FIGURE LIST `

pg

Figure 2.1.1: Show the Boat Land after Netting Fish

Figure 2.1.3: Base example
Figure 4.1.1: Belting system
Figure 4.2.1: Structure of gear
Figure 4.3.1: Structure of polymer
Figure 4.4.1: Machine 1
Figure 4.4.1: Machine 2
Figure 4.4.3: Machine 3
Figure 6.1.1: Electrical Motor
Figure 6.2.1.1: Female Gear
Figure 6.2.2.2: Male Gear
Figure 6.3.1: Winch
Figure 6.4.1: Bearing
Figure 6.5.1: Shaft Holder
Figure 6.6.1: Worm gear holder
1

Figure 6.7.1: Coupling

Figure 6.12.1: Basement
Figure 7.1.1: How to tight the base
Figure 7.4.1: How to hanging by cable
Figure 7.5.1: Process Drag the load
Figure 8.3.1: Product design (by using solid work)
Figure 8.3.2: Detail drawing
Figure 8.3.3: Part drawing
Figure 12.1.1: Assembly Drawing (Female Gear)
Figure 12.1.2: Assembly Drawing (Male Gear)
Figure 12.1.3: Assembly Drawing (Winch)
Figure 12.1.4: Assembly Drawing (Bearing)
Figure 12.1.5: Assembly Drawing (Shaft Holder)
Figure 12.1.6: Assembly Drawing (Worm gear holder)
Figure 12.1.7: Assembly Drawing (Coupling)
Figure 12.1.8: Assembly Drawing (Shaft)
Figure 12.1.9: Assembly Drawing (Bush)
Figure 12.1.10: Assembly Drawing (Basement)

TABLE LIST
Jadual 6.2.1 : Spesifikasi Am Enjin Proton Satria 1.3 (M)

19

Jadual 8.0.1: Senarai komponen yang digunakan

30

Jadual 8.2.1: Anggaran kos bahan

35

LIST OF CONTENT
1.0

ABSRACT

2.0

INTRODUCTION

2.1 Problem Statement

2.2 Design Concept

10

3.0

OBJECTIVE

11

3.1 Overal Objective

11

3.2 Main Objective

11

4.0

LITERATURE REVIEW

12

4.1 Belt and Chain System

12

4.2 Gear System

13

4.3 Type of Material

16

4.4 Available Boat Winch at Pantai kundur and Pantai Puteri

18

5.0

IMPLEMENTATION METHOD

21

6.0

COMPONENT

22

7.0

OPERATION METHOD

7.1 Basement

30

7.2 Position

30

7.3 Cable

31

7.4 Hanging Process

31

7.5 Drag

32

8.0 TECHNICAL SPECIFICATION

33

8.1 Product Cost

33

8.2 Product Specification

34

8.3 Product Design

35

9.0

1.0

30

DISCUSSION

37

10.0 CONCLUSION AND SUGGESTION

38

11.0 REFERENCES

39

12.0 APPENDIXES

40

ABSTRACT
First of all, this final project used to train us to become a knowledgeable and

matured in any field we attend, especially when we entered job environment after this.
Our design concept is according our problem statement. One of it, is to reduce the
machine cost at market but still effective. Then, the size of the machine must be smaller
than the product sold at market. From our literature review, we had recognized a few
types of gear that can transmit power from motor to a heavy load that not more than 1
tone. We add a few components like different gearbox from the available machine at
market. Our gearbox did not use oil, but only use grease to make it smooth. We also need
to draw the design using software to recognize the actual dimension before do the
machining process. The sketch for our design is our first idea before we find the really
effective design after our research from literature review and survey. After completing
our project at week 14, we still need more improvement for our product. What we mean
from the improvement phase is the aesthetic dimensional.
Pertama sekal tujuan projek ini adalah untuk merendahkan kos dan mengecilkan
saiz mesin. Berdasarkan kajian yang dijalankan terhadap produk yang sedia ada, terdapat
4

pelbagai jenis gear yang digunakan. Namun keupayaannya berbeza-beza yang

membuatkan kumpulan kami terpaksa mendapat khidmat pakar dalam pemilihan gear.
Mesin kami dijangka boleh menarik beban tidak lebih dari satu tan. Kami juga ter paksa
membuat lukisan menggunakan solid work bagi mendapatkan dimensi sebenar dalam
memastikan tiada masalah semasa proses pemasangan. Setelah selesai projek mesin ini,
masih terdapat kelemahan yang perlu diperbaiki iaitu dari segi fizikal dan bentuk produk
tersebut.

