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DEPARTMENT OF MECHANICAL

ENGINEERING

INTERGRATED DESIGN PROJECT

PORTABLE MECHANICAL CENTRIFUGAL PUMP


(PUMECA PUMP)
2017

SUPERVISOR: DR NABILAH RAMLI

Team members:
No. Name Matric no
1. MIQDAD MOHD ZAINUDIN 1222489
2. MUHAMAD IZZAT MOHTAR 1227783
3. MUHAMMAD FARIS MAZIDA 1228795
4. FAHMI AWA 1221991
5. MUHAMMAD SUBHI BAKHIR 1223929
6. SUHAILI HANANI BAHAUDIN 1314962
Contents
LIST OF TABLES ................................................................................................................................ 3
LIST OF FIGURES .............................................................................................................................. 4
CHAPTER 1 .......................................................................................................................................... 5
INTRODUCTION................................................................................................................................. 5
1.1 OVERVIEW ........................................................................................... 5
1.2 OBJECTIVES ......................................................................................... 7
1.3 BENCHMARK ....................................................................................... 7
CHAPTER 2 .......................................................................................................................................... 9
PROPOSED SOLUTION ..................................................................................................................... 9
2.1 Overview .................................................................................................. 9
2.2 Design Attribute and Criteria ............................................................... 9
2.2.1 CENTRIFUGAL PUMP ........................................................................................................ 9
2.2.2 MOTORCYCLE, HONDA EX5 ......................................................................................... 10
2.2.3 FORCE BODY DIAGRAM ................................................................................................ 12
CHAPTER 3 ........................................................................................................................................ 15
DESIGN ............................................................................................................................................... 15
3.1 OVERVIEW ............................................................................................. 15
3.2 DESIGN .................................................................................................... 16
3.2.1 ENABLERS ........................................................................................... 17
3.2.1.1 PUMP ............................................................................................................................... 17
3.2.1.2 IMPELLER ................................................................................................................. 19
3.2.1.3 PADDOCK ...................................................................................................................... 20
3.2.1.4 HOSE ............................................................................................................................... 21
3.2.1.5 BEARING AND SHAFT ................................................................................................ 22
CHAPTER 4 ........................................................................................................................................ 24
PERFORMANCE INTERGRATION .............................................................................................. 24

4.1 Detail of Enablers..................................................................................... 24


4.2 Paddock..................................................................................................... 24
4.2.1 Chemical Composition ....................................................................................................... 24
4.2.2 Physical Properties ............................................................................................................. 25
4.2.4 Mechanical Properties ....................................................................................................... 25

4.3 Shaft .......................................................................................................... 26


4.3.1 Chemical Composition ....................................................................................................... 26

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4.3.2 Physical Properties ............................................................................................................. 27
4.3.3 Mechanical Properties ....................................................................................................... 27

4.4 Bearing ...................................................................................................... 28


Chapter 5 ............................................................................................................................................. 30
PROJECT PLANNING...................................................................................................................... 30
5.1 Project management............................................................................. 30
5.1.2 TEAM MEMBER RESPONSIBILITY ........................................................................... 30
5.2 DEVELOPMENT PLAN ........................................................................ 31
5.3 Bill of materials ..................................................................................... 33
Chapter 6 ............................................................................................................................................. 34
Business Plan ....................................................................................................................................... 34
6.1 INTRODUCTION ................................................................................... 34
6.2 Value Proposition ..................................................................................... 34
6.3 Key Activities............................................................................................ 35
6.4 Key Resources .......................................................................................... 35
6.5 Key Partner .............................................................................................. 35
6.6 Customer Relationship ............................................................................ 35
6.7 Channels.................................................................................................... 35
6.8 Cost ............................................................................................................ 36
6.9 Revenue ..................................................................................................... 36
6.10 Sales Projection ...................................................................................... 36
Chapter 7 ............................................................................................................................................. 39
Ethics and Social Responsibility ........................................................................................................ 39
7.1 Ethics, environment and sustainability ................................................. 39
7.2. Warning of the Product ....................................................................... 40
7.3. Safety and health .................................................................................. 41

2
LIST OF TABLES

Table 1: Existing Method to Supply Water to the Plantation…………………...6


Table 2: Motorcycle Specification……………………………………………..14
Table 3: List of Components…………………………………………………...15
Table 4: Pump Specification……………………………………………………18
Table 5: Impeller Specification……………………………………...…………19
Table 6: Paddock Specification……………………………………………….. 21
Table 7: Hose Specification……………………………………………………22
Table 8: Bearing Specification………………………………………………... 23
Table 9: Paddock Analysis……………………………………………………..26
Table 10: Yield Factor of Safety……………………………………………......28
Table 11: Fatigue Factor of Safety…………………………………………......28
Table 12: Bearing Lifetime………………………………………………..........29
Table 13: Gantt Chart………………………………………………………......32
Table 14: Bill of Materials…….…………………………………………….....33
Table 15: Land Cultivated by Farmers…………….……………………............36

