1

CHAPTER 1

INTRODUCTION & BACKGROUND RESEARCH

1.0

Introduction

In order to design the horse feeding mechanism at UTM equine some back
ground research was carried out in areas that are related to this problem. The problems
can be divided into few areas as follows.

1.1

Feeding time of the horse [Bala]

Horse feeding time plays an important part as well. Horse can become stressed
if they are feed long period of intervals between their meals. They will perform well if
they are feed well and according to the time. Generally horse should be fed three to
five times per day. It should be fed little and often. Currently UTM equine is practicing
three meals per day. Morning 6.45 is, afternoon 12.00 pm and evening 6.45 pm. There
should be a delay for any activities or exercise for at least two hours after the horse
feeding. This is because horse with a full stomach will have a great pressure on its
lungs and can cause improper breathing. At the same time horse also should not be fed
immediately after exercise. Its best to follow the same time for the horse feeding as it

will get used to its routine time fast. Horse will tend to get stressed if their daily meal
routine changed frequently.

1.2

Codes of Recommendations for Horse Welfare Feeding [Chin YS]

In the United Kingdom (UK), there is an act, called the Animal Welfare Act
2006 that is used to protect class of animals that is described in the act. However,
there is no act that is targeting specifically on horses. In order to perform more research
on for horse welfare, codes of recommendations and minimum standards of New
Zealand and Australia are being used. Noteworthy the terms codes of
recommendation and minimum standards, instead of rules and regulations, or
act, are being used as these are recommendations for best horse welfare.

Other than horses welfare, human safety, especially workers safety is a

concern in the code of recommendations. This is to ensure no accidents and incidents
happen.

Not all of the contents will be discussed, but major items relating to feeding of
horses is presented.

1.2.1

Feeders [Bala & Chin YS]

There is also recommendation for placement of feeders and water container.

Feeders and water containers are recommended to be raised to a height of about 1.07m
and placed in a corner. They should be smooth and free of protrusions, resist tipping
over and should be easy to clean.

1.2.2

General Feed Requirements [Bala & Chin YS]

In its natural state, the horse eats a variety of forages (mainly grasses) to meet
its nutritional needs. Due to the small size of its stomach, the horse will normally
consume its daily intake over 16-20 hours. When the energy requirements are low,
such as for horses in light work, dry broodmares and non-working horses, fresh forage
can provide most of the horses needs. When pasture is limited, however, the diet
should be supplemented with dried forage, which is hay or chaff.

Provided the stocking rate is correct, most broodmares can meet their energy,
protein and mineral demands from an adequate supply of good quality spring pasture,
since they have adequate time to consume the quantities required.

When a horse is working, its feed demands increase and a pasture-only diet
may not be sufficient to meet the increased needs. Forage takes a long time to digest
and the horse may not physically be able to eat enough to sustain its needs. Horses in
moderate-to-heavy work generally need supplementary feeding in the form of grains
or concentrates.

1.2.3

Supplementary Feeds [Bala & Chin YS]

Horses are very selective of their food. They use their whiskers, lips and
incisors to feel and choose what they want to eat. Horses are herbivores and they have
a unique digestive system. They have a very long digestive system and require a high
fibre meal. Normally horse spends most of the time eating.

When considering the supplementary feeding of horses, an important point to

note is that horses tolerate poor feed poorly. Horses will not thrive unless they are fed
good feeds in the right quantities. The contents below describe the nutritional value to
the usual food and supplements that is fed to UTM horses.

Hay is the most important nutrition for the horse. So in feeding the horse, it is
very important to focus on the type and the quality of the hay. Hay is the mixture of
grass and legumes which is dried until about 18% of the moisture remains. Hay is a
form of roughage commonly fed to horses to supplement pasture. It must be of good
quality to supply nutritional requirements and avoid health problems. Hay should be
dry at the time of feeding, smell fresh and be free from dust and mound. To reduce
potential respiratory problems, it is important that chaff is dust-free. Normally hay is
fed in the forms of square cubes for stabled horse. Dampening of feeds with high chaff
content, just before feeding, is recommended to aid digestion and prevent dust
inhalation.

Figure 1.1: Hay in square cube forms

Oat is another mixture in the meal that is very important. It requires a lower
digesting energy by horse and at the same time contains high fibre compared to other
grains. Oats is very safe to feed, as it forms a loose mass in the stomach which aids
digestion. Oats should be bright in appearance. Bruising is considered by many to aid
digestion, but the storage of bruised oats reduces its nutritional value and should be
avoided. Oat well suited to the horse digestive system and easily digested compared to
other grains.

Figure 1.2: Oat

UTM is giving blended feed called the cool performance, or CP in short, to

the horses. Providing the manufacturers feeding recommendations are followed (this
information should be printed on the label along with an analysis of ingredients), these
provide a simple method of supplementation. Where small numbers of horses have
similar supplementary feeding needs, premixed balanced feeds can save the horse
owner work and ensure continuity of diet.

Chaff is simply dried forage that has been cut into small pieces. The principle
advantage of chaff is that it can be mixed with the concentrate portion of the feed so
that the horse consumes forage with the concentrate. This can slow the intake of
concentrate and prevent starch overload in the large intestine.

Oil is also added in horses feed. With the high calorie demands of elite
performance horses, Oils plays an important role in reducing grain intake. Oils contain
2.5 times more energy than oats and also are digested more efficiently in the horses
small intestine. Thus reduces the sugar high sometimes associated with high grain
intakes [3]. Unless fat (e.g. some type of vegetable oil) is added to the diet, horse
rations are very low in fat, typically less than 2%-3%. However, horses are able to
digest and absorb dietary fat quite well (up to 20% of their energy intake). In fact, it is

important that horse diets contain at least some fat or oilit is needed to facilitate
absorption of the fat-soluble vitamins A, D, E, and K.

Supplement such as salt to be included in concentrated mixture in the meal.

Salt normally very helpful when horse are craving and vitamins will be beneficial to
horse when feeding low quality of hay, illness, active in sports or travelling. Beside
these minerals such as calcium, phosphorus, sodium or potassium also include into the
concentrated mixture.

1.2.4

Specific Feed Requirements

UTM horses activities were described in the first part of this chapter. This subchapter will describe in more detail on the feed requirements, based on maintenance
and activities.

Feeding levels can be worked out in terms of either dry weight expressed as
kilograms of dry matter (kg DM), which can then be converted into actual weight fed.
Besides this, feeding level can also be expressed as energy content in mega calories
(MCal). This method is more accurate as it takes into account the different energy
values of the same weight of feeds. It should be used by those involved in training
horses for strenuous activities that require high levels of fitness and for stud properties.

For simplicity, the amount of feed required by the horse is made up of two
factors:

(i)

Maintenance needs;

(ii)

Activity needs (which include rate of work, growth, lactation and

pregnancy).

Both requirements must be satisfied to maintain body condition and weight.

