TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENTS iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLE xi
LIST OF FIGURE xii
LIST OF SYMBOLS xviii
LIST OF APPENDICES xix
1 INTRODUCTION
1.1 Introduction 1
1.2 Objective of The Study 3
1.3 Scope of The Study 3
1.4 Problem Statement 4
2 LITERATURE VIEW
2.1 Introduction 5
2.2 The Value of Onions 6
2.3 Onion Nutrition Facts 8
2.4 Pattern Search on Peeling Machine
2.4.1 Onion Peeling Pattern Number 4476778 2.4.2 Automatic Onion Skin Peeler
9 9 10
2.4.3 Onion Topper & Tailer Machine 12 2.4.4 Onion Peeling Machine 13
2.5 Assess Customer Needs 14
2.5.1 Maintain a Customer Focus 15 2.5.2 Identifying External Needs 15
2.5.3 Questionnaire 17
2.5.4 The Questionnaires Pros and Cons 18
2.6 The Activity of Concept Generation 19 2.6.1 Structured Approaches Reduce the
Likelihood of Costly Problem 20 2.6.2 Product Design Specification 21
2.7 Experimental Design 23
2.7.1 Step-By-Step Procedure in the Effective
Design of an Experiment 24
2.7.2 Problem Selection 25
2.8 Design of Experiment 25
2.8.1 Full Factorial Design 28
2.8.2 Two Level Fractional Factorial Design 30
3 METHODOLOGY
3.1 Introduction 31
3.2 Identifying Customer Needs 33
3.3 Interview 36
3.3.1 Case Interview 36
3.4 Interview questions 37
4 RESULTS AND DISCUSSION
4.1 Introduction 39
4.2 Customer Needs Survey Results and Analysis 40
4.3 Customer Raw Data 43
4.4 General Specification of Peeler Machine 46
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4.6 Analysis and selection of the best concept 51 4.6.1 Onion Peeler Machine with 3D design 52
4.7 Fabrication and Testing 54
4.7.1 Selection of motor 55 4.7.2 Selection of Electrical Timer 58 4.7.3 Selection of an Electrical Water Pump 62 4.7.4 Problems feed and Counter Measure 66
4.7.4.1 Change From Three Phase To One
Phase Motor 66 4.7.4.2 Uncontrolled Motor Speeds 67
4.7.4.3 Misallignment 69
4.7.4.4 Inefficient Peeling Actions 71 4.7.5 Overall Installation and testing for Onion
Peeler Machine 73
4.7.5.1 Measuring 76
4.7.5.2 Testing 79
4.7.6 Peeling result of small size onions 80 4.7.7 Peeling result of medium size onions 83 4.7.8 Peeling result of larger size onions 85
4.8 Onion with Ten Test Processes 87
4.9 Analysis Of Shaft Assembly and Its Components 88
4.9.1 Shaft 89
4.9.2 Shaft analysis using COSMOSXpress 89 4.9.3 Stress Analysis of the Shaft 93 4.9.4 Displacement analysis of the shaft 94
4.9.5 Deformation of the shaft 95
4.9.6 Shaft Holder 96
4.9.7 Shaft holder analysis using
COSMOSXpress 98
4.9.8 Stress analysis of the shaft 101 4.9.9 Displacement Analysis of the Shaft 102 4.9.10 Deformation of the shaft 103
5 EXPERIMENTAL DESIGN AND ANALYSIS
5.1 Introduction 105
5.2 Factorial Design 106
5.3 Study of Small-Sized Onion 108
5.3.1 Detail analysis for small sized onion (less
than 50% peeled) 109
5.3.2 Analysis for small sized onion (51-79%
peeled) 113
5.3.3 Analysis for small sized onion (80-100%
peeled) 117
5.4 Study of Medium-sized of onion 120
5.4.1 Analysis for medium sized onion (less
than 50% peeled) 121
5.4.2 Analysis for medium sized onion (50 –
79% peeled) 125
5.4.3 Analysis for medium sized onion (80 –
100% peeled) 128
5.5 Study of Larger-sized of onion 131
5.5.1 Analysis for large sized onion (less than
50% peeled) 133
5.5.2 Analysis for large sized onion (50 - 79%
peeled) 137
5.5.3 Analysis for large sized onion (80 - 100%
peeled) 140
6 CONCLUSION AND RECOMMENDATIONS FOR
FUTURE WORKS
6.1 Introduction 144
6.2 Conclusions 144
6.3 Recommendation for Future Works 146
REFERENCES 147
xi
LIST OF TABLES
Table Remarks Page
2.1 Number of Runs for a 2Full Factorial 28 2.2 Two-level 2-Factor Full-Factorial Experiment Design
Pattern 29
3.1 Mission Statement for Onion Peeler Machine 34 4.1 Customer data template filled in with sample customer
statements and interpreted needs 44
4.2 Customers Need & Relative Important 46 4.3 List of Metrics for the Onion Peeler Machine 47
4.4 The Needs-Metrics Matrix 49
4.5 The Onion Peeler Concept Scoring Matrix 50 4.6 List of Single Phase AC Motor (XTD model) 56
LIST OF FIGURES
Figure No Title Page
1.0 Zhecheng Jingxin Machinery CO., LTD Onion Peeler
Machine 2
2.0 Brown and white onions 7
2.1 Sliced onion structure 9
2.2 Onion Peeling Pattern Number 4476778 10
2.3 Automatic Onion Skin Peeler Machine (NAKAYA NT-
