The Dumpling Maker. EDSGN 100 Section 008 Team 5.

Transcription

1 The Dumpling Maker EDSGN 100 Section 008 Team 5 Submitted by: Abdullah Albaze Hamad Al Nema Jonathan Barnes Jarod Blake 1

2 Abstract (Jarod Blake) The goal of this design project was to design a dumpling maker for consumers as well as for use within restaurants. Without readily available alternatives, the goal was to have a machine that would make dumplings quickly and easily. This report outlines the research and development of an automatic dumpling maker. ii

3 Table of Contents Description of The Design Task Introduction 1 Problem Statement 1 Mission Statement 2 Design Specifications 2 Design Approach Gantt Chart 3 Customer Need Assessment 3-4 Concept Generation 5 Design Selection 5-6 The Final Design and Its Prototype Working Drawing of Final Design 7-11 Prototype Photos and Scale 12 Design Features 13 Operation Instructions 14 Engineering Analysis Working Analysis 14 Cost Analysis 15 Summary 15 Acknowledgments References 17 iii

4 Introduction (Hamad AL Nema) Contained in this report is the process by which our group developed a prototype dumpling maker in Engineering Design 100. The prototype was developed for use within restaurants and at home for cooks who require a spatially conservative and time-efficient dumpling maker. The machine will automatically cut, fill and shape the dumplings, but pre mixed dough and filling must be loaded into the machine. We first began with a simple design and made continuous adjustments meet the given design requirements. Following the initial design, we produced five additional design concepts and choose the best one by evaluating it according to the customer needs, and later implemented the best components from each design to create the final product. The following report further explains the development of the final prototype. Problem Statement (Jonathan Barnes) Making dumplings by hand is an inconvenience to restaurant staff and cooks at home. While there are large industrial dumpling makers, they are not cost effective for a small-scale Chinese restaurant or for a home cook. There are few dumpling makers available that are simple in operation, cost effective, and efficient for both restaurant staff and home cooks. 1

5 Mission Statement (Jonathan Barnes) The goal is to develop a dumpling maker that is automatic, cost-effective to manufacture, easy to clean and maintain, safe to operate, and comprised of food grade materials. The machine should yield dumplings of consistent size and profile at a fast rate, and should be easy to separate into parts that will fit comfortably and safely into either an industrial or home kitchen dishwasher. Design Specifications (Jonathan Barnes) There are several conditions the dumpling maker must meet. The final product should be automatic or semi-automatic in function, it must produce at least ten dumplings per minute, it should cost less than two hundred dollars to produce, and meet a list of mechanical requirements. For safety, the dumpling maker must be as safe as food processors and similar items currently on the market, made of food grade materials, dishwasher safe, and easy to clean and maintain. 2

6 Gantt Chart (Jonathan Barnes) Table 1 Gantt Chart Customer #1 Needs Assessment (Hamad Al Nema) 1. How fast should a dumpling maker be? a. It should make from 8-9 dumplings per minute. 2. What do you prefer using: a dumpling maker or your hand? a. I prefer to use my hands because machines are unreliable. 3. Should the machine be completely automatic? a. Yes it would be preferable if it was automatic. 4. How much would you pay for a dumpling maker? a. I would be willing to pay $250-$ Do you make dumplings on a daily basis? If so, how many do you make a day? a. I do make them on a daily basis and I make approximately depending on the demand. 3

7 Customer #2 Needs Assessment (Jonathan Barnes) 1. How fast should a dumpling maker be? a. It needs to make one serving of 8 dumplings in under a minute 2. Would you prefer using a dumpling maker or your hand? a. If the dumpling maker is faster, I would prefer the dumpling maker 3. Should the machine be completely automatic? a. Yes, the machine should be automatic 4. How much would you pay for a dumpling maker? a. I would pay less than $ Do you make dumplings on a daily basis? If so, how many dumplings do you make per day? a. Yes, many people order dumplings. I can make over 100 dumplings in a day. 4

8 Concept Generation (Abdullah Albaze and Jarod Blake) Over the course of the project, several brainstorming sessions have been conducted, and from them five abstract ideas were created. Fig. No. 1 Model 1(Jarod Blake) Fig. No. 2 Model 2 (Jarod Blake) 5

9 Fig. No. 3 Model 3 (Hamad Al Nema) Fig. No. 4 Model 4 (Abdullah Albaze) Fig. No. 5 Model 5 (Jonathan Barnes) 6

10 Design Selection Matrices (Abdullah Albaze) In order to come up with the final design, several design selection criteria were set. Based on these criteria, the following design matrices were created: Table 2. Design Matrix 1 Table 2 compares the five design shown above in figures 1-5. Based on the criteria on the table, the designs would be compared by the scale of one with respect to the reference. For example if the design was as good as the reference it would get a zero, if it was better it would get a one, and it will get a negative one if it was worse. This comparison eliminated two of the initial five designs. Table 3. Design Matrix 2 7