1.2.4.1 Maintenance Needs [Chin YS]

Maintenance feeds is the amount required to maintain the horse at rest. "At
rest" means that the work required of the horse is no greater in physical activity than
that expected of a healthy horse grazing freely in a paddock. This includes horses being
spelled from their usual work, learners horses which rarely get into a canter, and
pleasure horses ridden carefully at a relaxing pace for no more than 1 hour/day.

If fed to appetite, the average horse will consume 2% of its bodyweight, as dry
matter, to meet daily maintenance requirements. Regular condition scoring or
weighing will help establish any individual variation required from the 2% bodyweight
guideline. Table 1.2 shows the approximate maintenance dry matter feed requirements
of different weights of horses.

Individual horses have varying digestive capabilities which affect maintenance

requirements. Periods of extremely cold weather may also increase maintenance needs
by up to 30%. Temperament is a further factor to be taken into account, as nervous or
highly strung horses consume far more energy than do quiet horses of the same
bodyweight.

Table 1.1: Average daily maintenance requirements of horses.

Bodyweight

Dry matter (kg)

Digestible
(MCal)

150

5.9

200

7.4

250

8.9

300

10.4

350

11.9

400

13.4

450

14.9

500

10

16.4

550

11

17.9

600

12

19.8

energy

1.2.4.2 Activity Needs of Working Horses [Bala & Chin YS]

Horses are normally they are very athletic type. This shows that they need
sufficient energy to maintain their weight and to do their jobs. An average horse
weighs about 450 kilograms will need approximately 15000 calories a day. However
its calories to be increased to 25000 calories if does riding activities but not to be too
strenuous. If the same horse involves in strenuous activities such as daily ridding,
involves in competition and also gallop jumping then its calories to be increased to
33000 calories. As we know the horses in UTM are very active and involve in
competition as well. This means horses in UTM falls in the 3rd criteria and they need
proper feeding according to time.

The general rule of thumb for working horses is:

1.3

(i)

Light work requires an extra 25% energy (above maintenance);

(ii)

Moderate work an extra 50%;

(iii)

Heavy work requires more than an extra 100%.

Horse feeding ratio [Bala]

There are totally seventeen horses in UTM equine. Each horse requires a
different type of ratio for each meal (breakfast, lunch and dinner). This is because the
ratio of the mixtures is purely depends on the type of the activities the horse involved
and how active is the horse. However this becomes very tedious to the workers because
they have to stay late in the evening in order to prepare the mixing for each horse next
day. The table below shows the meal distribution for each horse according to its ratio
and timing.

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Table 1.2: Maintenance water requirements of horses

Early Morning

Afternoon

Evening

Horse Name

Chaff

CP

Chaff

CP

Hay

Chaff

CP

Hay

Billy

0.5

0.5

0.5

1.5

0.6

1.25

Saphire

0.5

0.5

0.5

1.5

0.5

Bold Sabre(Arab)

0.5

0.5

0.5

0.5

1.5

Blue Bronco

0.5

0.5

0.5

0.5

1.5

Moon Shadow

0.5

0.5

0.5

0.5

1.5

Loretta

0.5

0.5

0.3

0.5

0.4

0.5

Bonita

0.5

0.5

0.3

0.5

0.4

0.5

Dada

0.5

0.5

0.5

0.6

Neil Dancer

0.5

0.5

0.5

1.5

0.5

0.75

Zack Phenomena

0.5

0.5

0.5

0.75

1.5

0.5

0.75

Hard Foundation

0.5

0.5

0.5

0.5

Roy Austin

0.5

0.5

0.6

0.6

1.25

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Jack

0.5

0.5

0.5

0.5

1.5

Sunny

0.5

0.5

0.5

0.75

1.5

0.5

0.75

1.5

Qosmo

0.5

0.5

0.6

0.6

1.5

2.5

Silver Barloo

0.5

0.5

0.5

0.6

1.5

2.5

Pinocchio

0.5

0.5

0.6

0.6

1.5

2.5

1.4

Ergonomics [Bala]

The feeding container that being used in UTM equine is not ergonomically
sufficient for the horse to eat. This discomfort causes the horse to damage the feeding
container. Finally the horse food spills down and cause contamination when it mixes
with their own waste. Taking into consideration of this some studies was done on the
horse shape, body measurement, eating posture and vision.

1.4.1

Horse Shape & Measurement [Bala]

The height of the horse is measured from the withers, where the neck meets the
back. Withers actually are the rigid part between the shoulder blades of a horse. It is
the tallest point of the horse. Normally this point is used because it is the stable point
of the horse. The horse shape and height is measured using hand and inches. One hand
is approximately equals to 4 inches. If the measurement of the horse states 14.2 H, it
refers to 14 hands and 2 inches which 58 inches. The weight of the horse is normally

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between 380 kilograms to 550 kilograms. The larger horse normally weighs between
500 kilograms to 600 kilograms and measures about 15.2 H. The figure 1.3 below
shows the typical parts of the horse body.

Figure 1.3: Body parts of the horse

1.4.2

Horse eating posture [Bala]

The horse body posture also plays important criteria that we have to take into
consideration. The body of the horse works most efficiently when eating at ground.
When the horse puts the head down to eat the lower jaw drops forward and when the
horse lifts its head to chew the jaw slides back. This forward and backward movement
helps to grind the teeth and keep it at the optimum length. However this does not
happen when the horse is fed with head from the ground. Thats why it is important to
feed at the ground level. Horses in UTM are fed in both methods. The hay is laid in
the ground; where else the other meals are fed through container. Figure 1.4 illustrates
best horse eating posture.

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Figure 1.4: Best horse eating posture

1.4.3

Horse binocular vision [Bala]

The food served to the horse should be within the horse binocular vision. The
horse binocular vision is about 65. This is to make sure that the horse could capture
the whole image of the food that being served and there would not be any wastage.
The figure 1.5 below shows the horse binocular vision.

Figure 1.5: Visual field of the horse

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1.5

Gather Raw Data from Customer [Afiq]

Consistent with our planning of creating new feeding system directly

from customer, gathering data involves contact with customers and experience
with the use of environment of the product. One method of customer approach
which is interview session.

Based on the information that we had obtained from Mr. Idris Jala who
is one of the management staff in Equine Park, the horse feeding system has
been practiced with manual way since the equine park was built in UTM. We
have founded several issues, which we had founded during interview, was that
they consumed lots of time and energy to feed the horses. We might see table
1.1 which had shown the problems that the staff is always facing during feeding
the horses.

Table 1.3: Interpretation of Raw Data

Customer: Equines Staff in UTM

Interview(s): Chin, Bala & Afiq

Address: Equine Park Centre, UTM, Skudai

Telephone: 019-7722333

Date: 20/09/2014

Currently uses: Manual Feeding System

Type of User: Trainer & Coach

Question/Prompt

Customer Statement

Interpreted Need

How many times actual Actual feeding meal is 3 Feeding system that can
feeding meal?
times. However, 5 meals supply food every time
are recommended.
horse is needed.
How is the mixture done?