400S) 11
2.4 Onion Topper & Tailer Machine (NAKAYA NT-8) 12 2.5
2.6
Onion Peeler Machine A process model
13 27
3.1 Identifying customer needs 32
3.2 Interviewer session 38 4.1 Conceptual Design 1 40 4.2 Conceptual Design 2 41 4.3 Conceptual Design 3 41 4.4 Conceptual Design 4 42 4.5 Conceptual Design 5 42 4.6 Conceptual Design 6 43
4.7 3D designs for Onion Peeling Machine 52
4.8 Exploded view of Onion Peeling Machine 53
4.9 The Solid Work drawing for Onion Peeler Machine 53 4.10 Actual fabrications for the Onion Peeler Machine (a)
xiii
4.11 Single Phase AC Motor (XTD-60) for Onion Peeler
Machine 55
4.12 Single phase AC Motor of Onion Peeler Machine (a)
Single Phase AC Motor (b) AC motor Template 57
4.13 Single phase AC Motor basic operations 58
4.14 Example of ANV Timer and Diagram (a) Actual
Electrical Timer (b) Circuit Diagram 59
4.15 Example of 5 seconds coil energization 60
4.16 Example of 5 seconds coil de-energization 61
4.17 The AH3 Timer for onion peeler machine (a) Timer
Instruction (b) Actual Electrical Timer 61 4.18 The Atman At104 Liquid filter for Onion Peeler Machine 62 4.19 The installation of Atman At104 (a) Installation of water
pump (b) Place of water pump located 63
4.20 The installation of Water Sprinkler (a) Water Sprinkler
(b) Installation of water sprinkler 64
4.21 The installation of Water Sprinkler 65
4.22 Timer allocations on Onion Peeler Machine 65
4.23 Three phase motor 66
4.24 Single phase motor 67
4.25 Circuit diagram of the light Triac dimmer 68 4.26 Triac dimmer for onion peeler machine to control the
motor speed 68
4.27 Old designs for brush shaft holder with alignment problem (a) Old shaft holder design (b) Shaft with
misalignment problem 69
4.28 New design for brush shaft holder (a) Shaft Holder (b) The combination of shaft and shaft holder (c) Prefect
alignment 70
4.29 Old design for brush shaft 71
4.30 New designs for brush shaft (a) Planned to place a brush
(b) Fabrication of brush (c) New Peeler shaft 72 4.31 General components for producing the Onion Peeler 73
4.32 Iron frame as base for Onion Peeler Machine 73 4.33 Tank and Electrical component fixed with the frame 74
4.34 Adjusting the Onion Tank 74
4.35 Adjusting and fix shaft holder to the motor shaft 75 4.36 Adjusting and fix brush shaft to the shaft holder 75
4.37 Fixing the pipe hose to the water pump. 75
4.38 Process of testing a few onions into peeler machine 76
4.39 A few onions inside peeler machine 76
4.40 Training Tacho Meter 77
4.41 The allocation of Capacitive Sensor approximately
4-5mm to the sensing plate 78
4.42 Speed Value in RPM 78
4.43 OXD-844-2200K Electronics Weighing Scale 79
4.44 Sum of onions wants to be studied 80
4.45(a) Small size of onion not been peeled 80
4.45(b) Small size of onion not been peeled with weight of 541
grams 81
4.46 Small Onion already peeled skin (a) After Peeled Onions (b) After 2 minutes peeling operation for small size of
onions 81
4.47 Small Onion skins after are taken apart (a) Onion skin
after peeled (b) Weight or onion skins after peeled 82 4.48 Medium size of Onion not been peeled (a) Medium Size
Onion (b) Medium Size Onion Weight 83
4.49 Medium Onion already peeled skin (a) Medium Size Onion after peeled (b) After 2 minutes peeling operation
for medium size of onions 84
4.50 Medium Onion skins after processing 85
4.51 Large size of Onion not been peeled (a) Large Onions
before peeling (b) Large Onions Weight 86
4.52(a) Large Onion already peeled skin 86
4.52(b) After 2 minutes peeling operation for large size of onions 87
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4.54 Material of Shaft to be analyze 90
4.55 Location Shaft face to be analyze 90
4.56 Location Shaft load to be analyze 91
4.57 Load force applied to the Shaft 92
4.58 Safety factor of the Shaft 92
4.59 Shaft-COSMOSXpress-Stress Analysis 94
4.60 Shaft-COSMOS Xpress-Displacement Analysis 95
4.61 Shaft-COSMOSXpress-Deformation Analysis 96
4.62 Shaft-Holder 97
4.63 Actual Shaft-Holder 97
4.64 Material of Shaft Holder to be analyze 98
4.65 Location Shaft Holder face to be analyze 99
4.66 Location Shaft Holder load to be analyze 99
4.67 Load force applied to the Shaft 100
4.68 Safety factor of the Shaft Holder 101
4.69 Shaft Holder-COSMOSXpress-Stress Analysis 102
