DESIGN OF NEW INTERLOCKING BRICKS MAKING MACHINE
DESIGN OF NEW INTERLOCKING BRICKS MAKING MACHINEMOHD RIDHWAN BIN RAMLIA project report submitted in partial fullfilment of therequirements for the award of the degree ofMaster of Engineering (Mechanical – Advanced Manufacturing Technology)Faculty of Mechanical Engineering,Universiti Teknologi MalaysiaMAY 2010
To my beloved my wife Zariwani Zakaria, dedicated supervisor Associate ProfessorZainal Abidin Ahmad, Tn. Haji Fadhil Ahmad, Tn. Haji Azhar Zubir, and Mr. HelmiAhya Ilmuddin . Thank for all your support .
iiACKNOWLEDGEMENTAlhamdullilah, thank to Allah, because of Him we are still here, breathingHis air, pleasuring His entire gift in this world. And most of all, for giving meopportunities to learn His knowledge.This work was supervised by Associates Professor Zainal Abidin Ahmad atthe Universiti Teknologi Malaysia. I greatly appreciate all his help and guidance.I am indebted to lovely wife, Zariwani Zakaria whose help, encouragementand patience I would never have gotten this thesis completed and who made it allworthwhile.I would also like to thank my friends, Imran Ibrahim, Huzaimi A. Hamid, andHamzah Mahmood for their support and encouragement and other help throughout. Iam also grateful to Tuan Haji Fadhil Ahmad and Tuan Haji Azhar Zubir who alsogave me a great deal of support and encouragement.Finally, thank you to all the other people who have supported me during thecourse of this work. Thank You! Thank You!
iiiABSTRACTThis report presents a systematic approach to enhance the current design ofinterlocking brick machine. The design starts with data gathering from the literaturereview and information given by the interlocking bricks maker. Product specificationis then being developed and refine to the specific points. The weaknesses of thecurrent design are being analyzed by looking at the movement waste done by themachine operator and the machine limitation is being identified. The interlockingbricks are different from other normal bricks as it requires no mortar or cement formasonry work. This bricks interlocked with each other by means of positives andnegative frogs on the top and bottom of the bricks which disallow the horizontalmovement of bricks. Selection of best design is chosen from the several designconcepts proposed. Finally, the drawing and detail design is produced according tostandard and ready to be built by the machine developer.
ivABSTRAKKertas ini mempersembahkan penyampaian sistematik tentang bagaimanauntuk menambahbaikan rekabentuk sedia ada bagi mesin membuat bata.Pengubahsuaian dan penambahbaikan mesin yang sedia ada adalah bertujuan untukmeningkatkan produktiviti pengeluaran bata. Langkah pertama untuk membuatrekabentuk baru bagi projek ini adalah mengumpul maklumat dengan membuatkajian ilmiah tentang rekabentuk sedia ada dan mengumpul maklumat daripadapengeluar bata tempatan. Kelemahan yang terdapat pada mesin sedia ada diujidengan melihat pergerakkan operator mesin dimana segala pergerakkan yangmembazir akan dikenalpasti untuk penambahbaikan. Had penggunaan mesin jugaakan dikenakpasti untuk dilakukan proses yang sama. Bata yang dihasilkan olehmesin ini adalah berbeza dengan bata yang lain kerana penggunaannya tidakmemerlukan semen untuk dilekatkan antara satu sama lain. Bata jenis ini mempunyaikunci positif dan negative yang membolehkan ianya melekat sendiri tanpamenggunakan semen. Setelah beberapa konsep rekabentuk dihasilkan, Cuma yangterbaik akan dipilih untuk diteruskan dengan menghasilkan lukisan kejuruteraanmengikut piawaiannya dan sedia digunakan oleh pengilang untuk menghasilkanmesin ini.