The mixture needs to be The feeding system can

done manually by mixing stir the mixture and can be
each of the element of the setting in meal time.
food depend on meal time
in the bag.

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Do you have any meal Dont have any mixture The feeding system able
mixture standard?
standard. However, we to measure and sense the
prepare the mixture based amount of the food.
on horse requirement.
Moreover, every horse has
their own ratio of the food.
What is the problem of Due to use manual system,
current practice?
we have to supply by
ourselves. Sometimes, we
need overtime because we
dont
have
enough
manpower. Moreover, we
need to feed the horse on
time. Otherwise, the horse
will eat the food late and
the training time will
postpone which is not
good for the horses.

The feeding system able

to feed the horse by time
like morning, afternoon,
evening and night. On the
other hand, the system
able to feed on time. So
that, the horse able to rest
2 hours after meal time for
training exercise.

Food separation

Hay needs to be isolated The feeding system have

from other mixtures.
their own space for each
of the element of the
mixture like Cp, Chaff,
oil, oat, calcium and hay.
However, hay has its own
space.

Water Supply

The horses need 80 L per

day for its drinking water.
The worker needs to
check
manually.
Sometimes, the worker
forgot to check water level
which made the horse
become thirsty.

The feeding system can

provide
water
continuously and can fill
the water automatically
without
manual
inspection.

Food storage

The food especially hay

have to keep in cold
environment. So that, the
nutrition and quality can
be maintained.

The feeding system can

provide not only feeding
the horses but also storing
the food with cooling
system.

Hygienic

The mixture, water and The feeding system able

hay
are
always to cover the food by any
contaminated by soil dust seal type. Moreover, the

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because the container is container can be clean

not covered with any seal. easily.
Aesthetic

1.6

The container shape make The shape have to follow

the horse uncomfortable biological posture of the
during eating its meal. The horse during meal session.
container shape also make
body posture of the horse
become wrong and may
affect
the
horse
performance.

Organize The Needs into Hierarchy. [Afiq]

We have to organize the needs that we have chosen from previous section into
hierarchical structure in figure 1.6. The structure typically consist of a set of primary
needs, each one of which will be further characterized by a set of secondary needs.
The primary needs are the most general needs, while the secondary and tertiary needs
express needs in more detail. Figure 1.6 shows that the resulting hierarchal structure
of needs for horse feeding system.

We had founded that they consumed lots of time and energy to feed the horses.
They only used a bag to mix the food and lot of manpower were needed to provide and
preserve the food for the horses.

The horses also consume water which is 80 L per day. Thus, the feeding system
need to supply water continuously. One more important thing that the horses need to
be fed on time to avoid late training time. The horses can be trained 2 hours after their
feeding time based on explanation from Mr. Idris because of good food digestion. On
the other hand, they have to provide three meals per day instead of five meals as other
equine parks do for their horses. So that, the system able to supply food continuously.

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Able feed on time

Able feed 5 times per day

Time
Able supply water
continuously
Able to control element of
food according each horse
need

Able to control the ratio of

the food.

Able to isolate hay from

main mixture

Able to supply hay

continuously.

Mixture

Able to store in cold

environment

Feeding Horses System

Food Storage

Able to sense the quality of

the food after open the
pack

Environment

Able to seal the food from

soil dust and contaminate
particle.

Need Ergonomic
Materials
Easy clean & handle

Figure 1.6: The hierarchal Structure for Feeding Horses System

The horses also consume water which is 80 L per day. Thus, the feeding system
need to supply water continuously. One more important thing that the horses need to
be fed on time to avoid late training time. The horses can be trained 2 hours after their
feeding time based on explanation from Mr. Idris because of good food digestion. On
the other hand, they have to provide three meals per day instead of five meals as other
equine parks do for their horses. So that, the system able to supply food continuously.

Each of the horse has their specific mixture depend on time which they are be
fed. As example, in the morning, they are fed with Chaff and Cooling performance.
However, in afternoon, they add more mixture which is oat. So that, the system is able
to control each of the element of the food. Each of the horses has been provided

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standard ratio for capacity of the food. That mean that each of the horses have their
own standard requirement for feeding ratio depend on their physical attribution
example like weight, height, gender and others. Thus, the system is able to measure
and sense the ratio.

For food storage, the quality of the food is inversely proportional with time.
The quality of the foods can be reduced if we stored the food with long time duration.
It will affect the performance of the horse. So that, the feeding system can be able to
store the food in cold environment. Moreover, the quality of the food can also be
sensed the feeding system.

In term of environment, the foods are always contaminated by soil dust and
contaminate particle from surrounding. Thus, the feeding system need to seal the
container. Moreover, in term of material, the container needs to be ergonomic. The
feeding system also requires the container which can clean and handle easily.

1.7

The Relative Importance of the Needs [Afiq]

____________________________________________________________________

The Feeding System_________________________________________

Before we continued with scoring activity, we have to indicate on a scale of 1 to 5.
Please use the following scale:

1. Feature is undesirable.
2. Feature is not important.
3. Feature would be nice to have.
4. Feature is highly desirable.
5. Feature is critical.

Importance of feature on scale of 1 to 5

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__5__Feeding machine able to feed the horses on time

__3__Feeding machine able to feed the horses 5 times per day

__5__Feeding machine able to supply water continuously

__5__Feeding machine able to control element of food according each horse need

__4__Feeding machine able to control the ratio of the food.

__5__Feeding machine able to isolate hay from main mixture

__3__Feeding machine able to supply hay continuously.

__5__Feeding machine able to store in cold environment

__5__Feeding machine able to sense the quality of the food after open the pack

__5__Feeding machine able to seal the food from soil dust and contaminate particle.

__5__Feeding machine able to be clean & handle easily

__5__Feeding machine able to be ergonomic depend on the biological of the horses

1.8

The Summary [Afiq]

Based on section 1.3, we had done our scoring where nine of critical needs
have to be focused for designing the feeding machine. The critical needs are:

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1. Feeding machine able to feed the horses on time

2. Feeding machine able to supply water continuously
3. Feeding machine able to control element of food according each horse need
4. Feeding machine able to isolate hay from main mixture
5. Feeding machine able to store in cold environment
6. Feeding machine able to sense the quality of the food after open the pack
7. Feeding machine able to seal the food from soil dust and contaminate
particle.
8. Feeding machine able to be clean & handle easily
9. Feeding machine able to be ergonomic depend on the biological of the
horses

However, the other needs only desirable if we included in the system which
are:

1. Feeding machine able to feed the horses 5 times per day

2. Feeding machine able to control the ratio of the food.
3. Feeding machine able to supply hay continuously.

Based on the scoring result, we can focus on the critical needs which is
important and crucial part in the feeding system. With this information, it will be easy
for us to create product design specification (PDS).

