DESIGN AND INVESTIGATE THE MANUAL SUN TRACKING SYSTEM IMRAN BIN AHMAD ROSDI BACHELOR OF ENGINEERING UNIVERSITY MALAYSIA PAHANG

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1 DESIGN AND INVESTIGATE THE MANUAL SUN TRACKING SYSTEM IMRAN BIN AHMAD ROSDI BACHELOR OF ENGINEERING UNIVERSITY MALAYSIA PAHANG 2012

2 UNIVERSITI MALAYSIA PAHANG BORANG PENGESAHAN STATUS TESIS JUDUL: DESIGN AND INVESTIGATE THE MANUAL SUN TRACKING SYSTEM SESI PENGAJIAN: 2011/2012 Saya, IMRAN BIN AHMAD ROSDI ( ) mengaku membenarkan tesis (Sarjana Muda / Sarjana / Doktor Falsafah)* ini disimpan di perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis ini adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi / badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: NO 282 JALAN H2, Mr LEE GIOK CHUI FASA 5, TAMAN MELAWATI, (Nama Penyelia) KUALA LUMPUR. Tarikh: 25 JUNE 2012 Tarikh: 25 JUNE 2012 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).

3 DESIGN AND INVESTIGATE THE MANUAL SUN TRACKING SYSTEM IMRAN BIN AHMAD ROSDI Report submitted in fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG JUNE 2012

4 ii UNIVERSITI MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING I certify that the project entitled Design and Investigate The Manual Sun Tracking System is written by Imran Bin Ahmad Rosdi. I have examined the final copy of this project and in our opinion, it is fully adequate in terms of scope and quality for the award of degree of Bachelor Engineering. I herewith recommend that it be accepted in partial fulfillment of the requirements for the degree of Bachelor of Mechanical Engineering. (Mr. RosmaziRosli) Examiner Signature

5 iii SUPERVISOR S DECLARATION I hereby declare that I have checked this project and in my opinion, this project is adequate in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering. Signature : Name of Supervisor : Mr. Lee Giok Chui SMN, KMN. Position : LECTURER Date : 22 June 2012

6 iv STUDENT S DECLARATION I declare that this report titled Design and Investigate The Manual Sun Tracking System is my result of my own research except as stated in the references. The project has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature : Name ID Number : IMRAN BIN AHMAD ROSDI : MA08072 Date : 22 June 2012

7 ix TABLE OF CONTENTS EXAMINER S DECLARATION SUPERVISOR S DECLARATION STUDENT S DECLARATION DEDICATIONS ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS Page ii iii iv v vi vii viii ix xii xiii xvi xviii CHAPTER 1 INTRODUCTION 1.1 Project background Project problem statement Project objective Project scope 2 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction Solar radiation Radiation Types of thermal solar collector Flat-plate solar collector Concentrating solar collector Technical analysis 6

8 x Mechanism design study Stress analysis The von Mises stress The maximum shear stress theory Buckling Design consideration Stress Concentration 12 CHAPTER 3 METHODOLOGY 3.1 Introduction Project flow chart Design Bill of material Material selection Frame Base Link Crank Pin Assembly Meshing and modeling assumptions Input loads and fixture Base Frame Link Crank Pin The mechanism design study 33 CHAPTER 4 RESULT AND DISCUSSION 4.1 Introduction Load and stress calculation Finite element analysis Frame Link Crank Pin Base Mechanism design study 46

9 xi CHAPTER 5 CONCLUSION 5.1 Conclusion Recommendations 49 REFERENCES 50 APPENDICES A1 Gantt chart for FYP 1 52 A2 Gantt chart for FYP 2 53 B1 Drawing for Frame 54 B2 Drawing for Base 55 B3 Drawing for Link 56 B4 Drawing for Crank 57 B5 Drawing for Pin 58 B6 Drawing for Assembly 59 C1 Von Mises Stress for Frame 60 C2 Von Mises Stress for Link 61 C3 Von Mises Stress for Crank 62 C4 Von Mises Stress for Base 63 C5 Von Mises Stress for Pin 64 D1 Safety Factor for frame 65 D2 Safety Factor for link 66 D3 Safety Factor for crank 67 D4 Safety Factor for base 68 D5 Safety Factor for pin 69 E1 Displacement for frame 70 E2 Displacement for link 71 E3 Displacement for crank 72 E4 Displacement for base 73 E5 Displacement for pin 74

10 xii LIST OF TABLES Table No. Title Page 2.1 The short, intermediate and long classification of columns Bill of material Mechanical Properties of the AISI 1020 steel Evacuated tube collector Seido 2 ` specification Table of mesh information Data for stress calculation 35

11 xiii LIST OF FIGURES Figure No. Title Page 2.1 Flat-plate collector Concentrate collector Buckling of columns Stress concentration factor for flat bar with holes under axial loading The methodology flow chart The front view of the frame The right view of the frame Theclose up view of the frame The front view of the base The close up right view of the base at the stopper The front view of the link The front view of the crank The front view of the pin The front view of the assembly Mesh condition of the Base Mesh condition of the frame Mesh condition for the link Mesh condition for the crank Mesh condition for the pin The mechanism design study Safety factors for frame at base holes 37

12 xiv 4.2 von Mises stress at base holes for frame von Mises stress for link Safety factors for link von Mises stress for crank Close up view of von Mises stress at stopper holes Static Nodal Stress for frame base pin Static displacement for base von Mises stress for base case Safety factors for base Graph of displacement of the frame and crank Two- dimensional drawing of frame Two- dimensional drawing of base Two-dimensional drawing of the link Two-dimensional drawing of the crank Two-dimensional drawing of the pin Two-dimensional drawing of the assembly part The von Mises stress distribution across the frame The von Mises stress distribution across the link The von Mises stress distribution across the crank The von Mises stress distribution across the base The von Mises stress distribution across the pin The safety factor across the frame The safety factor across the link The safety factor across the crank 67

13 xv 6.15 The safety factor across the base The safety factor across the pin Frame displacement under given load Link displacement under given load Crank displacement under given load Base displacement under given load Pin displacement under given load 74

14 xvi LIST OF SYMBOLS mm d MPa Millimeter Diameter Mega Pascal Degree % Percent o C kn m min Mn C mm 2 N kg m/s ave F s A τ b Degree Celsius Kilo Newton Meter Minutes Manganese Carbon Millimeter square Newton Kilogram Meter per second Average Stress on X-axis Stress on Y-axis Stress on Z-axis Sheer Force Area Sheer Stress Bearing Stress

15 xvii F b t Bearing Force Thickness Stress F.S S y τ max M I SR L eff r max ave K t N/mm 2 kg/m 2 m 2 Ø Factor of Safety Yield Point Maximum Sheer Stress Bending Moment Moment of Inertia Slenderness Ratio Effective Length Radius Maximum Stress Average Stress Stress Concentration Factor Newton Per Millimeter Square Kilogram Per Meter Square Meter Square Diameter

16 xviii LIST OF ABBREVIATIONS ASTM ASME MS AISI ANSI SENB American Society for Testing and Materials American Society of Mechanical Engineers Malaysian Standard American iron and steel institute American National Standards Institute Single edge notch bending SimulationExpresss SolidWorks simulation software FEA Sam6.1 Finite element analysis Mechanism design simulation software