vTABLE OF iiACKNOWLEDGEMENTSivABSTRACTvABSTRAKviTABLE OF CONTENTSviiLIST OF TABLESxLIST OF FIGURESxiLIST OF ABBREVIATIONSxiiiLIST OF SYMBOLSxiiiLIST OF ive41.2Scope of Work5LITERATURE REVIEW2.0Introduction7
vi2.1Overview of the Previous Data onBricks Making Machine2.2Overview on the Previous Data RegardingResearch on the Interlocking Bricks316METHODOLOGY3.0Introduction173.1Concept development phase183.23.3473.1.1Identifying customer needs183.1.2Establishing target specifications183.1.3Concept generation193.1.4Concept selection193.1.5Setting final specification20Concept development3.2.1Identifying customer needs213.2.2Establishing target specifications223.2.3Concept generation293.2.4Concept selection39Discussion43RESULT AND DISCUSSION4.14.2Product architecture464.1.1Detail Design474.1.2Material and Process Selection554.1.3Detail Drawing65Components analysis774.2.1Top Structure784.2.2Table Structure80
vii4.34.2.3Compactor Structure824.2.4Planar base Structure84Cost analysis4.3.1Guideline for CalculatingBricks selling Price4.3.2586Machine component andRaw Material Cost4.486Product design onclusion1045.3Future Development105REFERENCES108APPENDICES111
viiiLIST OF TABLESTABLE NO.TITLEPAGE3.1Customer statement and interpretation213.2Customer needs223.3Matrix table283.4Needs-matrix table283.5Concept 1 description353.6Concept 2 description373.7Concept 3 description393.8Concept screening matrix403.9Concept scoring matrix424.1Material and process selection554.2Hydraulic function diagram714.3Material cost974.4Screw and nuts cost984.5Mechanical system and equipment cost994.6Manufacturing cost1004.7Final product design specification1015.1Project 1 schedule1065.2Project 2 schedule107
ixLIST OF FIGURESFIGURE NO.TITLEPAGE1.1Type of Interlocking Brick41.2Flow chart represents the scope of work62.1 Brick making machine by Hans C. Sumpf82.2Brick making machine by Judson A. Hereford92.3Brick inverter machine by Nicholas Lyons and C.K. George102.4Brick making machine by C.D. Vernon112.5Brick making machine by Lewis Polak122.6Brick making machine by Donald P. Chennells132.7Small size bricks making machine142.8Medium size bricks making machine152.9Large size bricks making machine163.1Method of designing the interlocking brick making machine203.2Cement charging/loading303.3Operator leveled the cement303.4Device to turn the brick303.5Process of turn the brick313.6Before compaction process313.7Pressure loading on bricks323.8Operator manually pick-up the brick one by one323.9Operator manually insert lower mold plate one by one.333.10Concept 1-Cantilever concept (3D view)343.11Concept 1-Cantilever concept (Drawing view)343.12Concept 2-Center cylinder concept (3D view)363.13Concept 2-Center cylinder concept (Drawing view)36
x3.14Concept 3-Horizontal compaction concept (3D view)383.15Concept 3-Horizontal compaction concept (Drawing view)384.1Total assembly design484.2Mold assembly design494.3Table structure assembly design504.4Top structure assembly design514.5Charging system assembly design524.6Inside control panel534.7Electrical Wiring Diagram664.8PLC Wiring Diagram674.9Indicator Lamp Wiring diagram684.10Hydraulic circuit diagram694.11Top structure stress analysis784.12Top structure displacement result794.13Table structure stress analysis804.14Table structure displacement result814.15Compactor structure stress analysis824.16Compactor structure displacement result834.17Planar Base structure stress analysis844.18Planar base structure displacement result854.19Total assembly drawing924.20Mold assembly934.21Table assembly drawing944.22Top structure assembly drawing954.23Charging system assembly drawing96