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CHAPTER 2

PRODUCT DESIGN SPECIFICATION

2.1

Customer [Afiq]

The customer will be the Equine Centre Park in UTM, Skudai. An interview
session was prepared and held at Equine Centre UTM, Skudai. From the interview
session, the following conclusion can be made:

1.

The manual feeding system causes insufficient number of times to feed the
horses.

2.

Current feeding system is not totally hygienic.

3.

The food become waste after the horses finished eating its food.

4.

The food storage is not in proper manner and standard for the food.

5.

Man power is not enough because of cost reduction.

6.

The Equine Centre Park in UTM, Skudai is willing to upgrade the feeding
system.

From the interview session, we can conclude that the improvement of feeding
system needs to be considered due to maintain the health quality and performance of
the horses. This equipment should be aimed at all the horses at the Equine Centre Park
in UTM, Skudai.

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2.2

Time Scale [ChinYS)

1) 18-19 October 2014 - Product design specification and concept generation.

2) 8-9 November 2014 - Evaluation of concepts and finalisation of concept.
3) 6-7 December 2014 - Completion of final design
4) 28 December 2014 - Presentation of completed model.

2.3 Environment [Afiq]

i. Resistance to adverse weather: If the equipment is exposed or partially exposed

on the outdoor, then it must withstand all extreme weather.
ii. Temperature: The equipment should perform well and cant be damaged by
ambient temperature in range from 7.0 C to 40 C based on the environment
temperature.
iii. Pressure: The equipment should be perform and cant be damaged by
atmospheric pressure from 101325 Pa and above.
iv. Corrosion resistance: The unit should be resistant corrosion from water vapour
and dry air which are contained in atmospheric air.
v. Dust: The equipment can be sealed and filtered from dust and small particle.
vi. Keeping an inventory of the waste deposited into each waste container.

2.4 Performance [Afiq]

i.

Time: The equipment can be setting variably in time depend on the range in
second, hour, day, week, month and year which is needed.

ii.

Quantity of Food Measurement: The equipment is able to measure and sense

the weight of the food depends on the quantity requirement that needed by the
horses.

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iii.

Storage: The food need to be stored under room temperature which is 25 deg
C depend on the requirement of the food. Feed should be stored in containers
with close-fitting, hinged lids to prevent the entry of vermin. Materials used
also should be water-resistant or waterproof to prevent spoiling of feed. Metal
should be the preferred material of choice.

iv.

Capability: The equipment can stir the mixture in the container which can be
controlled in term of time and speed of the rotation.

v.

The equipment can sustain a stress impact from the horses due to avoid
machine breakdown.

vi.

The equipment is easily carried and handled by operator who is in charge for
feeding horses.

2.5 Processes [ChinYS]

i. There are no limitations to the manufacturing processes as there are no

constraints on the manufacturing facility.
ii. The mechanical parts can be done in UTM Mechanical Department where
possible.
iii. Electrical, electronics, wiring, and control system can be integrated by UTMs
Electrical Department.
iv. Other heavy parts, if not possible to be manufactured in UTM, can be
outsourced to qualified suppliers near UTM.

2.6 Installation [Bala]

i.

All wear and tear parts should be bolted type connection, for easy replacement.

ii.

All the permanent connections should be welded.

iii.

Hinge to be installed for folding parts.

iv.

Engineering tolerance and fit required for assembly parts.

24

v.

Bolts and nuts to be used in metric standards.

vi.

Parts length to be kept at minimum size for easy installation, replacement and
shipping.

vii.

All bolted connections should sustained collision force due to horse behaviour
during meal period.

viii.
ix.

Perform tightness check on bolt connections.

Appropriate tolerance should be given to assembly parts to avoid misalignment
during installation.

x.

Moving parts such as bearing, pulleys and beltings must be supplied with
enough lubricants.

xi.

If there are any high precisions parts in use then it is necessary to be installed
with dowel pin.

xii.

All electrical installation such as wiring of electrical cables must be done in

proper manner and tidy.

2.7 Material [ChinYs]

i. Material of feeder must be non-poisonous, and does not pose any harm to
horses.
ii. Material of feeder must be durable enough so that feeder will not be damaged
by horses due to chewing.
iii. For the construction of body of machine, the material must be non-corrosive
so that the machine will be able to last within its operating life.
iv. Chosen material for body of machine must be resist to wear and tear.
v. Chosen material for body of machine must not be too reflective as reflection of
sunlight may cause certain psychological effect to horses.
vi. Chosen material must be strong enough to withstand strong impact due to
kicking of horses.

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2.8 Ergonomics [Bala]

i. All hand switches must be suitable for the height of operating personnel.
ii. All the switches must be able to be operated by one finger; point finger.
iii. The food container should be easily accessed by the operator so that it can be
refilled when its empty.
iv. The food container should give allowance for the horse to drop the lower jaws
forward when the horse puts the head down to eat.
v. The food container should accommodate the average horse face length
53 cm 60 cm, 21 cm 22 cm width and height which is 14 H 15 H.
vi. The food to be served within visual field of the horse; which is 65 from the
face centre and take note of the blind spot area which is 3
vii. There should not be any sharp edges for safety purpose of the horse and the
operator.

2.9 Safety [Bala]

i. Avoid any sharp edges on the parts of the feeding system

ii. The feeding system should not create any tripping hazard, head knock injury
or obstruction to both operator and horse.
iii. All the parts of the materials that are direct contact with the horse food should
not create any chemical hazard that might cause food poisoning.
iv. All the electrical wiring should be done with proper earthling.
v. Electrical wiring, switches and other devices should be insulated to avoid any
contact with water or rain.
vi. Any machine lubricants should not drip into the food container that could
contaminate the food.
vii. Minimize wiring exposure to horse to prevent any hazard and damage.
viii. Feeding system should minimize the exposure of the food to environment so
that there is no any contamination from surrounding.

26

ix. Feeding system to be included with red coloured emergency stop button for
case of emergency.
x. Signage of dont touch on the moving parts to be included with the machine.
xi. Feeding system to be included with auto alarm system if there is any case of
emergency to alert the operator.

2.10

Shipping [Bala]

i. Assembly parts will be stored in boxes and top side facing upwards.
ii. Lengthy parts will be folded and will be stored in boxes.
iii. Bolts, nuts and screws will be kept in plastic bags and stored together with the
assembly parts which it belongs to.
iv. All the parts will be transported by lorry.

2.11

Maintenance [Bala]

i. Preventive maintenance chart to be established during initial stages for best

performance.
ii. Frequency based maintenance to be done on the moving parts such as bearings
and beltings.
iii. Counter to be installed to monitor numbers of cycles done for moving parts.
iv. Checklist to be filled up each time the maintenance is done.
v. Bolts and nuts tightness to be checked frequently.
vi. All maintenance parts to be removed and installed with minimal duration.
vii. Operating manuals should be in three copies.