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LIST OF FIGURES

Figure 1: Traction Force………………………………………………………..12


Figure 2: Free Body Diagram of Motorcycle…………………………………..13
Figure 3: Free Body Diagram of Paddock. ……………………………………..13
Figure 4: Design sketch………………………………………………………...16
Figure 5: Top view (left), shaft and pump design (right)……………………....16
Figure 6 Cross Section of Water Pump………………………………………...17
Figure 7: Types of impeller…………………………………………………….19
Figure 8: Paddock stand rear…………………………………………………...20
Figure 9: Hose………………………………………………………………….21
Figure 10: Drawing of Position of Bearing and Shaft…………………………..22
Figure 11: Business Canvas… ……………………………………………..…..34
Figure 12: Sales Projection. ……………………………………………………38

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CHAPTER 1

INTRODUCTION

1.1 OVERVIEW

Agricultural sector is one of the most important sectors in Malaysia. The main agricultural
activity in our country is paddy plantations specifically wetland paddy. Wetland paddy is the
primary paddy type planted in Malaysia and comprises of different varieties of paddy. Due to
geographical factors, this semi-aquatic paddy is very suitable with Malaysia’s climate as we
have a uniform temperature, high humidity and lots of rain1.

According to statistic on 2010 mentioned in Utusan Online2, there are 172,230 wetland paddy’s
farmers in Malaysia that cultivate 673,745 hectars arable land. Yet, this large value still did not
manage to fulfil the targeted paddy production’s percentages that have been launched b55 |
P a g e y our late second Prime Minister, Tun Abdul Razak, on 1971 which is exactly 46 years
ago. This is due to the increase of imported rice from neighbour countries as we itself did not
manage to fulfil the consumers need. Thus, it increased the competition among local product
and imported product.

However, this situation gives bigger impact to the small scale farmers than large scale farmers
that cultivate on granary area. Granary area referred to major irrigation schemes (area greater
than 4000 hectares) and recognized by the Government in the National Agricultural Policy as
the main paddy producing areas. These farmers received help and support from the
Government to maintain their paddy’s production. Compare to small scale farmers, they
struggle to maintain their paddy’s productivity rate and have to solve any technical problems
by themselves without having large sum of money as modal.

One of the obstacles faced by the farmers is supplying enough water to their paddy lots.
Therefore, our team has come out with a solution to encounter it and at the same time influence
their paddy’s quality and quantity thus indirectly increases the productivity of our nation’s
paddy. Through mechanical approach, we come out with an idea to maximise the function of

1
http://www.met.gov.my/web/metmalaysia/education/climate/generalclimateofmalaysia

2
http://www.utusan.com.my/rencana/utama/bajet-2016-pemerkasaan-bidang-pertanian-1.151519

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existing components and create a new innovation which we called as “Portable Mechanical
Centrifugal Pump”.

Basically our idea is to use centrifugal pump to suck water from water source and flow it to the
paddy lots with power provided by the rear wheel of a motorcycle. The motorcycle’s engine
will provide enough torque to the rear wheel to turn in contact shaft that will be connected to
the centrifugal pump. Later on, the turning shaft will turn the impeller inside the pump and
suck water before pushing it through a hose as an output.

Actually, the cause of the obstacle is, the distance between the paddy lot with water source is
far, approximately 54 meters. As mentioned above, wetland’s paddy is a semi-aquatic paddy
which for it growing, the paddy’s lot must be filled with certain volume of water according to
the paddy’s growing cycle. If the volume of water is less or more than it supposed to be, it will
affect the paddy productivity as the paddy might die or the growing rate will be stunted. The
size of one paddy lot is 2877.78 meters square and usually the lot must be filled with 10 cm
depth of water, meaning 1 lot of paddy need 287 778 litre of water.

Based on our study, currently the most used solution for the small scale farmer is water pump
generator. The sad truth is, the farmers do not afford to buy this pump so alternatively they rent
it whenever they wanted to used it. It is not a smart decision since the pump generator is a
heavy duty type, powered by diesel and not user friendly.

In order to fulfil the unmet needs, we are targeting to invent a smart investment product. First
of all, we will assume the farmers have their own motorcycle to reduce the cost of this product
and to maximise the function of their own possession. We also want to reduce human workforce
by using motorcycle as source of power. Plus, our bench mark for design is portable. With
that, we are targeting to produce a cost efficient product that every small scale farmers are
affords to take it home.

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1.2 OBJECTIVES

The objective of this project are:

1. To invent a product that has lower cost than existing product.


2. To design a product that use simple components which are easy to assemble and
dissemble.
3. To power the product with a motorcycle which we assume every customer own a
motorcycle.

1.3 BENCHMARK

Our team made a study regarding existing method that supplied water to the plantation.
The result of our study is shows per Table 1 below.

