not less that RM 3000 and our product
costs RM 1663 only. The price should be less because the price is including try and error
price. Our machines also ease and low cost to maintenance because its use open gearbox
which no need to use gear box oil. Those types of oil will the increase the maintenance
cost. Our machine can pull not more than 1tonne load and very useful for those low
income fisherman. Lastly, this machine is design with high flexibility which it can shift
according the boat coordinate because its only needs a sling with a tough pole as a
basement. The available machine need a high, big and really tough basement to install the
machine before can use it. Finally our product is successfully done and gives more
satisfaction to the buyer from the available product.
For our improvement and suggestion, we need to use thicker cable as a safety
because the diameter for our cable is 5mm. its maximum stress is 800 kg. it might
fracture when more than 1 tone load given. We need about 10mm diameter of cable to
make this machine confident to pull load not more than 1 tone.
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11.0 REFERENCES
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12.0 APPENDIXES
12.1 Assembly Drawing
Female gear
Figure 12.1.1: Assembly Drawing (Female Gear)
Male gear
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Figure 12.1.2: Assembly Drawing (Male Gear)
Winch
Figure 12.1.3: Assembly Drawing (Winch)
Bearing
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Figure 12.1.4: Assembly Drawing (Bearing)
Shaft holder
Figure 12.1.5: Assembly Drawing (Shaft Holder)
Worm gear holder
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Figure 12.1.6: Assembly Drawing (Worm gear holder)
Coupling
Figure 12.1.7: Assembly Drawing (Coupling)
Shaft
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Figure 12.1.8: Assembly Drawing (Shaft)
6.11 Bush (custom made)
Figure 12.1.9: Assembly Drawing (Bush)
6.12 Basement
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Figure 12.1.10: Assembly Drawing (Basement)