Publication: Design analysis of a semi-automatic machine for collecting fresh fruit bunches (ffbs)
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Date
2024-07-01
Authors
Tan Xing Han
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Abstract
Traditional manual methods of fresh fruit bunches (FFB) collection by using
loading spike often involve repetitive and forceful movements, awkward postures, and
heavy lifting, all of which significantly contribute to high Rapid Entire Body Assessment
(REBA) scores and increased ergonomic risk for workers. Consequently, there is a
requirement for mechanization to address these issues. This project aims to design,
develop, and analyse a semi-automatic prototype for effective collection of FFB without
causing musculoskeletal disorders (MSDs), reducing the need for labour and enhancing
overall efficiency and productivity in FFB collection. This project involves designs and
simulations using SolidWorks and fabrication. The functionality and performance of the
prototype are then analysed and discussed. Based on the motion analyses, the actuators are
able to provide enough force to operate different mechanisms properly. Finite element
static simulations also show that the structure of the prototype will not yield under load,
exhibits minimal displacement, and has an adequate safety factor. Based on the
functionality and performance testing of the prototype, the prototype is able to load both
small and large FFB with the mass of 5.382 kg and 15.424 kg respectively into the tray.
However, the scissor lift cannot function due to the failure of the motor coupling, and the
tipping mechanism needs improvement to unload the FFB effectively. Moreover, the tray
of the prototype has an estimated loading capacity of between 50 kg and 100 kg of FFB.
The driving mechanism can be achieved by changing to a new motor driver, and the
steering mechanism works well. The times for loading FFB, raising the scissor lift, and
unloading FFB are 23.473 s, 27.24 s, and 17.5 s, respectively. Therefore, the total collection
time, excluding transportation of the prototype, is 68.2 s.