4.70 Shaft Holder-COSMOSXpress-Displacement Analysis 103 4.71 Shaft Holder-COSMOSXpress-Deformation Analysis 104
5.1 Design Expert Software Versions 6.0.5 106
5.2 2k Factorial of Design Expert Software Version 6.0.5 107
5.3 22 Factorial Design for small size Onion 108
5.4 Complete data for small size Onion 109
5.5 Half normal plot for small sized of onion (less than 50%
peeled) 110
5.6 ANOVA result for small sized onion (less than 50%
peeled) 110
5.7 Normal plot for residuals of small sized onion (less than
50% peeled) 111
5.8 Intersection for point A(less than 50% peeled) 112 5.9 Intersection for point B(less than 50% peeled) 112 5.10 Intersection for point AB (less than 50% peeled) 113 5.11 Effects of small sized of onion (51-79% peeled) 114 5.12 ANOVA result for small sized onion (51-79% peeled) 114
5.13 Diagnostics result for small size of Onion (51-79%
peeled) 115
5.14 Intersection for point A (51-79% peeled) 115
5.15 Intersection for point B (51-79% peeled) 116
5.16 Intersection for point AB (51-79% peeled) 116
5.17 Effects of small sized of onion (80-100% peeled) 117 5.18 ANOVA result for small sized onion (80-100% peeled) 118 5.19 Diagnostics result for small sized onion (80-100% peeled) 118
5.20 Intersection for point A (80-100% peeled) 119
5.21 Intersection for point B (80-100% peeled) 119
5.22 22 Factorial Design for medium size Onion 120
5.23 Complete data for medium size Onion 121
5.24 Diagnostics result for medium sized onion (less than 50%
peeled) 122
5.25 ANOVA result for medium sized onion (less than 50%
peeled) 122
5.26 Diagnostics result for medium sized onion (less than 50%
peeled) 123
5.27 Intersection for point A (less than 50% peeled) 123 5.28 Intersection for point B (less than 50% peeled) 124 5.29 Intersection for point AB (less than 50% peeled) 124 5.30 Diagnostics result for medium sized onion (50 - 79%
peeled) 125
5.31 ANOVA result for medium sized onion (50 - 79% peeled) 125 5.32 Diagnostics result for medium sized onion (50 - 79%
peeled)
126
5.33 Intersection for point A (50 - 79% peeled) 126 5.34 Intersection for point B (50 - 79% peeled) 127 5.35 Intersection for point AB (50 - 79% peeled) 127 5.36 Diagnostics result for medium sized onion (80 - 100%
peeled) 128
5.37 ANOVA result for medium sized onion (80 - 100%
xvii
5.38 Diagnostics result for medium sized onion (80 - 100%
peeled) 129
5.39 Intersection for point A (80 - 100% peeled) 130 5.40 Intersection for point B (80 - 100% peeled) 130 5.41 Intersection for point AB (80 - 100% peeled) 131 5.42 22 Factorial Design for larger size Onion 132
5.43 Complete data for large size Onion 133
5.44 Diagnostics result for larger sized onion (less than 50%
peeled) 134
5.45 ANOVA result for large sized onion (less than 50%
peeled) 134
5.46 Diagnostics result for large sized onion (less than 50%
peeled) 135
5.47 Intersection for point A (less than 50% peeled) 135 5.48 Intersection for point B (less than 50% peeled) 136 5.49 Intersection for point AB (less than 50% peeled) 136 5.50 Diagnostics result for large sized onion (50 - 79% peeled) 137 5.51 ANOVA result for large sized onion (50 - 79% peeled) 138 5.52 Diagnostics result for large sized onion (50 - 79% peeled) 138 5.53 Intersection for point A (50 - 79% peeled) 139 5.54 Intersection for point B (50 - 79% peeled) 139 5.55 Intersection for point AB (50 - 79% peeled) 140 5.56 Diagnostics result for large sized onion (80 - 100%
peeled) 141
5.57 ANOVA result for large sized onion (80 - 100% peeled) 141 5.58 Diagnostics result for large sized onion (80 - 100%
peeled) 142
5.59 Intersection for point A (80 - 100% peeled) 142 5.60 Intersection for point B (80 - 100% peeled) 143 5.61 Intersection for point AB (80 - 100% peeled) 143
LIST OF SYMBOLS
AL - Aluminium
ANOVA - Analysis Of Variance
V - Voltage
A - Ampere
RPM - Rotation Per Minute
ON - Pulse On Time (Pulse Duration) OFF - Pulse Off Time (Pulse Interval) AC - Alternating Current
DC - Direct Current
CMOS - Complementary Metal–Oxide–Semiconductor IC - Integrated Circuit
NOTC - Normally-Open, Timed-Closed NOTO - Normally-Open, Timed-Open
xix
LIST OF APPE DICES
O TITLE Page
A Questionnaires for the Customer’s Needs Survey 149 B Ranking on The Customers Needs Obtained 153
C Patents on The Onion Peeler Machine 155