The purposes to develop a new design for a boat wicnh are to reduce machine cost
with machine easy to maintenance, easy to be used and can pull a heavy load. The
machine is design to improve the boat movement form the sea to the seashore at Pantai
Kundur. Survey conducted shows the existing machine consume high cost and limited
use where that machine cannot be shared with other fishermen

mesin tarik bot direkacipta untuk menarik bot di kawasan sekitart pantai kundur.
mesin yg telah sedia ada lebih tinggi kos dan tidak user friendly. ia juga terhad untuk
kemudian nelaya tertentu sahaja dan tidak dapat dikongsi dengna nelayan2 yg lain.
beberpa kajian telAH DILAKUKAN UNTUK MENCIPTA MESIN YG PALING
EFEKTIF DARI SEGI KPOS, PENYELEMNGGARAAN PEMASANSANGAN DAN
JUAG KEUPOYAAN. ANATAR YG TELAH DILAKUKAN ADALAH SURVEY
TERHADAP MOTOR, PENGGUNANN GEAR PEMASANGAN YANG RINGKAS
DAN JUAG KESELAMATN. MESIN YUG TELH BERJAYA DICIPTA DAPAT
MENARIK SEHIN NGA 500KG DENGAN KOS PEMBUATAN SEBANAYK
RM1663. BERBanding debgfab mesin yg sedia ada penjimatan jkos hampir 40 % daripad
harga di pasaran. mesin yg telah dicipta menaplikasikan gabungan motor dan gear utk
berfiungsi.

2.0

INTRODUCTION

2.1 Problem statement

2.1.1 Most of fisherman at Pantai Kundur has problem while dragging their boat to
the land after netting fish. As we know boat is so heavy and beach sand give
only a bit help to pull it.

Figure 2.1.1: Show the Boat Land after Netting Fish

2.1.2 Only a few fishermen can afford to buy the previous machine because the
price is too high. It cost not less than RM 3000 per machine. The cost is
including motor, winch and gearbox, not with the cable cost. The cost for
3 phase wiring needs another RM 300.
2.1.3 The available machine can only can pull or drag one or two of boats that
really situated opposite of the machine because the available pole or
basement is fixed and cannot shift.

Figure 2.1.3: Base example

2.1.4 The basement and the machine available at Pantai Kundur is too big which it
needs high cost and more space.

2.2 Design concept

2.2.1 From the problem statement, the main focus of our product is to reduce cost
by design a product that used another application machine without giving
problems to the fisherman at Pantai Kundur.

2.2.2 The design concept will only need the fisherman to spend only half of the
cost of available machine. The estimation cost is around RM 1500
including motor, gearbox and winch. Our design concept might use
another type of gearbox. The gearbox named worm gear which transmit
more power, need small space, simple, more efficient and low of cost.

2.2.3 Our product would drag or pull the load or boat not only in front of the
machine but it can shift about 30 degree from the left or right of the
basement. This concept will help another fisherman boat which still
cannot afford to have the machine. This because our product need to
tightened to a pole using sling which it can shift according to the load
position.

2.2.4

A pole or basement of our machine only need half feet shaft and deeply
fixed in a surface to make it stronger.

3.0

OBJECTIVE

3.1 Overall objective

3.1.1 To train and improve students creativity in producing a product which can
generate students idea.

3.1.2 Train the students how to do presentation and force their project design
while seminar session.

3.1.3 Apply how to write a technical report and how to take part in an exhibition.

3.1.4 Train the students how to handle any project with a minimum supervise.

3.1.5 Teach the students to become more innovative and competitive

3.2 Main objectives

In this project, we have our own objective where to get A in our final project and
also to support our mission to solve the fisher problem. The objective is:

4.0

To reduce machine cost

Design a machine easy to maintenance

Design a machine easy to use

Design a machine can pull heavy load

Design a machine more flexible

LITERATURE REVIEW

Along this project, to design a good project, we had study many things from book,
internet and also from our analysis from customer comment, it like;
I. how to transfer the power from motor to winch
II. what is the efficient system for us to apply to our design
III. what the material we should be used
IV. how to reduce project cost
Every data collection we do analysis and discuss in group to make sure it really efficient
to apply or not. The data we collect is referring to the system what we want to used and is
it inside our mission where to reduce cost machine. The data is:
belt and chain system
gear system

type of material
4.1 Belt and Chain System
Belt and chain tensioners reduce belt or chain slack and transmit drive torque uniformly.
They also reduce noise and vibration; decrease sprocket, pulley, belt, and chain wear; and
increase the life of drive components. In drives, belts and chains are installed with
enough tension to create a level of friction that causes the belts or chains to grip the
pulleys and the pulleys to turn. Most belt drives consist of flat leather, rubber, or fabric
belts running on cylindrical pulleys, or belts with a V-shaped cross section running on
grooved pulleys. V-belts require less tension than flat belts because their greater surface
area creates more friction. Chain drives that use sprockets are reliable systems for long
running, continuous drive applications with limited shock and torque loads.

