Dumpling Maker. EDSGN 100 Section #6 Team Number 3. Team Members: Jared Franz, Josh Pezzulo, Sammy Binkin, Mike Allibone. Submitted to: Xinli Wu

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1 Dumpling Maker EDSGN 100 Section #6 Team Number 3 Team Members: Jared Franz, Josh Pezzulo, Sammy Binkin, Mike Allibone Submitted to: Xinli Wu Date of Submission: March 20th, 2017

2 Abstract Typically, making dumplings requires immense skill, time, and efficiency. However, the process leaves room for human error, slowness, and sanitation issues. By creating a semiautomatic dumpling machine, the dumpling making process will drastically become faster, cleaner, and more efficient with little skill involved. Consumers could use a dumpling maker instead of hand-making dumplings themselves. ii

3 Table of Contents Abstract - Sammy Binkin...Page ii Introduction - Sammy Binkin.Page 1 Design Task - Jared Franz...Page 2 Design Approach - Mike Allibone..Page 3 (Concept Generation Drawings) - Sammy Binkin The final design and prototype - Jared Franz and Josh Pezzulo.Page 10 Engineering Analysis - Mike Allibone...Page 16 Summary and Conclusions - Josh Pezzulo.Page 17 References - Everyone...Page 18 iii

4 Introduction The typical hand-making process for dumplings requires mixing flour, salt, and water into a dough. The dumpling artist must cut, flatten, and form the dough into circular wrappers. Then, he or she must create a filling out of various ingredients, places it inside the circular wrapper, and then folds it. In retrospect, the dumpling-making process takes time for the dumpling artist and requires a substantial amount of manual labor. Although, a semi-automatic dumpling machine would cut the time down, increase efficiency, and improve sanitation. Such aforementioned dumpling-making machine would cut out the process of forming and filling the dumpling wrappers. While not fully automatic, the user would have to form his or her own dough and filling and insert into the machine s respective compartments. Once the machine is powered on, dumplings would automatically be made in a quick, practical, and userfriendly manner. The user would then have to steam or boil the dumplings. The machine, while efficient and practical, must also be cheap, small, lightweight, and dishwasher friendly for regular kitchen use. As such, the material must be $200 in order to reduce the consumer cost. The material and the size of the dumpling machine itself must also be dishwasher-friendly and easy to maintain. Therefore, Aluminum would be the best material to use. It is lightweight, as it is a third of the weight of steel or copper. Aluminum is also easy to mold and fold for production purposes. Aluminum also does not rust (Pappas 2014). Also, the machine itself should be well within the standard counter depth of 25 inches and the standard counter height of 26 inches, while also leaving room for more appliances (Feirer 2017). Keeping this criteria in mind, a semi-automatic dumpling maker would be the best tool for making dumplings in an easy and efficient manner. 1

5 Design Task Problem Statement: The process of making dumplings is very time consuming for cooks. Whether it is at home or in a small restaurant making the dough, placing the filling, and folding is a long process. There needs to be a machine that can make these dumplings at a faster rate but is also not a huge production machine. Mission Statement: A prototype for a dumpling maker will be designed and constructed that will be used within households or small restaurants in order to produce dumplings at a faster rate than they usually would. Design Specifications: - Needs to be automatic or semi-automatic - Should produce no less than 10 dumplings per minute on average - Material cost should not exceed $200 - The dumpling maker should be safe as a food processor, easy to maintain, safe to use, and dishwasher safe 2

6 Design Approach Project Management: The first step of the design approach was to do a Gantt chart to plan out the steps for designing and constructing our dumpling maker. Most of the first 20 days were allocated towards brainstorming and planning such as doing design matrices and drawings. The next 10 days were focused on constructing our prototype and preparing the report and presentation. The next step was to do the customer needs assessment. Several Chinese restaurants were contacted to see what they would look for in a potential dumpling maker. The design was intended to fit the criteria set by the customer needs assessment. Designs were split into two groups, the dough making process and the dumpling folding process. Designs for the folding process were graded in 4 categories (size, usability, cost, and if it was dishwasher safe). 5 designs were made for both categories. They were graded against each other by a design matrix. The design matrix determined that the roller method best fulfilled the criteria. Designs for the dough making process were graded in 6 categories (cost, usability, efficiency, volume, processing, dishwasher safe). Our design matrix determined that the roller method was the best for the criteria. 3

7 FIG 1. Gantt Chart Customer Needs Assessment: All three restaurants that were spoken too currently made all of their dumplings by hand. One restaurant said that they wouldn t consider purchasing a dumpling maker. The other two restaurants said they would consider purchasing a dumpling maker. The first restaurant stated that cost and the speed of dumpling production was important. The second restaurant said they would consider using a dumpling maker if it was easy to store and clean. 4

8 Concept Generation: FIG 2. Pull Tab and Horizontal Dough Roller Concept 5

9 FIG 3. Clamp from Top and a Vertical Dough Roller Concept 6

10 FIG 4. Clamp from Side and Manual Dough Roller Concept 7

11 FIG 5. Scissor and Horizontal Dough Roller Concept 8

12 Design Selection Matrix: Table 1. Design Matrix 9

13 The Final Design and its Prototype: FIG 6. Working drawing for mixing bowl: 10

14 FIG 7. Working drawing for filling dispenser body: 11

15 FIG 8. Working drawing for dumpling cutter: 12

16 FIG 9. Working Assembly Drawing: FIG 10. Working Pictorial Drawing 13

Prototype: The scale of the prototype was made 1:1 scale.

afterwards the working mechanism required the machine to be higher,

the actual design is a height of 6 inches instead of 4. FIG 11.