27

2.12

Documentation [ChinYS]

There are several documents need to be presented upon completion of the

design mechanism. This is to ensure machine is operated correctly and safely.

i.

Standard Operating Procedure (SOP) - ensures operators (UTM Equine Park

workers) are able to operate the machine correctly. The SOP must be very
comprehensive, that must include, but not limited to:

ii.

Construction of machine design

iii.

Detailed description of operation manual

iv.

Safety precautions

28

CHAPTER 3

CONCEPT GENERATION

3.1

Introduction [Afiq, Bala & Chin]

A concept is an idea that is sufficiently developed to evaluate the physical

principles that govern its behaviour. Concept generation is a five step method. The five
step methods are:

i.

Clarify the problem

ii.

Search externally

iii.

Search internally

iv.

Explore systematically ( Morphology chart )

v.

Reflect on the solution process.

To clarify the problem a general statement was defined based on the back
ground research done. The general statement summarises the input and the output to
the overall system.

29

Input
General statement

Output

Figure 3.1: General statement

Input: Food in powder and pellet form.

Output: Food for each meal timing (breakfast, lunch and dinner) according to each
horse nutrition eating ratio.

General statement: To disperse all the food in the form of powder and pellet in proper
ratio for the particular meal timing (breakfast, lunch and dinner) for the designated
horse.

Energy: Electrical power.

From the above general statement the sub system needed was identified. All
the sub systems are gathered to make up the system. Take note that some sub system
will be further break down to create another sub system. Refer to figure 1 and 2 below.

Input

Food mixing
Food delivery
Feeder
Food container
Timer

Output
Figure 3.2: Series of sub system

30

Input

Storage
Measurement of food
Selection of type of meal
Container transportation of mixing
Food dispenser

Output

Figure 3.3: Break down food mixing sub system

Figure 3.4: Morphology chart 1[Afiq, Bala & Chin]

31

From the above sub systems the morphology chart is used to refine the sub
system. Refer to figure 3.4 and figure 3.5.

Figure 3.5: Morphology chart 2[Afiq, Bala & Chin]

Based on the morphology chart the conceptual design sketches were done. The
conceptual sketches will explain the functions, forms and components. There were
totally seven sketches was done to explain the concepts. All the concepts are shown in
the figures below.

32

Figure 3.6: Concept 1 [Bala]

Figure 3.7: Concept 2 [Bala]

33

Figure 3.8: Concept 3 [Chin YS]

Figure 3.9: Concept 4 [Chin YS]

34

Figure 3.10: Concept 5 [Afiq]

Figure 3.11: Concept 6 [Bala]

35

Figure 3.12: Concept 7 [Bala]

A scoring sheet was developed to select the final conceptual design. The table
3.1below shows the scoring sheet. As per scoring sheet the design concept 6 had been
selected as the final concept.

36

Table 3.1 Scoring Sheet

Concepts
Criteria

Weight
(W)

Rating, W x Rating, W Rating, W Rating, W Rating, W Rating, W Rating, W

R

xR

xR

xR

xR

xR

xR

35

35

35

14

35

35

35

horse

35

35

28

21

14

28

28

Hygienic

12

24

60

60

36

60

3.5

42

60

workers

35

21

35

14

35

35

28

Safety for horse

2.5

17.5

21

21

28

14

35

21

User friendly

30

24

24

30

30

30

30

clean

12

36

2.5

30

48

36

24

36

36

Easy to install

28

21

28

21

28

28

35

low

21

14

28

21

28

28

14

Less manpower

15

75

75

60

60

30

75

75

measurement

13

26

52

39

39

39

39

26

Total

100

Ergonomics for
workers
Ergonomics for

Safety for

Easy to
maintain &

Machine cost is

Accurate food

362.5

388

406

320

337

411

388

37

CHAPTER 4

CONCEPT DEVELOPMENT

4.1

Introduction [Afiq, Bala & Chin]

As the design concept 6 had been selected as the final concept, further
development was done to make improvement to any failure risk on the final concept
selected. FMEA tool was used to study the potential cause of failure and the precaution
method to be taken. In FMEA all the function affected, failure modes, failure effects
and cause of failure will be studied to come out with proper recommended action. The
FMEA was done on the flake form food container, food delivery unit and pallet food
container. The details of the FMEA are shown in the table 4.1 and 4.2 below. However,
we need to determine functional analysis first before we proceed to the FMEA. The
purpose of functional analysis is to reduce repeated function during design process.
The detail functional analysis are shown in figure 4.1.

38

Figure 4.1: Functional Analysis for the horse feeding system.

39

Table 4.1: FMEA Flake-form food container [Chin YS]

No.

Function

Potential

Potential Failure

Affected

Failure Modes Effects

Unable to move rod,

thus unable to drop

food to mixer

Potential Causes
of Failure

Recommended Actions

Responsible
Person

Use compressor that has

Main power supply emergency/alternative
cut off

power supply run using

Taken Actions

Source for compressor that has

Chin YS

alternative power supply, and

test for its reliability.

gasoline or petrol.
Testing results from supplier

Pneumatic
2

cylinder
movement

Unable to move rod,

No compressed thus unable to drop Compressor tank
leakage
air supply
food to mixer

must show high reliability

for the tank's service life.

Supplier

Test tank reliability.

Supplier

Test compressor reliability.

Regular checks and

maintenance.

Unable to move rod,

3

thus unable to drop

food to mixer

Testing results from supplier

Compressor motor must show high reliability
failure

for the compressor's service

life.

40
Regular checks and
maintenance.

Testing results from supplier

must show high reliability
Cylinder part

failure

Unable to move rod,

thus unable to drop
food to mixer

Wear and tear of

moving parts

for the compressor's service

life.

Go through technical sheets

Supplier

and suggest checking and

maintenance schedule

Regular checks and

maintenance.
Choke (that is
connected to shaft)
5

Shaft buckle
Cylinder shaft

unable to be lifted up,

thus unable to drop

and choke

Weight of food too

heavy

Design shaft with given

diameter and length so that Chin YS
it will not buckle.

Calculate optimum shaft

diameter.

food to mixer

holding fixture
6

Choke

Choke (that is

disconnected

connected to shaft)

from shaft

unable to be lifted up,

Weight of food too Obtain technical sheet and

heavy

test results from supplier.

Chin YS

Test shaft fastener over mould

using high load.

41
thus unable to drop
food to mixer

42

Table 4.2: FMEA Food delivery unit [Bala]

No.