Table 1: Existing method to supply water to the plantation

Based on the Table 1 above, out of five approaches only three managed to fulfil all
requirements needed by the farmers. The two methods that failed to supply water to the
plantation are water drip irrigation and water sprinkle system. Water drip irrigation is a method
that applicable and suitable for an area that has small quantity of rain and lack of clean water.

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Meanwhile, water sprinkle system has small flow rate and high time consuming which would
not be useful for paddy’s farmers.

Out of the three methods, the most efficient ones is water pump generator that used
diesel to power up. But due to its disadvantage which is high cost, it become less suitable and
not affordable for small scale farmers.

On the other side, water drains system is a traditional method that has been passed
down from one generation to another. The farmers will make continuous drain around the lot
and flows water through it. The concern with this method is, water could only flowing and
reached until certain distance causing farther paddy’s lot left unreachable.

Meanwhile, for water displacement pump, it required human work force to make it
functioning. It is very out dated and drained the farmer energy.

As a summary, the mechanical centrifugal pump must be design to defeat these unmet
characteristics in order to achieve its objectives to become a smart invention.

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CHAPTER 2

PROPOSED SOLUTION

2.1 Overview

The purpose of the idea has been described in chapter 1. This chapter will describe about the

attribute and characteristic of the design. The portable mechanical centrifugal water pump

consist of certain components which are paddock, centrifugal pump, bearing, impeller in the

centrifugal pump, shaft and also host for intake and output of water.

2.2 Design Attribute and Criteria

To achieve the goal of the idea proposed, a few calculations have been done in order to ensure

the prototype meet the requirement and work as desired. The target of this device is to fulfil

the paddy field when the water level in the paddy field decrease. Therefore, the pump should

supply water to paddy field at flow rate of 400L/min, or 24000L/hr. The water reservoir such

as river will be the main supply of water to the paddy field in village by using the pump. The

pressure needed to pull the water from reservoir is 1.951bar, when the distance between the

pump level and the water level is 20m. Input host will connect the reservoir to the pump, and

the output host will drain the water to the paddy field. For the calculation is as mention in 2.2.1,

2.2.2 and 2.2.3.

2.2.1 CENTRIFUGAL PUMP

Target: Head = 20 meter, Flow rate = 400L/min

Use Bernoulli’s Equation to find Pressure for targeted head.

𝑃 = 𝜌𝑔∆ℎ = 994.72 × 9.81 × 20 = 1.95164 𝑏𝑎𝑟

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Find Power needed to achieve flow rate.

1 𝑁𝑚
𝑃𝑜𝑤𝑒𝑟 = 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑥 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 0.4 × × 1.95164 × 105 = 1301.067
60 𝑠𝑒𝑐

Find Input power of pump from shaft.

We assume Ƞ of pump is 0.70, assumption is made by on the size of pump. A small size

centrifugal pump has efficiency 50%-70%.

1301.067
𝑃𝑜𝑤𝑒𝑟 (𝑠ℎ𝑎𝑓𝑡) = = 1858.67 𝑊𝑎𝑡𝑡
0.7

Shaft must deliver 1858.67 Watt which is 2.492hp to the pump.

2.2.2 MOTORCYCLE, HONDA EX5

Specifications:

Power = 8.7741hp @ 8000rpm

Torque = 9.120184 N.m

Top speed =90km/h

Fourth gear ratio 0.958

Final reduction ratio= 2.571

𝑛𝑔 = 2.571 x 0.958= 2.463

Rim size = 17inch diameter 0.4318m

Tire dimension = front 60/100, Rear 70/90

Find distance travel by motorcycle for 1 complete revolution.

90
𝑡𝑖𝑟𝑒 ℎ𝑒𝑖𝑔ℎ𝑡 = 100 × 70 = 0.063𝑚

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0.4318
𝑇𝑜𝑡𝑎𝑙 𝑟𝑒𝑎𝑟 𝑤ℎ𝑒𝑒𝑙 𝑟𝑎𝑑𝑖𝑢𝑠 = + 0.063𝑚 = 0.2789𝑚
2

𝑅𝑒𝑎𝑟 𝑤ℎ𝑒𝑒𝑙 𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = 2𝜋𝑟 = 2(0.2789) = 1.75238𝑚

Thus, 1 cycle of rear wheel equal to 1.75238m distance travel by the motorcycle.

1 Rev = 1.75238m

Find maximum RPM based on top speed.

90𝑘𝑚 1𝑟𝑒𝑣 1ℎ𝑟 1000𝑚


𝑅𝑃𝑀 = × 1.75283 × 60𝑚𝑖𝑛 × = 855.979 𝑟𝑒𝑣/𝑚𝑖𝑛
ℎ 1𝑘𝑚

Find traction force of the wheel and torque.