Belt and chain tensioners are available in a variety of sizes, styles, and materials. They
can handle different minimum and maximum loads as well as temperatures. With chain
drives, maximum chain pitch is an additional consideration. Belt and chain tensioners are
used in machinery and equipment, automobiles, bicycles, conveyor belts, and numerous
other applications

10

Figure 4.1.1: Belting system

4.2 Gear System
In gear system, they have many aspects we have to see like there size, bill of tooth, the
material we used and more. The picture below show the basic structure of gear:

Figure 4.2.1: Structure of gear

11

We also know, they have many type of gear in industry, where every type has their own
application and different function, but if we look it closely all of this gear has same
application where to transfer the rotation of movement. The main type of gear likes;

Table 4.2.2: Type of gear

No.
1.

Type of gear

Picture

Helical
- In helical gear, the system if like spur
gear but the angle of tooth is not 90
degree.
- Basically used for transfer rotation in
heavy load; like car, bus and more
- Used the concept of gear ratio to
increase the power or system
- Used direct load from motor or supply

2.

Hypoid
- this gear is used to change the angle of
rotation from vertical to horizontal
- Used direct load from motor or supply
- Not efficient at heavy load

12

3.

Spur
- In spur gear, the system if like helical
gear but the angle of tooth is 90 degree
straight
- Basically used for transfer rotation at
light load; like bicycle, clock and more
- Used the concept of gear ratio to
increase the power or system
- Used direct load from motor or supply

4.

Worm
- the concept worm gear is like screw,
where it can reduce load and at the same
time can reduce speed of motor rotation

5.

Bevels
- basically only to transfer the rotation
directly from motor or supply
- where if more speed we give the
rotation also increase like car coupling
and arm

13

6.

Rack and pinion

- basically used at conveyer system where
the gear cannot static when move
-

4.3 Type of Material

For convenience most engineering are divided into 3 main classes; metallic, polymer
(plastic), and ceramic materials. All of this we have to know their important mechanical,
electrical and physical properties. Where must choose it correctly to make sure it have all
specs that we wanted such as; strength, durability, hardness, and more that able to apply
base on applications. The basic materials are;

I.

Metallic
-

These materials are inorganic substance that are composed of one or more
metallic elements and may contain some nonmetallic elements.

Metal and alloy are commonly divide into 2 classes; ferrous metals and
alloy that contain a large percentage of iron such as the steel and cast ion
and nonferrous metals and alloys that do not contain iron or contain only a
relatively small amount of iron

II.

Ceramic
-

Ceramic material is inorganic material that consists of metallic and nonmetallic element chemically bonded together.

Ceramic material can be crystalline, non-crystalline or mixtures of both.

Most ceramic material have high hardness and high-temperature strength
but tend to be brittle.

14

III.

Polymer
-

Most polymer materials consist of organic (carbon

(carbon-containing)
containing) long
molecule chains or network.

Structurally, most polymer material is no crystalline but some consist of

mixtures of crystalline and no crystalline regions. The strength and
ductility of polymer vary greatly

Figure 4.3.1: Structure of polymer

IV.

Composite
-

Composite are mixtures of two or more material. Most composite consist

of a selected filler or reinforcing material and a compatible resin binder to
obtain the specific characteristic and properties desired

Composite can be of many types. Some of the predominant types are

fibrous(composite of fiber in a matrix) and particulate (composite of
particles in a matrix)

V.

Electronic
-

Are not a major of material by volume but are an extremely important type
of material for advanced engineering technology.

The most important electronic material is pure sil

silicon
icon that is modified in
various ways to change its electrical characteristic.

