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Machine assessment

Design process
After several complaints from the CRW manager. Meeting has been carried out with the sales manager,
technician and CRW manager, the decision is to provide the Mechwell to study the limitation and revised
the machine methodology. Since the basic requirement could not been establish. The engineering
process shall be as below:

Process 1
Mechwell has identified the problem of the machine and set the new objectives and Mechwell has been
given 1 week dated from 7/1/15. Then the suggestions are as per below:
1. To change all the cutting knives to a thicker material: from existing 10mm to 15mm thick, and this
job will complete latest by
19/1/15.
2. To install a warning lighting and reverse button to sense the outlet conveyor in case the outlet
being over loaded.
During this critical activities, impact has been identified in the design ergonomics and shall be explained in
details.
Since the agreed 1 week case study has been utilized, several cases occurred after the machine
capabilities was conducted, resulting in extension of testing and repairing period until today.
In understanding the complications carried over than 6 months, the challenge faced by Mechwell is the
machine is custom make based on engineering requirement, where the crushing capabilities are
extensively to all nestle expiry product. Nevertheless the identified product are different in size and
content. In order to identified the crushing capabilities, the cutting requirement at least of 50 percent to
prevent product to be resell. Single cutting capabilities has been chosen, where we have option such as
double cutting capabilities.

Design ergonomic
There are several criteria that has been use to access the machine capabilities, there are;

i.

Operator Control Access


Operator control access has been evaluate as per picture below:

Picture 1
The emergency button for crushing/cutting motor is on the panel and operator
has to bend and will consume time to press.

Picture 2
Emergency push button located at the conveyor area are very good where operator
can reach when emergency occur.

ii.

Machine productivity
i.

Feeding/Loading

Machine loading and feeding are being fed thru the conveyor with 1hp motor below:

Picture 3
During feeding this deliverables are permeable thru out swivel and cutting cover shown below:

Picture 4
Output deliverables from the swivel conveyor to the storage as shown below;

Picture 5

ii.

Output deliverables

Picture 6

iii.

Working principle
Machine specification
1.
2.
3.
4.
5.
6.
7.

Shaft carbon steel OD100 X 1100 L


Bearing UCP212 4 pcs
Water pump hp
Tank material Thk 12mm stainless steel
Frame square hollow section 3 X 3
Conveyor belt 600 X 2438 motor 1HP
knife specification : 10mm converted to 16 mm (Hot role allot steel plate
45CR)
8. Screw and barrel
The crushing machine using three induction motor
9. 1hp Feeding motor 500rpm
10. 1hp Swivel motor 500rpm
11. 25hp Cutting motor 1400rpm
Calculation of speed with 1400 rpm that will produce torque or amount of force
approximately 111lbft where force per 1 meter is
150 111
15 0.101971621 150
And equivalent to 150 Newton ;approximately 15kg of cutting force at the output of
the driven pulley since Mechwell are using 1:1 pulling configuration (refer picture 7)
shaft, this specification will be:

Picture 7

iv.

Cutting methodology

Investigation of the cutting methodology has been found that there are some
product 1/50 that are not being cut (shown on picture 6) and jumping outside the
cutting cover(picture 8)

Picture 8

The justification of rotation and force theoretically will cut any of the product.
However, the conveyor and cutting rotation are turning in the clockwise condition
so when feeding, the product will bring forwards and into the cutting area shown
in orange arrow (picture 9) while the cutting action only happen in left side of the
cutting cover (picture 10), so when rotating the force direction of the blade will
push the product jumping out from the cover because of the conveyor and
feeding direction (shown on picture8)

200

Picture 9
The cutting principle only occur in left side of the cover because in picture 10 the
secondary blades are mounted then the rotation of cutting will cut the product thru
this section while on the right side there has been gap between each blade so that
when feeding, the product will randomly goes on the left or fight. If the product fell
thru the swivel on the right, there might be occurrences of the product are not
being cut as shown in picture 6.
This statistic of product feeding are not acceptable since there will be product uncut
and jumping out from the cover.

Picture 10

i. Shaft vibration Vs Casing Vibration


The machine are loud and vibrating more than usual and has been identified
in shaft vibration because rotation in 1400 rpm with different placement of
blade at the shaft (picture 11)
80

60

130

70
610
Picture 11

When the distribution of the blade is not even, the amount of force rotating
will become uneven and cause the shaft to vibrate when attach to the casing,
furthermore there is no bushes to absorb the vibration resulting the casing
vibrating and cause noise level more than 90db. This can be classified as danger
level and should wear hearing protective instead.

v.

Sealing capabilities

Sealing capabilities could not been perform effectively because the sealing has
compromised due to vibration of the crushing machine at the shaft. This resulting
in picture 12. In addition, prolong vibration will cause severe damage to the
motor performance, pulley, belt and cutting cover.

Picture 12

vi.

Clearing jams and cleanup (maintenance)

1hp water pump has been introduced and there are several condition that could not reach by
the pump and for access operator for cleaning in the swivel are limited. Poor housekeeping and
cleaning perform resulting in clogging and swivel motor stopped.

\
Picture 13

Warranty specification
Warranty specification has been stated as 1 year from the purchase. However, the machine undergo
feasibility study and could not deliver as per production and ergonomic requirement. Except there are
cases such as picture 14

Picture 14

Where the approach is to weld the shaft instead of replacing. Furthermore, arranging the blade distance
after weldment are not properly clean and shall be test using penetration test to justify strength and
tightness. (Picture 15)

Picture 15