𝑓𝑖𝑛𝑎𝑙 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 × 𝑑𝑟𝑖𝑣𝑖𝑛𝑔 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 × 𝑡𝑜𝑟𝑞𝑢𝑒 𝑜𝑓 𝑒𝑛𝑔𝑖𝑛𝑒


𝑇𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒 =
𝑤ℎ𝑒𝑙 𝑟𝑎𝑑𝑖𝑢𝑠

𝐹𝑡= 2.463×𝑛𝑑 ×𝜏𝑒


𝑟𝑤

Assume 𝑛𝑑 = 0.85 ;

𝐹𝑡 × 𝑟𝑤 = 2.463 × 0.75 × 9.120184

Torque at wheel = 19.094N.m

𝑅𝑃𝑀 × 𝜏𝑤 855.979 × 19.094


Power developed at wheel = = = 3.1119 ℎ𝑝
5252 5252

Power developed at wheel > Power need by shaft to deliver to the pump

Enough power to turn impeller inside pump.

Using flow rate 400L/min = 0.4 m3/min to fill 1 cm of water in 1 paddy lot,

28.7778
Time taken for 1 cm depth = = 71.9445
0.4

71. 9445 ≅ 1 ℎ𝑜𝑢𝑟 12 𝑚𝑖𝑛𝑢𝑡𝑒𝑠

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2.2.3 FORCE BODY DIAGRAM
Find traction force at wheel.

Figure 1: Traction Force

𝑇𝑜𝑟𝑞𝑢𝑒 𝑜𝑓 𝑤ℎ𝑒𝑒𝑙 19.094


𝐹𝑡 = = = 68.462 𝑁
𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑤ℎ𝑒𝑒𝑙 0.2789

Find Friction Force applied to whole body.

Kerb Weight of Honda EX5 = 99kg

Figure 2: Free body Diagram of Motorcycle

N = W/2 = 49.5 kg ; Weight of Pumeca = 15kg

Find friction force between contact surfaces (rear wheel (rubber) meet shaft (rubber)

𝜇 = 1.16 ; 𝑁 = 𝑚𝑔 = 485.595 𝑁

𝐹𝑓𝑠 = 𝜇𝑁 = 563.29 N

Total weight = Motor + Pumeca = 64.5 kg

𝑁 = 𝑚𝑔 = 64.5 × 9.81 = 632.725


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Figure 3: Free Body Diagram of Pumeca Pump

∅ = 90° − 𝜃 = 38.9° ; 𝐹𝑡 cos 𝜙 = 53.28𝑁

Coefficient of friction of Sheet metal meet soil = 0.3

𝐹𝑓 = 𝜇𝑁 = 189.8175 𝑁

Friction force of base > Traction force (horizontal):

The paddock stand will not moving.

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From the calculation that we have done, it can be said that Motorcycle such as Honda

EX5 (97.99cc) which commonly used by our target consumer for their everyday ride, is capable

of running our pump. This can be seen by comparing the power needed by the pump and the

power produce at the wheel of the motorcycle which surpass the required power.

As to make our device capable to be universally use and not only focusing on that

particular motorcycle only, below is the list of others motorcycle specification that commonly

used by our target consumer comparing it with the requirement from our device.

Table 2: Motorcycle Specification

Device Honda EX5- Modenas Kriss Yamaha 135LC

Specification 97.99cc 120cc 135cc

(requirement) (rear wheel) (rear wheel) (rear wheel)

Speed (RPM) 3600 855.979 951.087 1017.953

Power 2.822 3.1119 4.202 5.214

(horsepower)

Torque (N.m) 5.504 19.094 23.205 26.905

It can be stated clearly that most of our consumer ‘daily ride’ motorcycle is more than

capable of running our device if we compared it through our theoretical calculation outcomes.

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CHAPTER 3

DESIGN

3.1 OVERVIEW

In this section, the enablers or system components will be discussed in detail. The system

components are the component required to completed and run the design including

specification, characteristics and overall architecture. For our design, the main components

required are six in total including motorcycle and pump.

Table 3: List of Components

No Components Specification
1 Rear Tire Of Motorcycle Torque Rear Tire: 9.12 N.M
Power Rear Tire: 2hp
Rpm: 1105.46rpm

2 Pump Centrifugal Pump


Size: 2 Inch (30 X 22 X 33)
Torque:10.5N.m (500l/Min)
Rpm: 3600
Hp:4.15hp
Min Flow Rate: 24m3 /H
Size Impeller : 116mm
Weight Impeller: 0.8kg
Weight Pump : 1.5kg
Type Of Pump: Cast Iron
Type Of Impeller : Steel
3 Paddock Stand Rear (40 X 77 X 31.5)Cm

4 Hose Diameter:55mm
Output:54meter Long
Input: 0.5-1.5meter Long
5 Roller Shaft And Oil Seal Diameter : 19mm
Length: 350mm
6 Bearing (Roller Bearing) -

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3.2 DESIGN

In this section, the part of the device will be explained. The basic part of this project are consist

of pump, paddock stand and shaft. The sketch and the design of the part as shown below in

Figure 1 and Figure 2.