xiLIST OF ABBREVIATIONSCAE-Computer Aided EngineeringCATIA-Computer Aided Three-Dimentional Interactive ApplicationD-Bore DiameterDfX-Design for Assembly, Manufacturing, and EnvironmentEDM-Electrical Discharge MachineKg-KilogramKN-KiloNewtonPDS-Product Design SpecificationPLC-Programmable Logic ControllerLIST OF SYMBOLSπ-pi (3.1415)P-PressureᵒC-Degree CelsiusᵒF-Degree Fahrenheit
xiiLIST OF APPENDICESAPPENDIX NO.TITLEPAGEA-1Machine assembly drawing112A-2Mold assembly drawing113A-3Table assembly drawing114A-4Top structure assembly drawing115A-5Charging system assembly drawing116A-6Brick pusher drawing117A-7Charger drawing118A-8Compactor drawing119A-9Container drawing120A-10Cover drawing121A-11Hinge drawing122A-12Middle bar drawing123A-13Mold drawing124A-14Movable base drawing125A-15Planar base drawing126A-16Horizontal plate structure drawing127A-17Pusher base drawing128A-18Pusher shaft drawing129A-19Rod drawing130A-20Slider base drawing131A-21Slider compactor drawing132
xiiiA-22Slider pusher drawing133A-23Structure table 1 drawing134A-24Structure table 2 drawing135A-25Structure base drawing136A-26Table structure drawing137A-27Top mold drawing138A-28Top structure 1 drawing139A-29Top structure 2 drawing140B-1Hydraulic cylinder141B-2Hydraulic power pack 1142B-3Hydraulic power pack 2143B-4Vibration motor144C-1Socket hex cap screw145C-2Bolt, washer and nut146C-3Bearing bush147DSteel; cost estimation148
1CHAPTER 1INTRODUCTION1.0IntroductionNo construction is possible without bricks. Since many centuries brick makinghas been practiced by human beings. Presently, bricks are easily made by usingmachines using new technologies. Generally two types of bricks are manufactured byusing machines that are concrete block machines and clay brick machines. Differenttypes of automatic machines use different techniques to make bricks. The raw materialsused by the machines for making interlocking bricks are fly ash, sand lime, iron oxide,lime sludge, quarry wastes etc.The focus of this project is on the production of concrete bricks, specifically interlockingbricks which offer a speedier, cost effective, environmentally sound alternative toconventional walling materials. It is based on the principle of densification of a leanconcrete mix to make a regular shape, uniform, high performance masonry unit.Concrete Block Technology can be easily adapted to suit special needs of users bymodifying some design parameters such as mix proportion, water to cement ratio and
2type of production system. It is an effective means of utilizing wastes generated by stonecrushers, quarrying and stone processing units. The technology has high potential inareas where raw materials are easily available. The new technique in producing thisinterlock brick can generate a highly profitable business for micro and small scalebuilding material producers and construction companies. The market for this type ofbrick in Malaysia is not yet growing at a rapid rate, even though there are demands inconstruction industries due to low production rate which reflect the cost of brick itself.1.0.1Interlocking Brick SpecificationThe interlocking bricks are different from other normal bricks as it requires nomortar or cement for masonry work. This bricks interlocked with each other by means ofpositives and negative frogs on the top and bottom of the bricks which disallow thehorizontal movement of bricks. There are various application of this bricks namely; loadbearing wall, lintels, sills, wall corners etc. The specifications and the characteristics ofthis brick depend on the machine used to manufacture it. The most common size of brickis 300x150x120mm. The basic raw material is cement, fine aggregate and coarseaggregate. Very little water is used. This is possible only with mechanized compactionand vibration and gives the block high quality in spite of the lean mix, which uses verylittle cement. Weight of this brick is about 2 - 3 Kg.