Function Potential Failure

Potential Failure

Potential Causes of

Recommended

Affected

Effects

Failure

Actions

Modes

transferred to main Air cylinder failure

mixer

Sliding

No power to pull

Mechanism the slider plate

transferred to main
mixer

Food will not be

mechanism from
pneumatic to electrical

Bala

Electric motor with

high torque is chosen

motor with high torque

Over weight of food

Change the drive

dispersed from the food mechanism from

cylinder to food

pneumatic to electrical

transfer container

motor with high torque

inability of the load

transferred to main sensor to detect the

mixer

Taken Actions

Change the drive

Food will not be

Food will not be

Responsible Person

weight

Bala

Electric motor with

high torque is chosen

Supplier need to give

check for the sensitivity
of the sensor

Supplier

the sensitivity of the

sensor and adjusting
method

43
insufficient clearance

Increase the tolerance

of the slider plate and

during assembly of the

the food transfer

slider plate to food

container

transfer container

Inadequate angle for Improper food

Plate angle not

Install rotating

mixing

sufficient for mixing

assembly

Insufficient feeding

Enlarge the feeding

space for horse face

space

Food will not be

transferred to main
mixer

Mixer

Feeder space
inadequate
3

mixing
Horse avoid eating

Bala

Done

Bala

Done

Bala

Done

Bala

Done

Feeder
Injury to horse face Horse avoid eating

sharp edges at the food Chamfer the sharp

container

edges

44

Table 4.3: FMEA Pallet Food Container [Afiq]

No.

Function
Affected

Potential Failure
Modes

Potential Failure
Effects

Potential Causes
of Failure

Recommended Actions

Responsible
Person

Taken Actions

Plate Opener

Stuck to open

Hinge will be
broken

Hinge Failure

Protect hinge from any dust

or particle covered by metal
plate

Afiq

Vendor required to modified

the hinge

Stuck to open

Hinge will be
broken

Bolt and nut

bending lead to
failure

Need to ensure using high

tensile stress bolt and nut

Afiq

Supplier need to supply

suitable bolt and nut

No torque to
open

Solenoid Valve
not function

Plunger unable to
create magnetism

Calibrate or inspect solenoid

valve based on maintenance
schedule

Afiq

Need to plan Total Preventive

Maintenance schedule

No torque to
open

No air supply

Air compressor
not function well

Need to Maintain air

compressor based TPM
schedule

Afiq

Need to plan Total Preventive

Maintenance schedule

Valve stuck
during closing

Bearing Failure

Large particle slip

into bearing

Using suitable valve for

pallete

Afiq

Supplier need to supply

suitable valve for special
application

Valve/Dampener

45

CHAPTER 5

ENGINEERING ANALYSIS

5.1

Material Selection for Horse Feeding Equipment [Afiq, Bala & Chin]

High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a

polyethylene thermoplastic made from petroleum. With a high strength-to-density
ratio, HDPE was selected as our material selection for the feeding horse machine.
HDPE is known for its large strength-to-density ratio. The density of HDPE can range
from 0.93 to 0.97 g/cm3. Although the density of HDPE is only marginally higher than
that of low-density polyethylene, HDPE has little branching, giving it stronger
intermolecular forces and tensile strength than LDPE.

The difference in strength exceeds the difference in density, giving HDPE a

higher specific strength. It is also harder and more opaque and can withstand somewhat
higher temperatures (120 C/ 248 F for short periods, 110 C /230 F continuously).
Furthermore, HDPE has several features that give us particular advantage to use this
material.

46

The advantages are:

i.

UV resistant

ii.

Moisture resistant

iii.

Fungus and Moulds resistant

iv.

Abrasion resistant

v.

Graffiti can be easily cleaned

vi.

Stain resistant

vii.

Chemical resistant

viii.

High durability

ix.

Low coefficient of friction

x.

Food Grade for food industries application

xi.

High impact strength

xii.

Fire retardant

xiii.

Low maintenance cost

xiv.

No delamination

xv.

Easily work with most wood and metal working tools

xvi.

Vacuum formable

xvii.

Thermal formable

Moreover, with the aid of innovation and advanced manufacturing facilities

backed by a dedicated team of experts, this material can undergo several processes
which are nearly same as steel like thermoforming, HDPE sheets extrusion process,
CNC Routing and Engraving and Plastics Welding.

If we compared with other plastic materials in figure 5.1, we may determine

that HDPE has the lowest properties in term of tensile strength, flexural strength,
compressive strength, shear strength and impact strength. It is reasonable for our
requirement to meet reasonable factor of safety which we will discuss on next section.

47

Figure 5.1: Comparison Table for plastic material.

48

49

5.2

Engineering Analysis

5.2.1

Slider holder [Bala]

Based on figure 5.2, we had analysed slider holder part which is subjected to
bending stress by the load. After we did some engineering calculation, we optimized
the data and did the comparison by changing the size and length to determine suitable
size where we can meet our requirement for safety factor which is less than 4.

(b)

(a)

(c)

Figure 5.2: The slider holder which is subjected to bending stress by load. (a)
and (b) Isometric view (c) Side view

50

Table 5.1 shows that the comparison for each parameter that we have changed
to optimize the design.

Table 5.1: Comparison Table for Optimization for the slider holder

(mm)

(mm)

(mm4)

(MPa)

(MPA)

1.

30

1.125 x 10-8

1.64

2.

20

3.33 x 10-8

3.

10

4.17 x 10-8

No

F.S

Result

31.6

19.62

Bad

3.69

31.6

8.6

Bad

14.78

31.6

2.13

Good

Based on the table 5.1, we may conclude that the third optimization is chosen
due to,

1 << F.S << 4

(Detail calculation can be referred in Appendix section.)

5.2.2

Food Discharge Unit [Bala]

Based on figure 5.3, we had analysed food discharge part which is subjected to
bending stress by the load. After we did some engineering calculation, we optimized
the data and did the comparison by changing the size and length to determine suitable
size where we can meet our requirement for safety factor which is less than 4.

51

(a)

(b)

Figure 5.3: The food discharge unit part which is subjected to bending stress by load.
(a) Isometric view (b) Side view

Table 5.2 shows that the comparison for each parameter that we have changed
to optimize the design.

52

Table 5.2: Comparison Table for Optimization for the food discharge unit

(mm)

(mm)

(mm4)

(MPa)

(MPA)

1.

80

8.33 x 10-10

6.48

2.

80

4.27 x 10-10

10.1

No

F.S

Result

31.6

4.8

Bad

31.6

3.12

Good

Based on the table 5.2, we may conclude that the second optimization is
chosen due to,

1 << F.S << 4

Therefore, HDPE sheet plastic will be used to with the dimension b = 80 mm,
h = 4 mm and length = 160 mm.

(Detail calculation can be referred in Appendix section.)

5.2.3

Rod Actuator [Afiq]

Based on figure 5.4, we had analysed rod actuator part which is subjected to
shear stress by the load. After we did some engineering calculation, we optimized the
data and did the comparison by changing the diameter size and mass to determine
suitable design where we can meet our requirement for safety factor which is less than
4.

53

(b)

(a)

Figure 5.4: The rod actuator part which is subjected to bending stress by load F (a)
Full scale drawing (b) Internal force analysis
Table 5.3 shows that the comparison for each parameter that we have changed
to optimize the design.