Figure 1: Design Sketch

Figure 2: Top View (left), Shaft and Pump Design (right)

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3.2.1 ENABLERS

3.2.1.1 PUMP

I. GENERAL

Figure 3 Cross Section of Water Pump

Another important component for this design is water pump. The type for water pump

used in this design is centrifugal type-using mechanical power to run the pump. By

definition itself, water pump’s function is to deliver and transmit water from one point to

another point by increasing the water pressure. The pump required to deliver water 400-

600 liter per minutes in order to achieve 1cm level increasing in paddy field. The pump

itself is assembly from several parts which is impeller, pump casing, impeller case, oil seal

and mechanical seal, and input and output source. The pump will be welded into the

paddock as we seen in full architecture design above. After we are doing survey, the body

of pump is made of cast iron which is difficult to weld but as alternative, we may be using

a drilling, nut and fastener to stick the pump into the paddock. The pump must be designed

in air-tight mode and any leakage does not permissible. We are using oil seal and

mechanical seal to keep the pump in air-tight mode. A centrifugal pump is a piece of

precision machinery that must not be subjected to external strains beyond those it was

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designed to encounter. It must be installed in the intended position, carefully aligned, and

free from piping forces and moments.

Table 4: Pump Specification

Type Mechanical- Centrifugal Water Pump

Brand snb-50x-6

Body Size

Type of Body Cast Iron

Weight of Pump 1.3 Kg

Size Input/output 2 inch

Torque 10.5 N.m (500L/min)

RPM 3600

Horsepower 4.15Hp

Min Flow Rate Required 24m3/hour

Mechanical Seal -

Oil Seal Size -

Suck In Force (0.5m-1.5m elevation) -

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3.2.1.2 IMPELLER

Figure 4: Types of impeller


The impeller of the pump is arranged from one side only and called single-suction

design. Centrifugal force pushes the liquid outward from the eye of the impeller where it

enters the casing. Differential head can be increased by turning the impeller faster. The

impeller and the fluid being pumped are isolated from the outside by using mechanical

seals. In our intended-use pump, the impeller use semi-open type of impeller which is has

higher efficiency compared to open impeller. Number of impeller is one because it is a

single stage centrifugal pump.

Table 5: Impeller Specification

Type Semi-Open Impeller

Design Single Suction

Metal Type Steel

Max RPM 5000-7000

Weight 0.5Kg

Size 116mm

No of Impeller 1

Impeller Axial Loading Subject to Continual End Thrust

Sum of Radial Loading ( Estimation) 0 ( Cancel Each Other)

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3.2.1.3 PADDOCK
Adjustable Swing
Arm Holder

410mm

Roller
Joint

Figure 5: Paddock stand rear

Paddock stand rear is use to lift up the rear tire of motorcycle by holding swing arm.

The using of paddock is to increase the stability of motorcycle. The pump and bearing will be

welded to the paddock. Easy to assembly and require small space only because of joint.

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Table 6: Paddock Specification

Type Paddock Rear Stand

Function Lift up the rear tire by swing arm

Metal type Hollow Steel

Max Load 250Kg

Weight ( before Welding) 1Kg

Weight (After Welding) 4.5Kg

Size 770 x 315 x 410

Attribute 1-Roller

2-Ability to dissemble

3.2.1.4 HOSE

Figure 6: Hose

A hose is a flexible hollow tube designed to carry fluids from one location to another. The

shape of a hose is cylindrical (having a circular cross section). In our project, two hose are

needed for input water and output water. The design of hose should be foldable and light-

weight but depending on water pressure.

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Table 7: Hose Specification

Hose Brand

Input Hose

Type of Input Hose

Diameter of Input Hose 2 inch

Length of Input Hose 0.5-1.5 m

Output Hose

Type of Output Hose -

Diameter of Output Hose 2 inch

Length of Output Hose 54 m

Attribute of Hose 1-Foldable

2-Light-weight

3.2.1.5 BEARING AND SHAFT

Solid Rod Shaft

To the Impeller

Plain/Roller Bearing

Figure 7: Drawing of Position of Bearing and Shaft

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Bearing is used to hold and allow the shaft that connecting to impeller of shaft to rotate when

the rear tires is rotate. The bearing will be welded into the top of hollow metal of paddock with

the shaft will be inserted into the bearing straight to the impeller. The oil seal or key will be

used to hold firm the shaft in the bearing to remove the slipping. When the design is in the

ready mode, the shaft should be in contact with the rear tire and rotating as the tire rotate. The

design of shaft also needed to be high friction when in contact with tire to avoid the slipping

using rubber itself, oil seal or modified the surface of the shaft.