15

4.4 Available boat winch at Pantai Kundur and Pantai Puteri

This entire machine we get it from our survey at Pantai Kundur and Pantai Puteri.
There have 3 machines still function like figure below:

Figure 4.4.1: Machine 1

High cost of machine( more than RM 3000.00)

The cable not arrange correctly

Used motor 4 Hp

16

Figure 4.4.2: Machine 2

High cost of machine( more than RM 3000.00)

Difficult to find the spare part

Difficult to maintenance (high cost)

Used motor 7 Hp

17

Figure 4.4.3: Machine 3

High cost of machine( more than RM 3000.00)

Used bigger space to put the machine

Difficult to maintenance (high cost)

18

5.0

IMPLEMENTATION METHOD

Table 5.0: Gantt chart for our scheduled project

NO. Activity
W1 W2 W3
1
Title selection
#

W4

W5

W6

W7

W8

W9 W10 W11 W12 W13 W14

Idea of design concept

Sketching

Searching information

Motor survey

Worm gear survey

Book worm gear/bush/motor

Buy parts

Design winch

10

Design shaft

11

Design 4 pieces holder

12

Design base

13

Product assemble

14

Product testing

15

Presentation and seminar

#
#
#
#
#
#

#
#

#
#

19

6.0

COMPONENTS

6.1 Motor (custom made)

Figure 6.1.1: Electrical Motor

2 horsepower
3 phase
1500rpm
20 ampere

20

6.2 Worm gear (custom made)

The main system that used in our product is worm gear, where we have to order from
supplier because it difficult to make it, figure below show the worm gear we used:
6.2.1 Female

Figure 6.2.1.1: Female Gear

Hardened brass
Have 32 teeth
4 holes for screw

21

6.2.2 Male

Figure 6.2.2.2: Male Gear

Hardened mild steel

Have 4 teeth
Has key way

22

6.3 Winch

Figure 6.3.1: Winch

The material is from mild steel

Have 4 holes for screw
Tightened with cable
The with is about 5 times of cable diameter
Welding and grinding

23

6.4 Bearing (custom made)

Figure 6.4.1: Bearing

High speed steel

3 pieces
Inner diameter is 1 inch

24

6.5 Shaft holder

Figure 6.5.1: Shaft Holder

The material is from mild steel

Use milling process
2 pieces

6.6 Worm gear holder

Figure 6.6.1: Worm gear holder

The material is from mild steel

Use milling, chamfering, drilling and threading process
4 pieces
25

6.7 Coupling

Figure 6.7.1: Coupling

The material is from mild steel

Has key way
2 Key jam holes
2 shaft jam holes

6.8 Key
The material is from mild steel
Milling process
1 pieces
6.9 Shaft

The material is from mild steel

Using lathe process
1 pieces

6.10 Hook (custom made)

The material is from mild steel
Adjustable

26

6.11 Bush (custom made)

The material is from mild steel

6.12 Basement

Figure 6.12.1: Basement

The material is from mild steel

6.13 Key jam

The material is from mild steel
5mm screw
6.14 Bolls
The material is from mild steel
10mm screw
12 pieces
6.4.15 Cam starter (custom made)
Model QS5
AC.500V50-60Hz
6.4.16 Cable (custom made)
Alloy
Long - 10 meter
Maximum load 450 kg

27

7.0

OPERATION METHOD

7.1 Basement
First of all, the machine need to join to any base or pole for holding the machine
while pulling the load such as boat. The joining process we done are using to test
our product or machine is using sling. The sling can used to hang a load not more
than 4 ton. But, for the real testing at Pantai Kundur we need to join our machine
basement with the basement that ready for the previous machine using bolls and
nuts. The fasteners for the sling and our machine must be tidy.

Figure 7.1.1: How to tight the base

7.2 Position
The position of the machine might in any position. The motor is either at the
upside or down side. As long as the winch of this machine is opposite of the load
that were pulled.

28

7.3 Cable
Before any process started, the cable need to be release as far as the load from the
machine was tighten with the basement. To release the cable we need to connect
the socket to the power supply. Then, switch on the power supply switch. Next,
push on the cam starter forward and the motor part will move the shaft which
connected to the worm fear and the winch. All the parts will move backward to
release the cable. The distance for the cable to release is according to the boat or
load situated.

7.4 Hanging process

At the end of the cable, we had tightened the cable with a hook. The hook that
joins with the cable needs to entwine about two times at the boat head or the load.
For our test we entwine the hook two times around the load and for the last
entwine we put the hook back with the cable to make it firmly fixed.

Figure 7.4.1: How to hanging by cable

29

7.5 Drag
After tighten the cable with the load we start to drag the load. To drag the load we
just push the cam starter backward which will move the motor and the parts
related backward together.