54

Table 5.3: Comparison Table for Optimization for the rod actuator

No

(mm) (mm2)

(N)

(kg/day)

(MPa)

(MPa)

F.S

Result

1.

15

176

147.15

15

23.3

0.83

28

Bad

2.

10

78.5

147.15

15

23.3

1.87

12.4

Bad

3.

10

78.5

220.75

22.5

23.3

2.81

Bad

4.

10

78.5

367.88

37.5

23.3

4.68

Bad

5.

10

78.5

515.03

52.5

23.3

6.56

Good

Based on the table 5.3, we may conclude that the fifth optimization is chosen
due to,

1 << F.S << 4

Therefore, HDPE sheet plastic will be used to with the mass = 52.5kg/day and
D = 10 mm.

(Detail calculation can be referred in Appendix section.)

5.2.4

HDPE Mounting Plate [Afiq]

Based on figure 5.5, we had analysed HDPE mounting plate part which is
subjected to tensile stress by the load. After we did some engineering calculation, we
optimized the data and did the comparison by changing the diameter size and mass to
determine suitable design where we can meet our requirement for safety factor which
is less than 4.

55

Figure 5.5: The HDPE plate part which is subjected to tensile stress by load
Table 5.4 shows that the comparison for each parameter that we have changed
to optimize the design.

56

Table 5.4: Comparison Table for Optimization for the HDPE plate

No

F.S Result

N1,2

(N)

(mm)

(mm)

(N)

1.

36.79

25

73.58

7.5

31.7

0.73

43

Bad

2.

36.79

10

73.58

7.5

31.7

1.84

17

Bad

3.

257.4

10

515.02

52.5

31.7

12.87

Good

(kg/day) (MPa) (MPa)

Based on the table 5.4, we may conclude that the third optimization is chosen
due to,

1 << F.S << 4

Therefore, HDPE sheet plastic will be used to with the mass = 52.5kg/day and
h = 10 mm.

(Detail calculation can be referred in Appendix section.)

5.2.5

Tank Support Beam [Chin YS]

Tank support beam is used to support the weight of food tank and the support
structure itself. Thus it is crucial for this item not to yield or buckle so that the tank
will not fall off the support and cause failure of whole food delivery system.

The analysis is as follows, using stress, (force / area) applied on beam and
compared with the materials yield strength.

57
Beam
Height

14.74 mm

Width

2.08 mm

Length

75.68 mm

Load/Mass
Holder

0.162 kg

Tank

0.266 kg

Food

1 kg

Total

1.428 kg

Total weight

14.009 N

Material - HDPE
Yield strength

29.5 Mpa

Moment calculation
Weight/Force, F

14.009 N

Moment

1.060 Nm

Stress calculation
Distance to NA, c

7.37 mm

Second moment of area, I

Stress,

555.1 mm^4
1.408E+07 Pa

Analysis
Material yield strength

29.5 Mpa

Stress calculated

14.1 MPa

58

Figure 5.6: Holding beam of tank holding structure.

Material chosen was initially metal, which has very high strength relative the
overall load given. Thus material is suggested to be changed to plastic, which has also
enough rigidity and strength to hold the whole system. Suggested plastic material is
high density polyethylene (HDPE). The stress calculated is approximated half of
HDPEs yield strength. This gives the beam a safety factor of 2, which is very much
desirable in design.

5.2.6

Cylinder Shaft [Chin YS]

Cylinder shaft is one of the few moving parts and due to its slender structure,
it is calculated for its buckling strength. Buckling force is calculated using following
equation.
=

2
2

Tensional stress is neglected because effect of buckling force is higher than tensional
stress in slender object.

59

Cylinder
shaft

Figure 5.7: Cylinder shaft.

Shaft dimensions
Diameter
Length

5 mm
475 mm

Material - Aluminium 1100

Elastic modulus, E
6.89E+10 Pa
Mass
Food
Choke
Choke Ovrm
Total
Total weight
Design safety factor, k
Design weight

1.000
0.224
0.001
1.225
12.012
3
36.0

kg
kg
kg
kg
N

Analysis
Second moment of area, I
Buckling force, F

3.1E-11 m4
92.5 N

Re-define shaft geometry

Outer diameter
Inner diameter
Second moment of area, I
Buckling force, F

4
2
1.2E-11
35.5

mm
mm
m4
N

60

Based on calculation, using 5mm diameter solid shaft will give additional
safety factor of about 3. Thus the geometry of shaft is change to a hollow one to change
the second moment of area. The suggested dimensions are, outer diameter of 4mm,
and inner diameter of 3.6mm. The material of choice is Aluminium 1110, because
aluminium will not corrode over time, thus will not pollute food.

61

CHAPTER 6

COSTING

6.1

Costing Design [Afiq, Bala & Chin]

Table 6.1: Fabrication, Installation and Transportation cost.

62

Costing is another important part in design. A good design will be able to

meet design criteria, and at the same time uses minimal cost. Cost includes material
cost, labour cost, production cost, administrative cost, and transportation cost. The
horse feeding system is cost estimated as table 6.1.

Therefore, the total cost that we have estimated is RM 3049.58. This cost is
desirable and reasonable to purchase. Moreover, the feeding horse system is semiautomatic machine where it can be used without consume any additional cost
afterward.

63

CHAPTER 7

HORSE FEEDING SYSTEM OPERATION

7.1

Auto Horse Feeding System Operation [Afiq, Bala & Chin]

System operation for our feeding horse machine is user friendly where the

operator can operate the machine without any difficulties. This can be ensured by
referring to figure 7.1 where the process flow chart had been constructed. Therefore,
it is easy for a user to understand in a correct way.

Figure 7.1: The process flow chart for the horse feeding system.

64

The instruction how to operate this system can be referred as below,

1. Food in pellet form and powder will be loaded manually to its individual tanks.
2. This food is loaded for one week of the horse meal consumption.
3. As the meal time approaches, the timer will trigger signal to the tanks to
disperse the food to the plastic containers.
4. The weight sensor which is located below the slider plate will measure the
weight of the food dispersed by the tanks.
5. The weight sensor will send signal to tank to stop dispersing the food when the
weight is as per the ratio is detected.
6. Next signal will be send to the controller to release the food to the mixer..
7. This is sliding mechanism where the motion is driven by electrical motors.
8. While the food drops down, the rotating mechanism inside the mixer will rotate
to get a proper mixing.
9. This rotating will take place until all the food is fallen to the food discharge
unit.
10. When the sensor at the bottom of the food discharge unit detects the total
amount of weight of the food for the horse per meal, it will discharge the food
through the food slide to the meal container.
11. This cycle will take place for each meal timing based on the timer.
12. The meal timing and the ratio will be registered to the system main controller
according to each individual horse in UTM Equine Park.