Table 8: Bearing Specification

Type of Bearing Plain Bearing/ Roller Bearing

Metal Type Stainless steel

Number of Bearing 2 (Pair)

Size of Bearing 19 x 30 x 12

Maximum Load 250Kg

Type of Shaft Solid Metal Rod

Metal Type Steel

Diameter of shaft 19mm

Length of Shaft 400mm

Maximum Load

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CHAPTER 4

PERFORMANCE INTERGRATION

4.1 Detail of Enablers

In this section, the detail of enablers is discussed

4.2 Paddock

The material that is used for paddock is AISI 1018 mild/low carbon steel. AISI 1018 mild/low

carbon steel has excellent weldability and produces a uniform and harder case and it is

considered as the best steel for carburized parts. AISI 1018 mild/low carbon steel offers a good

balance of toughness, strength and ductility. Provided with higher mechanical properties, AISI

1018 hot rolled steel also includes improved machining characteristics and Brinell hardness.

4.2.1 Chemical Composition

Element Content

Carbon, C 0.14 - 0.20 %

Iron, Fe 98.81 - 99.26 % (as remainder)

Manganese, Mn 0.60 - 0.90 %

Phosphorous, P ≤ 0.040 %

Sulfur, S ≤ 0.050 %

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4.2.2 Physical Properties

Physical Properties Metric Imperial

Density 7.87 g/cc 0.284 lb/in3

4.2.4 Mechanical Properties

Mechanical Properties Metric Imperial

Hardness, Brinell 126 126

Hardness, Knoop (Converted from Brinell hardness) 145 145

Hardness, Rockwell B (Converted from Brinell hardness) 71 71

Hardness, Vickers (Converted from Brinell hardness) 131 131

Tensile Strength, Ultimate 440 MPa 63800 psi

Tensile Strength, Yield 370 MPa 53700 psi

Elongation at Break (In 50 mm) 15.0 % 15.0 %

Reduction of Area 40.0 % 40.0 %

Modulus of Elasticity (Typical for steel) 205 GPa 29700 ksi

Bulk Modulus (Typical for steel) 140 GPa 20300 ksi

Poissons Ratio (Typical For Steel) 0.290 0.290

Machinability (Based on AISI 1212 steel. as 100% machinability) 70 % 70 %

Shear Modulus (Typical for steel) 80.0 GPa 11600 ksi

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In order to test the strength of the paddock, FEA analysis is used. The analysis is to

determine the maximum Von Mises Stress of the paddock. For the test, we use 250 kg/ 2.5kN

force that apply to paddock.

Table 9: Paddock Analysis

From the result we can see that there is nearly zero deformation with the yielding factor of

safety is 4.56. So the paddock can withstand high load.

4.3 Shaft

The material that is used for shaft is AISI 1018 medium carbon steel. AISI 1045 steel is a

medium tensile steel supplied in the black hot rolled or normalized condition. It has a tensile

strength of 570 - 700 MPa and Brinell hardness ranging between 170 and 210.

4.3.1 Chemical Composition

Element Content

Carbon, C 0.420 - 0.50 %

Iron, Fe 98.51 - 98.98 %

Manganese, Mn 0.60 - 0.90 %

Phosphorous, P ≤ 0.040 %

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4.3.2 Physical Properties

Physical Properties Metric Imperial

Density 7.87 g/cc 0.284 lb/in3

4.3.3 Mechanical Properties

Mechanical Properties Metric Imperial

Hardness, Brinell 163 163

Hardness, Knoop (Converted from Brinell hardness) 184 184

Hardness, Rockwell B (Converted from Brinell hardness) 84 84

Hardness, Vickers (Converted from Brinell hardness) 170 170

Tensile Strength, Ultimate 565 MPa 81900 psi

Tensile Strength, Yield 310 MPa 45000 psi

Modulus of Elasticity (Typical for steel) 200 GPa 29000 ksi

Bulk Modulus (Typical for steel) 140 GPa 20300 ksi

Poissons Ratio (Typical For Steel) 0.290 0.290

Shear Modulus (Typical for steel) 80 GPa 11600 ksi

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From the calculation of our shaft, we can get the yield and fatigue factor of safety for the shaft.

Table 10: Yield factor of safety

Table 11: Fatigue factor of safety

From the result, the factor of safety is quite conservative.

4.4 Bearing

The bearing we use is 6309 deep groove ball bearing.

Characteristic of bearing dynamic load, C = 55,3 kN

Purely radial load, P = Fr = 10 kN

Lifetime coefficient, P = 3

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n – Rotational speed of the bearing (rpm)

L10h – Life time (in million hours)

Table 12: Bearing Lifetime

Based on the result on the lifetime of the bearing, we can see that it is in between 300-3000. It

is suitable for agriculture equipment.

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Chapter 5

PROJECT PLANNING

5.1 Project management

In order to complete this project, our group must have strong project management, including

position of all group members, Gantt chart, and bill of material. This management is important

to ensure all the works can be completed, not exceed the budget provided, and also to ensure

all works can be completed by the dateline.