17 Prototype: The scale of the prototype was made 1:1 scale. However, the height of the prototype was made to be 4 inches when afterwards the working mechanism required the machine to be higher, in order for the dumpling dough to slide down the ramp easier, so the actual design is a height of 6 inches instead of 4. FIG 11. Prototype Front View FIG 12. Prototype Overhead View FIG 13. Prototype Overall View 14

18 Design Features: Our dumpling maker contained many features that made it such a great automatic dumpling maker. All of our pieces are easily detachable from the machine to allow for easy cleaning. Our bowl is also completely removable from the device in order to allow users to make the dumpling dough separate from the machine. Our cutters at the very end of the machine allow for complete automatic shaping of the dumplings and for easy removal of the extra dough after the dumpling are run through. Our design also has an automatic dispenser for the filling that goes into the dumplings before they are folded and cut allowing for a completely automatic setup. Operation Instructions: 1. After needing and making the dumpling dough by yourself you can put that into the detachable bowl. 2. Once the dumpling filling is also completed you can place that into the dispenser in the middle of the machine. 3. Then you can open up the bowl door and turn the machine on in order to allow the dough to fall through into the machine. 4. As the machine is working it rolls out the dough into the correct width and then puts the correct amount of filling on top of the dough. 5. The dough then gets folded in half and cut to the dumpling shape. As the dumplings come out at the end of the machine there will be extra dough still around the dumplings. Simply rip the extra dough away from the dumpling and place it back into the bowl and the dough will then go back into the system to make more dumplings. 15

19 Engineering Analysis Working Mechanism: There is a removable hole in the bottom of the bowl that will allow the dough to slide down the bowl towards the rollers. The rollers which are powered automatically by motors will flatten the dough to a width of 1/8 th inch and push it through the rest of the dumpling maker. The flattened dough slides down a ramp and is folded into a V-shape by said ramp. Dumpling filling is inserted into the dough by a filing dispenser. The filing dispenser has a plunger above the filing that is controlled by an automatic spring-loaded device that dispenses the same amount of filing on a set interval. Two rotating folders controlled by motors seal the dumpling around the filing and the finished dumpling is pushed out of the dumpling maker. Cost Analysis: The dumpling maker is mostly comprised of aluminum and hard plastics. The cost of the removable mixing bowl is roughly $30. 1 foot of aluminum tubing can be purchased for about $10 which would be used for the rollers and folders. The body of the dumpling maker along with the ramp would be made out of sheet metal. The total cost of all the sheet metal for the dumpling maker is roughly $90. Plastics would be needed for the filing dispenser, both the body and the plunger. The plastics for the filing dispenser would cost roughly $20. This would make the cost of the dumpling maker about $

20 Summary & Conclusions A review of the design process and outcome, as compared to the problem statement, leads to the conclusion that the project has met all design specifications and was designed in an efficient manner. The dumpling maker produced was semi-automatic, where the dough making being the only manual process for the dumpling machine. The working mechanism of the machine is extremely simple, and minimizes user error and malfunction. Estimates suggest the dumpling maker should be able to output dumplings at a rate of 1 dumpling per 2 seconds (bar running out of ingredients). The total cost of the material was estimated to be $162.21, well under the $ budget given the level of automation, and build quality. All parts excluding electric motors are created using machine washable, and rust-free aluminum and plastics. All parts are also detachable to allow for easy repair, and cleaning. The biggest design challenge was during the customer needs phase due to a lack cooperation from sampled customers, however, enough data was collected satisfy project requirements. No major changes are suggested for this project, small recommended changes are, more prototyping time, more access to materials, better access to customers for sampling, and more competition between groups. 17

21 References - Pappas, S. (2014), Facts about Aluminum, LiveScience. - Feirer, M. (2017), All About Kitchen Cabinets, This Old House. Links for finding the Prices: - Metal Cut 4U, - Tap Plastics, - Webstuarant Store, leshopping&gclid=cjwkeajwkq7gbrdun9iu2jjyhmssjadhcd_huvsgta2b7swhy xfvflxp0bbhztkysiqwifmjicsf0bocvvdw_wcb 18

Semi-Automatic Dumpling Maker

EDSGN 100 Semi-Automatic Dumpling Maker Submitted by:, Abdulla Al Ali, Jillian Quill, Mitchell Ernst, Jason Scott, Aidar Mussabekov Submitted to: Xinli Wu, Ph.D., PE Table of Contents Abstract... Jillian