31.0.2Production of Interlocking Brick ProcessCurrent process of producing the interlocking brick is produced using a semimechanized stationary type machine. The other production systems are - manual mouldsthat require hand tamping, a mobile semi-mechanized egg-laying machine and fullymechanized system that combines compression and manual concrete filling in mould.The machine also compacts and consolidates the mix so that the blocks are uniform insize and attain desired physical properties. The blocks are cured for a minimum periodof 14 days, before they are ready to use. On an average 600-800 blocks can be in 8 hoursby 1 skilled and 6-8 semi-skilled workers.In this project, a high quality machines in which optimize from the currentmachine design is going to propose according to the feedback and the need from theinterlocking brick maker.1.0.3Types of Interlocking BricksThere are various types of interlocking bricks. The most commonly used cementinterlocking bricks are;i. Regular Shaped Brickii. Half Size Brickiii. U-Shaped BrickSee figure 1.1 for types of interlocking brick
4Half Size BrickRegular Shaped BrickU- Shaped BrickFigure 1.1: Type of Interlocking Brick1.1ObjectiveThe main objective of this project is to design a new bricks making machine withnew features and simplifying the machine for one man operation in order to reducedoperational cost and maximizes the production rate. Furthermore, the purpose of this isto design the interlocking bricks making machine that suitable for SME entrepreneurs.
51.2Scope of projectThe scope of project is clearly define the specific field of the research and ensure thatthe entire content of this thesis is confined the scope. This project is start with theliterature review on product specification in order to satisfy the project objectives. Afterobtaining the product specification, this project is done base on the scope below; Project will focus on interlocking brick making machine only. Designing the inter-locking brick making machine that fulfill the projectobjective. Machine design to suit the regular interlocking bricks (Figure 1.1). The project goes until detail design of interlocking brick making machine. The major output of this project is to produce the detail drawing for the machinedesign. Fabrication of machine is excluded in this project.The scope of work can be described in terms of flowchart as per the following Figure 2.
6Literature Review onInterlocking Bricks Making MachineMachine Specification Project IConceptual DesignSelection of Best ConceptDetail Design for SelectedConceptDesignMaterials SelectionMachine Simulation (Software)Detail DrawingFigure 1.2: Flow chart represents the scope of workProject II
2.5 Brick making machine by Lewis Polak 12 2.6 Brick making machine by Donald P. Chennells 13 2.7 Small size bricks making machine 14 2.8 Medium size bricks making machine 15 2.9 Large size bricks making machine 16 3.1 Method of designing
1.3 Deterioration Of Stones 8 1.4 Durability of Stones 9 1.5 Preservation of Stones 9 1.6 Selection of Stones 10 1.7 Bricks 10 1.8 Classification of bricks 11 1.9 Manufacturing Of Bricks 13 1.10 Testing of Bricks 19 1.11Fire-Clay Bricks Or Refractory Bricks 22 2 Lime – Cement – Aggr
that could be mixed with clay to produce mix bonding bricks was 20% by weight. As shown with up to 40% sludge ash added to the bricks, the strength achieved at all temperature can be as high as that of normal clay bricks. With up to 50% ash in the bricks, the strength is even higher than that of normal clay bricks.
LMM refractory Name of customer Furnace type Products Quantity(to n) Time of supply RCP, Philippines 60EAF& Ladle MgO-C bricks, MgO-Cr bricks,high alumina bricks, fireclay bricks 300 July, 2008 ERDEMIR,Turkey 90 EAF Magnesia bricks 250 October, 2009 Egecelik, Turke
2 BDA Guide on the use of Reclaimed Clay Bricks The BDA offers the advice in good faith, bricks are durable and therefore sustainable and reusable. While it is true that bricks that have been produced under EN 771-1 in recent years are likely to last for 150 years this may not be true of recycled bricks.
Plasma BRICKs that can be turned ON/OFF like a light bulb - with just one electrical switch. So I would like to leave you with 2 suggestive outcomes for Plasma BRICKs ; First, "Plasma BRICKs are plasma tool kits for transformative research that has the potential to create fundamentally new learning curves."
are 30 for current seniors, 100 for parents of students, 100 for graduates within the last decade and 250 for other alumni. across campus near the northwest corner of Kelly/Shorts Stadium, CMU athletics also offers bricks for lasting messages. Here, standard-size bricks cost 200, 8-inch by 8-inch bricks cost 500, and 8-by-16 bricks cost .
pressing the mix in the machine and curing the bricks for a stipulated period. Selection of machinery depends on the bricks mix contents. For manufacturing bagasse ash fly ash bricks, the best suited machinery is a Vibro - press machine, which is an indigenous low cost machin
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