Therefore, all of the members have specific position pointed. The group leader is act as

brainstormer and must make sure all group members do their parts and follow the direction

provided. Mechanical and components manager must make sure all the parts can be obtained

before the design be conducted. In addition, the other position is Head Designer where the

obligation is to design the device using solid work. Project simulator and analyzer must run the

porotype and analyze the component in order to make sure the device can work properly.

5.1.2 TEAM MEMBER RESPONSIBILITY

This team consist of 6 members which are all from Mechanical Automotive. Each tema

members are given out different roles and responsibility to complete this project. The

responsibility of each members is as follow:

1) Izzat Mokhtar : Project leader


2) Muhd Faris Mazida : Component & Parts Handler, Head Designer (CAD).
3) Fahmi Awa : Asst. Head Designer, Sketch & Drawing.
4) Mohamad Subhi Bakhir : Procurement, Component & Parts Handler.
5) Miqdad Mohd Zainudin : Project and Simulation Analyst, Business Planner.
6) Suhaili Hanani Bahaudin : Project Situation Analyzer, Procurement.

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5.2 DEVELOPMENT PLAN

The project is done by following development plan that are decided by each team member and

supervisor together. Starting from the first meeting, all group members were discussing about

what type of problem to be worked on and how to solve it. After the problem is chosen, the

solution idea is proposed to the supervisor for approval. After the project idea is approved, the

problem and solution are analyzed further for better understanding and come out with a good

solution. Next, the product component are analyzed and decided which specification is suitable

for the project. After that, all the components are bought and assembled to become a target

product. Finally, the report of the project is finalized and presentation about the project is done.

The project development is as shown in Gantt chart below.

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Table 13: Gantt Chart

Week/Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Briefing for problem statement

Project selection

Brainstorming of project

Research

Benchmarking

Introduction of project

Selection of part

Design analysis

Design drawing

Submission of first report

Procurement process

Vidsume

Product assemble and test

Submission of second report

Final report

Project presentation

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5.3 Bill of materials

For parts that we bought, the price is mentioned below in the table. All of this part bought from

different store due to the different type of part.

Table 14: Bill of Materials

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Chapter 6

Business Plan

6.1 INTRODUCTION
The business plan will be made by using business model canvas. Figure shows the

business model canvas that is used as references for sale projection.

Figure 8: Business Canvas

6.2 Value Proposition

The performance of this pump almost competent compare with conventional pump. It

has almost similar output with the diesel generator. Also Pumeca pump use rear wheel

motorcycle to run the impeller which is we assume every small farmers have their own

motorcycle. This pump also easy to setup and also low cost in maintenance.

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6.3 Key Activities

Key activities for this product is to assemble the raw material into a complete product. We are

responsible to manufacture and design the product to meet the specification from the customer.

6.4 Key Resources

The key resources to build this product is to have enough human power to weld and assemble

the product. On the other hand, designer of the product is important to have a good design and

geometry. Furthermore engineers will analyse the design in order to meet the engineering target.

6.5 Key Partner

The key partner for this product is the pump manufacturer. Pump manufacturer is needed to

get the best price of the centrifugal pump. Also we can deal with motorcycle dealer to market

this pump to targeted customer.

6.6 Customer Relationship

In order to maintain the relationship with customer, there will be a demonstration to teach

customers how to use Pumeca. The demonstration can be in term of exhibition, video, or social

media.

6.7 Channels

Channels is important in order to sells this product. the easiest channel is through online

shopping website like mudah.my, Lazada and others. Also we can involve the government

bodies like MADA, FAMA, KADA, MUDA and many others agriculture sectors.

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6.8 Cost

The cost that we need to take into account is the assembly cost, manufacturing cost, marketing

cost and transportation cost. All these cost is include human workforce and also storage.

6.9 Revenue

From all the business canvas above, we can generate the income through our sales. In other

hand after sales approach is need to increase the revenue. For example, we sales spare parts

and accessories to the customer. And also there is warranty sale to sustain their purchases.

6.10 Sales Projection

From the survey we make, we can say that over 50% of the paddy farmer is considered as small

farmer with their paddy field less than 5 hectare. This statistic can be seen from the Table 10

below.

Table 15: Land Cultivated by Farmers

Journal of Governance and Development Vol. 9, 79-92 (2013)

So that from the data above, we can see that many paddy farmers depend on others

to acquired their resource such as water pump, fertilizer, machinery and finance. There are

approximately 172,230 paddy farmers according to MADA. Assuming that for the first year,

the cost of the one Pumeca pump is RM 650. Assuming the start-up for marketing and

branding cost is about RM 30,000. The product will be sale at RM 750 per pump including

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warranty. The expected product will be sale is 300 units in the first year. So the total revenue

may be:

Total revenue (1st year) = 300 unit x RM 750 = RM 225,000

Total cost (1st year) = (300 unit x RM 650) + RM 30,000 = RM 225,000

Total gross profit (1st year) = RM 225, 000 – RM 225, 000 = RM 0

In second year of the sale, we may cut the production and branding cost for RM 20,000

in a year, and the sales projection is about 500 units in the second year. So the total gross

profit may be:

Total revenue (2nd year) = 500 unit x RM 750 = RM 375,000

Total cost (2nd year) = (500 unit x RM 650) – RM 20, 000 = RM 305,000

Total gross profit (2nd year) = RM 375,000 – RM 305,000 = RM 70,000

In the third year of sale, assuming we made reduction cost for each unit of pump for

about RM 50. The cost for one pump is RM 600 and the unit sell is remain unchanged for

approximately 500 units. So the total gross profit may be:

Total revenue (3rd year) = 500 unit x RM 750 = RM 375,000

Total cost (3rd year) = 500 unit x RM 600 = RM 300,000

Total gross profit (3rd year) = RM 375,000 – RM 300,000 = RM 75,000

In the fourth year of sale, assuming we boost up the product with the total of RM

50,000 for marketing and showcase so that the total sale for 4th year is about 1000 units. So

the total gross profit may be:

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Total revenue (4th year) = 1000 unit x RM 750 = RM 750,000

Total cost (4th year) = (1000 unit x RM 600) + RM 50,000 = RM 650,000

Total gross profit (4th year) = RM 750, 000 – RM 650,000 = RM 100,000

In the fifth year of sales projection, assume the maintaining from the previous sales

and the cost of marketing is approximately about RM 100,000. With this year sales is about

1500 units. So the total gross profit may be:

Total revenue (5th year) = 1500 unit x RM 750 = RM 1,125,000

Total cost (5th year) = (1500 unit x RM 600) + RM 100,000 = RM 1,000,000

Total gross profit (5th year) = RM 1,125,000 – RM 1,000,000 = RM 125,000

In Figure 9 shows the sales projection in five years. Starting from year 2, we start to make a

profit.

Years
Figure 9: Sales projection

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Chapter 7

Ethics and Social Responsibility

7.1 Ethics, environment and sustainability

The use of petrol for this pump was able to reduce the emission, compared to conventional

pump. Most of conventional water pump use diesel as source of energy. Combustion of diesel

produce more carbon monoxide, Sulphur dioxide, and produce more black smoke. The

conventional water pumps also are heavy, and not user friendly. Therefore, the Pumeca Pump,

are less emissive, and more user friendly compared to conventional water pump.

Besides that, the impeller that use to spin the water inside the centrifugal pump are made from

cast iron. Cast iron is a metal where it is resistance to corrosion. This characteristic is very

crucial in order to ensure the long life of the Pumeca Pump. User can save their money, and

will have no worry regarding the centrifugal pump of Pumeca Pump.

One of the most important thing in Pumeca Pump is that it was assembled part by part. If one

part broken, users can change only that part easily. They can find the part from any hardware

store near their house. In addition, user that buy this product can request the warranty up to two

years. Any part broken and not cause by themselves, they can claim to us.

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7.2. Warning of the Product

Gasket become the sealer between the shaft and the centrifugal pump. it contributes

very important rule in centrifugal pump, which is to ensure the pump is vacuum. Therefore,

any time that the water pump is serviced and the gaskets are removed, user must replace the

gaskets. Gaskets are inexpensive, and a faulty gasket will cause the pump to leak.

Besides that, water pressure is caused by resistance to flow. If a force tries to move water and

there is resistance to that movement for example rock or sand, then the water becomes

pressurized. The flow of water will be disturbed, and affect the flowrate. In order to void any

tiny object to enter the pump, user must make sure filter is attached at the tip of the intake hose

so that no sand or rock will enter the pump and cause failure.

Rock or sand within the working pump can cause the pump case to crack and no vacuum inside

the pump. User also must ensure that there is enough water present in the centrifugal pump to

allow safe pumping and avoid cavitation.

If user noticed low water output, one of the first things to check is the water pump shaft rpm

to ensure it is spinning within specifications. User needs to Increase the motorcycle gear so that

the speed of the tyre increase. As the tyre speed increase, the shaft that attached to the tire will

rotate faster, and increase the flowrate of the water.

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7.3. Safety and health

There are certain precautions where user need to pay serious attention. User must avoid

children from playing around the working device. The high speed of rotating shaft may cause

injury when trigger finger or other body parts.

Besides that, user must place the paddock below the motorcycle swing arm correctly before

they run the device. The heavy motorcycle may not be stable, when position of the swing arm

is not correct. Any misplaced can cause the motorcycle fall and cause failure.

Other than that, user also must make sure the exhaust hose place correctly when operate the

pump. Never point the hose to other people without any reason. This is because the high

pressure water at exhaust hose can cause injury when directed toward people.

Finally, user must avoid to much exposure to the running engine. Exposure to loud noise can

damage the ear and cause hearing loss. Use of earplug during running of this device will be

better.

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