11 Table 3 followed the same criteria as the previous one. However, this time each each one was weighted based on its importance, and this allowed for more accurate comparison. After creating the second design matrix, it was decided that model 2 would be eliminated, and model 5 would continue while implementing some parts of model 4 with in it. That lead to the final design. Final Design Working Drawing (Abdullah, Jarod and Hamad) The following Pictures illustrate the design of the Dumpling maker and its components. They also show three pictures of the prototype on a 1:1 scale. Fig. No 6 Dumpling Machine 8

12 Fig. No 7 Bill Of Materials Fig. No. 8 Machine Base 9

13 Fig. No. 9 Augur Fig No. 10 Bucket 10

14 Fig. No. 11 Dumpling Shaper Fig. No. 12 Connecting Rod 11

15 Fig. No. 13 Solidworks Illustration Fig. No 14 Prototype Top Fig. No. 15 Prototype Fig. No. 16 Prototype View Front View Side View 12

16 Design Features (Jonathan Barnes & Hamad AL Nema) The base of the dumpling maker is an 8 x 8 cube, which houses an electric motor and a sectioned tube through which dough and filling travel simultaneously. On top of the base is the bucket, which houses the dough and a central tube for the filling. The tube in the center of the bucket connects to the inner tube within the base of the machine; the dough enters from the bucket into the outer tube within the base. Upon exiting the bucket, the dough is forced through a port which regulates the thickness of the dough and filling as they exit. What forces the dough from the bucket through the tubes is an auger that is located inside the bucket. The auger part is actually composed of two connected augers; one spiral is a smaller diameter and fits flush inside the inner tube and forces the filling down through the machine. The outer auger spiral fits flush around the inner tube and forces the dough down through the machine. The pressure created by the whole rotating auger part forces the material through the machine, thereby driving the process of material moving through the tubes. The whole auger itself is powered by the electric motor located in the base of the machine. The shaping wheels that form and cut the dumpling are driven by the same electric motor and are connected by arms from the base of the dumpling maker, resting exactly next to each other at the end of the reservoir. These wheels feature machined pockets with ridged edges that shape each individual dumpling, thus completing the process. 13

17 Operation Instructions (Abdullah Albaze) The device can be operated via few simple steps: 1. Add the dough ingredients to the bucket 2. Add the filling ingredients in the center of the auger 3. Place the safety covers on the bucket and on top of the shaping wheels 4. Place a plate/container underneath the device Working Mechanism (Jarod Blake) This Dumpling Maker uses a sophisticated mechanism to efficiently produce dumplings with little waste. First, the bucket is opened to reveal the dough and filling chambers. The outside chamber around the inner tube is used to mix the dough while the inner chamber is used for the filling. Second, the blades inside each of the chambers push the dough and filling separately down into the base of the machine. Within the base of the machine, the dough is pressed into a smaller and smaller ring that surrounds the filling tube. The filling is also pressed into a 1-inch diameter tube. Third, the dough is forced out of the side of the machine into a long, continuous thin sheet of dough with a width of 3.5 inches. This thin sheet follows the contours of the reservoir, while the filling is placed on top of the dough. Lastly, the reservoir shapes the dough into a tube with the filling inside. The dough-and-filling tube then continues into the dumpling shapers that shape and crimp the dough and filling into individual dumplings with a 3.25 inch length. The dumplings then fall into a container that the owner places beneath the shaping wheels. 14

18 Cost Analysis (Jarod Blake) The original design involved making the machine out of stainless steel. There is roughly six square feet of material necessary to create the machine. If the machine was to be constructed out of stainless steel the cost of manufacture would be dollars (McMaster-Carr). A cheaper option would be to construct the machine out of food grade plastic. This would bring the cost down to 92.1 dollars for six square feet of material. With the manufacturing cost cut in half the retail price would also be cut in half. To cut more manufacturing costs, a less expensive motor could be used such as a AC Gearmotors with a cost of versus a compact DC gearmotors with a cost of With the expensive materials, the dumpling maker would have to be sold for roughly 500 dollars, but with the cheap materials the cost could be reduced to around 300 dollars retail price. Summary (Hamad AL Nema) Overall, the final design that was created is a compact dumpling maker with easily separable components. The final product was developed by collaborating with individual concepts and utilizing their best components. The efficiency, sterilization and ease of use of the dumpling maker is what makes it successful. It fulfills the customer s requirements and meets the given conditions. The design satisfies all the customer needs, which is why customers will be satisfied with the performance and price of the dumpling maker. 15

19 Acknowledgment (Team) Thank you to Jerod Barone for helping with any questions we had during the course of this project in solidworks. Also, thank you to Professor Xinli Wu for clearing up any questions we had during the project, as well as for his input following the in-class presentation of the physical model. Due to limitation of materials selection and quantity, a our 3D CAD model did not entirely match the prototype, and further adjustments were made to the 3D CAD model based on Xinli s input. 16

20 References (Jarod Blake) McMaster-Carr. (n.d.). Retrieved March 19, 2017, from McMaster-Carr. (n.d.). Retrieved March 19, 2017, from McMaster-Carr. (n.d.). Retrieved March 19, 2017, from McMaster-Carr. (n.d.). Retrieved March 19, 2017, from McMaster-Carr. (n.d.). Retrieved March 19, 2017, from 17