65

CHAPTER 8

MACHINE LAYOUT

8.1

Isometric Drawing

66

8.2

Orthogonal Drawing (Front View)

67

8.3

Detailed Drawing

8.3.1

Detail view of sliding mechanism

8.3.2

Detail view inside of Mixer

68

8.3.3

Detail view of Food Discharge Unit

8.4

Assembly Drawing

8.4.1

Assembly Drawing For Hay

Hay Slider 5
Hay Slider 4
Hay Slider 3
Hay Slider 2
Hay Tank

Hay Slider 1

69

8.4.2

Assembly Drawing For Horse Feeding System

70

REFERENCE
Abdul Rahim Abdul Manaf (2006). Mekanik Bahan Dan Elasticity. Universiti Malaya
Malaysia: Penerbit Universiti Malaya.

Budynas, R.G. and Nisbett, J.K. (2011). Shigleys Mechanical Engineering Design (9th
ed.). New York: Mcgraw-Hill.

Stephens, R.I., Fatimi, A., Stephens, R.R., and Fusch, H.O. (2001). Metal Fatigue in
Engineering. (2nd ed.). Canada: A Wiley-Interscience Publication.

71

APPENDIX
Slider Holder Calculation (Bala):

(a)

(b)
Figure 1: The slider holder which is subjected to bending stress by load. (a)
Isometric view (b) Side view

1. =

3
12

, b = 5 mm and h = 30 mm ,

M = 9.81 x 0.125 = 1.23 N.m

0.005(0.03)3
12

= 1.125 108 4 ,

, =

1.23(0.015)
1.125108

= 1.64

72

= 31.6 (From material properties table)

31.6

F.S = 1.64 = 19.62 (Too large)

2. =

3
12

, b = 5 mm and h = 20 mm ,

M = 9.81 x 0.125 = 1.23 N.m

0.005(0.02)3
12

= 3.33 109 4 ,

, =

1.23(0.015)

3.33 109

= 3.69

= 31.6 (From material properties table)

31.6

F.S = 3.69 = 8.6 (Too large)

3. =

= 0

12

, b = 5 mm and h = 10 mm ,

M = 9.81 x 0.125 = 1.23 N.m

0.005(0.01)3
12

= 4.17 1010 4 ,

, =

1.23(0.015)

4.16 1010

= 14.78

= 31.6 (From material properties table)

31.6

F.S = 14.78 = . (OK)

73

Food Discharge Calculation (Bala):

(a)

(b)
Figure 2: The food container unit which is subjected to bending stress by
load. (a) Isometric view (b) Side view

1. =

= 0

12

, b = 80 mm and h = 5 mm ,

M = 27 x 0.08 = 2.16 N.m

0.08(0.005)3
12

= 8.33 1010 4 ,

, =

2.16(0.0025)

8.33 1010

= 6.48

74

= 31.6 (From material properties table)

31.6

F.S = = 6.48 = . (Too Large)

2. =

3
12

= 0

, b = 80 mm and h = 4 mm ,

M = 27 x 0.08 = 2.16 N.m

0.08(0.004)3
12

= 4.27 1010 4 ,

, =

2.16(0.002)

4.27 1010

= 10.1

= 31.6 (From material properties table)

F.S =

31.6

= 10.1 = . (OK!)

75

Rod Actuator (Afiq):

(b)

(a)

Figure 3: The rod actuator part which is subjected to bending stress by load F (a) Full
scale drawing (b) Internal force analysis
1. F = mg, where m = mass = 15 kg & g = gravitational acceleration = 9.81 m/s2
F = (15kg)(9.81m/s2) = 147.15 N
(+ ) = 0

-F V = 0
V = -F = -147.15 N = 147.15 N ( )

76

147.15
= 0.83
(15 103 )2
4

= 23.3

23.3

F.S = = 0.83 = (Too Large)

2. F = mg, where m = mass = 15 kg & g = gravitational acceleration = 9.81 m/s2

F = (15kg) (9.81m/s2) = 147.15 N
(+ ) = 0

-F V = 0
V = -F = -147.15 N = 147.15 N ( )

Change diameter to 10 mm

147.15
= 1.874
(10 103 )2
4
= 23.3

23.3

F.S = = 1.874 = (Too Large)

3. F = mg, where m = mass = 22.5 kg/day & g = gravitational acceleration = 9.81

m/s2
F = (22.5 kg) (9.81m/s2) = 220.75 N
(+ ) = 0

-F V = 0
V = -F = -220.75 N = 220.75 N ( )

77

220.75
= 2.81
(10 103 )2
4

= 23.3

23.3

F.S = = 2.81 = (Too Large)

4. F = mg, where m = mass = 37.5 kg/day & g = gravitational acceleration = 9.81

m/s2
F = (37.5 kg) (9.81m/s2) = 367.87 N
(+ ) = 0

-F V = 0
V = -F = -367.87 N = 367.87 N ( )
367.87
= 4.68
(10 103 )2
4

= 23.3

23.3

F.S = = 4.68 = (Too Large)

5. F = mg, where m = mass = 52.5 kg/day & g = gravitational acceleration = 9.81

m/s2
F = (52.5 kg) (9.81m/s2) = 515.03 N
(+ ) = 0

-F V = 0
V = -F = -515.03 N = 515.03 N ( )

515.03
= 6.56
(10 103 )2
4

78

= 23.3

23.3

F.S = = 6.56 = (OK!)

Plastic Plate (Afiq):

Figure 4: The HDPE plate part which is subjected to tensile stress by load

79

1. W = 7.5 kg x 9.81 m/s2 = 73.58 N,

= 0 = 73.575 + 1 + 2

= 0

- 73.575(112.50 x 10-3) + N2 (225 x 10-3) = 0

N2 = 73.575 N1

- 73.575(112.50 x 10-3) + (N2 = 73.575 N1) (225 x 10-3) = 0

N1, 2 = 36.79 N

36.79
= 0.735
25 103 2 103

31.7

F.S = = 0.735 = (Too large!)

2. W = 7.5 kg x 9.81 m/s2 = 73.58 N,

= 0 = 73.575 + 1 + 2

= 0

- 73.575(112.50 x 10-3) + N2 (225 x 10-3) = 0

N2 = 73.575 N1

- 73.575(112.50 x 10-3) + (N2 = 73.575 N1) (225 x 10-3) = 0

N1, 2 = 36.79 N

80

Change length plate,

36.79
= 1.839
10 103 2 103

31.7

F.S = = 1.839 = (Too large!)

3. W = 52.5 kg/day x 9.81 m/s2 = 515.025 N, (Increase mass)

= 0 = 515.025 + 1 + 2

= 0

- 515.025 (112.50 x 10-3) + N2 (225 x 10-3) = 0

N2 = 515.025 N1

- 515.025(112.50 x 10-3) + (515.025 N1) (225 x 10-3) = 0

N1, 2 = 257.40 N

257.40
= 12.87
25 103 2 103

31.7

F.S = = 12.87 = (OK!)

81