Figure 7.5.1: Process Drag the load

30

8.0

TECHNICAL SPECIFICATION

Table 8.0.1 Product cost

Component

Price/unit

Quantity

3 phase 2 hp motor

RM 300

250.00

Coupling

RM 300

250.00

Key

RM 5.00

10.00

Jam screw

RM 0.50

2.00

Male worm gear

RM300

250.00

Female worm gear

RM300

280.00

Bearing

RM 10

30.00

Female worm gear shaft and acc

RM 80

80.00

Bush

RM 50

50.00

Winch and acc

RM 50

40.00

Worm gear holder

RM 50

200.00

Cable

RM 3

20 m

60.00

Hook and acc

RM 5

5.00

Base

RM 20

20.00

Bolls

RM 0.50

12

6.00

Wiring acc

RM130

1SET

TOTAL

Price(RM)

130.00
RM 1663.00

31

8.2 Product specification

Table 8.2.1 product for production
Parameter

Specification

Length

480 mm

Width

205 mm

Height

170 mm

Weight

30 kg

Type of gear box

Worm gear

Material used:Holder/shaft/ winch/base/coupling

Mild steel

Male worm gear

Hardened mild steel

Female worm gear

Hardened brass

Motor type

3 phase

Motor speed

1500 rpm

Motor volt

450 V

Motor current

20 A

Motor torque

2 hp

Cable type

Alloy

Color

Black and green

Capacity load

Below 1 tan

32

8.3 Product Design

Figure 8.3.1: Product design (by using solid work)

Figure 8.3.2 Part drawing

33

Figure 8.3.3: Detail Drawing

34

9.0

DISCUSSION
For along 14 weeks designing this project, we faced many problems. At the first

week until third week we cannot find the type of gear should be used. Is it the bigger ratio
is more powerful or type of material will make it different from each other? At last we
find Mr. Saifuddin at Muar Johor to make decision because he is an expert for custom
made product. He said for pulling a load the most powerful gearbox is using worm gear.
The other problems are selection of 3-phase and single phase motor. The available
machines at Pantai Kundur are using 3-phase motor. But the phase motor need 420volt
power supply, not as usual at Malaysia. The power supply is 240volt. Using 3-phase
motor need special wiring that need an application from Tenaga Nasional Berhad (TNB)
for that type of wiring. For 420 watt, it usually used at factory field or lab as at KUTKM
fasa B laboratory. 3 phase motor socket or plug also different. The single phase motor
plug is same as our home accessories. It is 3 pin plugs.
This subject is the most difficult subject which needs full concentration and
calculation from start until end. At last, we solve those problems with Mr. Saifuddin, our
gearbox expert.
We also difficult to find the raw material according to the size we want. To solve
this problem, we use a second hand part and rubbish material from mild steel which find
by our expert Mr. Saifuddin.

Capabilities of machine.

Problem of mounting

Cable

35

10.0 CONCLUSION & SUGGESTION

As a conclusion, our project was successfully done to reduce the available
machine cost. The cost we had reduced is more than half prize from the market price but
with same product efficient. The cost at market is not less that RM 3000 and our product
costs RM 1663 only. The price should be less because the price is including try and error
price. Our machines also ease and low cost to maintenance because its use open gearbox
which no need to use gear box oil. Those types of oil will the increase the maintenance
cost. Our machine can pull not more than 1tonne load and very useful for those low
income fisherman. Lastly, this machine is design with high flexibility which it can shift
according the boat coordinate because its only needs a sling with a tough pole as a
basement. The available machine need a high, big and really tough basement to install the
machine before can use it. Finally our product is successfully done and gives more
satisfaction to the buyer from the available product.
For our improvement and suggestion, we need to use thicker cable as a safety
because the diameter for our cable is 5mm. its maximum stress is 800 kg. it might
fracture when more than 1 tone load given. We need about 10mm diameter of cable to
make this machine confident to pull load not more than 1 tone.

36

11.0 REFERENCES

37

12.0 APPENDIXES
12.1 Assembly Drawing

Female gear

Figure 12.1.1: Assembly Drawing (Female Gear)

Male gear

38

Figure 12.1.2: Assembly Drawing (Male Gear)

Winch

Figure 12.1.3: Assembly Drawing (Winch)

Bearing

39

Figure 12.1.4: Assembly Drawing (Bearing)

Shaft holder

Figure 12.1.5: Assembly Drawing (Shaft Holder)

Worm gear holder

40

Figure 12.1.6: Assembly Drawing (Worm gear holder)

Coupling

Figure 12.1.7: Assembly Drawing (Coupling)

Shaft

41

Figure 12.1.8: Assembly Drawing (Shaft)

6.11 Bush (custom made)

Figure 12.1.9: Assembly Drawing (Bush)

6.12 Basement

42

Figure 12.1.10: Assembly Drawing (Basement)

43